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Benefits and limitations of N2 addition with Ar as shielding gas on microstructure change and their effect on hardness and corrosion resistance of duplex stainless steel weldments

  • Mohamed S. Melad EMAIL logo , Mohamed A. Gebril , Farag M. Shuaeib , Thabet M. Elrabei , Dawod Elabar , Farag I. Haider and Osama M. Irfan EMAIL logo
Published/Copyright: May 5, 2025
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REVIEWS ON ADVANCED MATERIALS SCIENCE
From the journal REVIEWS ON ADVANCED MATERIALS SCIENCE Volume 64 Issue 1

Abstract

Duplexes stainless steels (DSSs) are widely used in various applications due to the equal amounts of the two phases, ferrite and austenite. These combined benefits provide the material with superior strength, corrosion resistance, and good welding capacity. During the welding process of DSS, equal amounts of both phases are disrupted, resulting in precipitation. To investigate this phenomenon, this study aims to analyze the effect of adding N2 with Ar (as a shielding gas) on microstructure changes. The study found that adding a small amount of N2 with Ar as a shielding gas makes it possible to control the appearance of Cr2N precipitation better. Moreover, the results indicate a direct relationship between the volume fraction of austenite and the use of N2 as a shielding gas. Reducing N2 shielding gas increases the micro-hardness of DSS welds due to higher ferrite volume fraction. The study also indicated that up to 10% amount of N2 is also enough to form chromium nitrides; moreover, much more nitrogen in argon shielding gas deteriorates mechanical and corrosion properties of DSS weldments.

Keywords: duplex stainless steel; TIG welding process; N2 shielding gas; Cr2N precipitations; micro-hardness; potentiodynamic polarization curve

1 Introduction

Duplex stainless steels (DSSs) are widely used due to their high alloying elements, ferrite and austenite microstructure, which provide good welding capacity, superior strength, and corrosion resistance. DSSs are utilized in corrosive industries such as pulp and paper, oil and gas, power plants, chemical, and desalination plants due to their high mechanical properties [1,2]. Aggressive environments can heighten the chances of localized corrosion, especially pitting corrosion. This type of corrosion occurs when the protective layer of a material breaks down due to the presence of chloride ions, inclusions or precipitates, along with other microscopic imperfections on the surface [3–5]. Fusion welding is a commonly used technique in the fabrication of DSS for technical applications. However, this process can lead to a shift in the balance of γ/δ phases and cause the loss of alloying elements, resulting in the formation of harmful phases [6,7]. It is crucial to investigate the changes in the microstructure of the 2205 DSS weld joint and their impact on its corrosion behavior. This is because the microstructure changes can significantly reduce the mechanical characteristics of the joint and make it more susceptible to localized corrosion. Mirakhorli et al. [8] analyzed the microstructure of a DSS’s weld metal in many locations. They observed that the regions with higher cooling rates might have greater ultimate austenite content.

In a study conducted by Geng et al. [9], the researchers examined the impact of microstructure changes on the corrosion behavior and hardness in different zones of a 2205 DSS weld joint. The study concluded that the microstructure in each zone was unique and varied due to differences in the welding thermal cycle. They observed higher levels of intragranular and secondary austenite presented in the ferrite grains within the weld zone (WZ), and coarse ferrite grains occurred close to the fusion line in the heat-affected zone (HAZ). Xie et al. [10] conducted a study on the microstructure characterization of DSS weldments using a multi-pass welding process. Their findings showed a significant phase imbalance at the HAZ and weld fillers, with ferritization occurring at the HAZ while the weld fillers were dominated by austenite. The mechanical and corrosion properties of DSS are significantly affected by the equilibrium between ferrite and austenite [11]. To achieve the best properties of DSSs, it is important to have nearly equal proportions of austenite and ferrite in the microstructure. This phase balance can be attained in the base metal (BM) through the correct combination of composition and solution heat treatment. However, maintaining a balance of ferrite/austenite in welds is more challenging than in BMs [12,13].

To improve the mechanical properties and corrosion resistance of DSS, nitrogen is added as a nonmetallic austenite stabilizer [14]. This addition helps in enhancing the temperature transformation from ferrite to austenite. However, excessive ferrite concentration can lead to a loss of nitrogen from the weld pool and HAZ, which can reduce toughness and pitting corrosion resistance, and increase the susceptibility to hydrogen embrittlement [15]. Hence, proper control over the nitrogen content is essential to ensure the desired material properties [16–18].

Betini et al. [19] used autogenously pulsed tungsten inert gas (TIG) welding to investigate the impact of adding 2% N2 to argon (Ar) as a shielding gas on the microstructure and hardness of 1.8 mm-thick DSS. They concluded that during welding with a mixture of Ar + 2% N2 as shielding gas, the weldment had a higher austenite phase content than with pure gas. To achieve a satisfactory balance between austenite and ferrite phases, Rokanopoulou et al. [20] investigated the solubility of nitrogen in 2205 DSS weldments as a function of welding conditions. They concluded that combining of N2 with Ar as a shielding gas and using appropriate welding settings achieves a time- and cost-efficient technique. In a study conducted by Pimenta et al. [21], an autogenously TIG joint of hyper-DSS was used to investigate the optimum N2 amount to be added to the shielding gas. The results showed that the ideal volume proportion of austenite was found to be 50% when using values between 3.5 and 4.5%. This suggests that current industrial procedures need to be reviewed.

In a study conducted by Topić and Knezović [22], the ultimate tensile strength of specimens made of 2205 DSS plates was investigated. The specimens were created using laser welding techniques with different combinations of shielding gases. It was discovered that the introduction of N2 and Ar as shielding gases did not affect the ultimate tensile strength of the specimens. A study by Baghdadchi et al. [23] suggests that more research is needed to explore using nitrogen as a shielding gas. They found that using pure nitrogen instead of pure argon increased the welded austenite content from 22 to 39% when welding 1.5 mm-thick DSS using autogenous laser welding. Therefore, the aim of this study was to investigate the impact of adding N2 to Ar as a shielding gas on the microstructure of DSS weldments. The microstructure alterations were evaluated using measures of corrosion resistance and hardness. Furthermore, the research explores the optimal amount of N2 to add when Ar is used as a shielding gas.

2 Materials and methods

2.1 Material and welding procedure

The material used in the experiments was a DSS plate with the plate number of DSS 2205 and UNS number S32205. The filler material used was ER2209, which had a thickness of 1.6 mm. Table 1 provides the measurement chemical compositions of DSS and ER2209 filler material. The DSS BM was cut into 50 mm × 140 mm × 6 mm plates using an abrasive water jet-cutting machine. To perform a single pass on both sides, the samples were prepared as double V butt weld joints. Prior to welding, the samples were mechanically cleaned to eliminate corrosion and other impurities. This investigation used the TIG welding machine (DWHP250NL) with a heat input of 0.685 kJ·mm−1. For the experiment, an 8 mm cup size and a 2 mm arc gap were used along with a 2.4 mm tungsten electrode. Based on previous research, this study used shielding gas compositions of 100% Ar, 95% Ar + 5% N2, 90% Ar + 10% N2, 85% Ar + 15% N2, and 80% Ar + 20% N2.

Table 1

Measurement chemical composition of DSS and ER2209 filler material

Component Cr Ni Mn C Si P Mo Cu N Fe
DSS (wt%) 22.2 4.70 1.72 0.03 0.037 0.03 2.55 0.2 0.17 Balance
ER2209 (wt%) 23 8.5 1.6 0.02 0.5 0.01 3.1 — 0.11 Balance

2.2 Microstructure examination

A water jet-cutting machine was used to cut microstructure samples of the DSS weld joint. Microstructure observation was performed using the Olympus BX61 optical microscope (OM) coupled with an EP50 digital camera. Standard processes for polishing and grinding were followed to prepare all samples for microstructure analysis. Grinding was done using silicon carbide abrasive papers with grit sizes ranging from 240 to 1,200, according to the ASTM-E407-2002 standard. To achieve a dark ferrite and a white austenite phase, modified Bertha’s etching solution consisting of 60 mL H2O, 30 mL HCl, and 1 g K2S2O5 was used. Additionally, this method enables the observation of Cr-rich nitride by the OM [24–27]. The volume fraction of ferrite and austenite was measured using ImageJ software.

2.3 Hardness test

The AKASHI MVK-E Vickers micro-hardness tester was utilized to measure the hardness of the samples under a 500 g load for 15 s. Prior to the micro-hardness test, the samples passed through grinding, polishing, and etching as part of the preparation for microstructure analysis. Micro-hardness measurements were taken in the transverse direction at five different locations: BM, HAZ, WZ, HAZ, and BM. The WZ was measured at six positions, while the HAZ was measured at four locations on each side.

2.4 Corrosion test

Electrochemical polarization measurements were conducted using the ACM instrument field machine with an Ag/AgCl-saturated reference electrode and a graphite counter electrode to perform a corrosion test. Small rectangular corrosion samples were obtained from the original DSS weld joint using a water jet-cutting machine. The electric wire connected the samples, which were then covered in epoxy. After that, the samples were mechanically ground to 800 grit using SiC emery paper, cleaned with distilled water, and rapidly dried using hot air. To ensure that the E corr became constant, the samples were submerged in 3.5% sodium chloride NaCl (simulating seawater) for 20 h under open-circuit conditions. Anodic cyclic polarization tests were then conducted at a scan rate of 60 mV·min−1, with a swept range of 500 mV below E corr. The scanning was repeated in the opposite direction when the voltage reached 700 mV. To ensure the reproducibility of the results, each test was recorded four times.

3 Results and discussion

3.1 Microstructure characteristics

Figure 1 shows the microstructure of the DSS BM. The BM consists of white-like island austenite (γ) and dark ferrite (δ). The volume fraction of the γ phase in the BM is 48%, while the remaining 52% is composed of ferrite.

Figure 1 BM microstructure.
Figure 1

BM microstructure.

Figure 2 shows the microstructure changes that occur in the weldments of DSS due to the addition of N2 with Ar as a shielding gas. The weldments in the WZ have three different types of austenite phases: intergranular austenite (IGA), widmanstätten austenite (WA), and grain boundary austenite (GBA). In the HAZ, the austenitic grains are primarily present as tiny WA and elongated GBA due to improper heating and rapid cooling. Additionally, this study has observed Cr2N precipitates, as shown in Figure 2(a), (b), (h), (i), and (k). This finding is consistent with the research that was conducted by Xie et al. [10], Cervo et al. [28], and Hosseini et al. [29]. The primary austenite is directly solidified from the molten metal, resulting in the formation of liquid to primary austenite and liquid plus ferrite to a primary austenite. Furthermore, the ferrite undergoes a solid-state phase transition into the primary austenite, leading to the formation of different types of austenite.

Figure 2 Effect of adding N2 to Ar as a shielding gas on the microstructure of WZ and HAZ.
Figure 2

Effect of adding N2 to Ar as a shielding gas on the microstructure of WZ and HAZ.

The GBA began to nucleate and grew at pre-existing ferrite boundaries [30]. During the cooling process, the available nucleation sites at the ferrite boundaries decreased as the amount of GBA increased. This led to the formation of new nuclei at the ferrite–austenite interfaces. The new austenite nucleated at the ferrite–austenite boundaries grew toward the ferrite in the form of a side-plate WA [31]. The IGA ultimately forms at the center of ferrite grains. The findings indicate that the sample welded with 100% Ar as a shielding gas has a small amount of Cr2N precipitation in both WZ and HAZ, as shown in Figure 2(a) and (b). However, adding 5 and 10% N2 to Ar as a shielding gas resulted in the disappearance of these precipitations in both WZ and HAZ, as shown in Figure 2(c)–(f). Moreover, the addition of 15% N2 showed a small amount of Cr2N in HAZ, as illustrated in Figure 2(h). When increasing the amount of N2 up to 20%, the amount of Cr2N precipitation reappeared and increased in both WZ and HAZ, as clarified in Figure 2(i) and (k). It has been observed that the presence of a small quantity of N2 can prevent the formation of Cr2N precipitates. However, if the amount of N2 used as a shielding gas exceeds 10%, it can lead to the promotion of Cr2N precipitates in both WZ and HAZ, as illustrated in Figure 2(i) and (k).

Figure 3 shows how the amount of N2 added to Ar as shielding gas affects the measured austenite and ferrite volume fraction. The austenite volume fraction of the DSS weldment increased with an increase in N2 with Ar shielding gas. This aligns with the findings of Betini et al. [19] and Tahaei et al. [32]. There is a direct relationship between the amount of austenite present and the use of N2 shielding gas. However, the formation of Cr2N precipitates is a complex process. As shown in Figure 2(a), (b), (h), (i), and (k), welding on DSS without N2 addition and with a high concentration of N2 as shielding gas will encourage the development of Cr2N precipitates.

Figure 3 Austenite and ferrite content as a function of shielding gas composition.
Figure 3

Austenite and ferrite content as a function of shielding gas composition.

3.2 Micro-hardness behavior

Numerous micro-hardness measurements have been conducted to assess the hardness of DSS weldments that have undergone changes in shielding gas composition. These measurements were taken along the transverse direction of the three different zones of the DSS weld joint. Figure 4 demonstrates how the hardness behavior changes along the transverse direction from BM to BM between samples that were welded using various shielding gas compositions. It can be observed that the sample welded with 100% Ar has a higher hardness behavior, ranging from 300 to 400 HV. However, the samples welded with 5 and 10% of N2 exhibit approximately the same behavior, ranging from 300 to 350 HV in both WZ and HAZ. Moreover, increased N2 shielding gas by more than 15 and 20% showed less hardness behavior below 300 HV. It has been observed that the hardness decreases when the amount of N2 is increased with argon as a shielding gas. This is similar to the findings of a previous study [33]. The ferrite phase is known to have a higher hardness than the austenite phase [8,34,35]. Therefore, the decrease in hardness when N2 is added with argon as a shielding gas can be attributed to the decrease in the ferrite volume fraction. Since the relationship between the addition of N2 as a shielding gas and austenite content is proportional, as shown in Figure 3, increasing the amount of N2 as a shielding gas reduces the ferrite volume fraction and hardness of DSS weldments.

Figure 4 Effect of adding N2 to Ar shielding gas on the hardness behavior of DSS weldment.
Figure 4

Effect of adding N2 to Ar shielding gas on the hardness behavior of DSS weldment.

3.3 Corrosion resistance results

3.3.1 Open circuit potential (E corr)

Figure 5 shows how the open circuit potential (E corr) changes over time for welded samples using different shielding gas compositions. It is noticeable that the E corr of the samples welded with 5, 10, and 15% N2 mixed with Ar shielding gas shifted toward a more positive direction compared to the BM. However, both samples showed a shift in E corr toward the negative direction. The shift was more pronounced in the sample welded with 100% Ar–0% N2 and the sample welded with 80% Ar–20% N2. Moreover, the sample welded using 90% Ar–10% N2 as a shielding gas shows the highest E corr value, exceeding the E corr value of samples that welded with added 15 and 20% N2.

Figure 5 E corr behavior as a function of time of the DSS samples welded using different shielding gas compositions.
Figure 5

E corr behavior as a function of time of the DSS samples welded using different shielding gas compositions.

When the potential rises in a positive direction, this means that the passive film develops and is strong. On the other hand, a negative potential drop indicates film fractures, collapse, or no film formation, which is an active corrosion. If a constant potential is maintained, it suggests that the film is still intact and protective. This information is based on research [36]. It has been found that the addition of a small quantity of N2 to Ar, as a shielding gas, can improve the strength of the passive film of DSS weldments, as observed in previous studies [37]. However, when the N2 concentration is raised to 20%, the passive film fails. The passive film can collapse due to the reappearance of Cr2N precipitations, resulting in a depletion zone of Cr when the amount of N2 increases.

3.3.2 Potentiodynamic polarization curve

Figure 6 illustrates how changes in shielding gas composition affect the polarization curve behavior of DSS weldments.

Figure 6 Effect of N2 addition with Ar shielding gas on the polarization curve of DSS weldments.
Figure 6

Effect of N2 addition with Ar shielding gas on the polarization curve of DSS weldments.

The figure indicates that the critical pitting potential of the sample welded with pure argon (100% Ar) is around 157.19 mV. However, when 5 and 10% N2 were added to Ar, the pitting potential increased significantly to 188.41 and 322.16 mV, respectively. This indicates a proportional relationship between the pitting potential and the addition of N2 with Ar as a shielding gas. However, when the percentage of N2 was further increased to 15 and 20%, the pitting potential showed a decreasing trend, with values of 274.2 mV and 147.5 mV, respectively. Thus, the relationship between the pitting potential and the addition of N2 with Ar as a shielding gas is initially proportional but becomes reversed when the percentage of N2 goes beyond 10%. The reason behind this behavior is linked to the volume fraction of austenite and the Cr2N precipitates. The volume fraction of austenite increases as the amount of N2 with Ar as a shielding gas increases, as demonstrated in Figure 3. Furthermore, the Cr2N precipitates vanish upon the addition of 5 and 10% N2, and reappear when N2 is increased to 15% in HAZ and 20% in both WZ and HAZ, as depicted in Figure 2.

Adding 10% N2 with Ar provides the highest pitting potential due to high austenite volume fraction without Cr2N precipitations (Figures 2(e), (f) and 3). The surface morphology of samples welded using different compositions of shielding gas was observed under an OM following a cyclic polarization test, as shown in Figure 7. The results indicate that when 100% Ar or 20% N2 + 80% Ar shielding gas is used, intergranular corrosion (IGC) and large pits are observed. However, no IGC has been observed, and the pits will be extremely small when shielding gas containing 5, 10, and 15% N2 is used.

Figure 7 OM surface morphology of the samples welded with different shielding gas compositions after a potentiodynamic polarization test.
Figure 7

OM surface morphology of the samples welded with different shielding gas compositions after a potentiodynamic polarization test.

4 Conclusions

DSS was welded using the TIG welding process with N2 and Ar as a shielding gas. The study evaluated the impact of different N2 and Ar gas mixtures on hardness and corrosion resistance. The conclusions are based on the results of this study:

  1. To prevent the formation of Cr2N precipitates, Ar gas with less than 10% N2 is used as a shielding gas. However, if N2 exceeds 10%, Cr2N precipitates will reappear.

  2. Introducing more N2 to Ar as a shielding gas increases the austenite volume fraction.

  3. Adding N2 to Ar as a shielding gas reduces the ferrite content in DSS weldments, leading to a decrease in hardness.

  4. By increasing the volume fraction of austenite and suppressing Cr2N precipitates, the critical pitting potential of DSS weldments increases when the amount of N2 addition rises to 10% with Ar shielding gas. Exceeding 10% addition results in decreasing critical pitting potential due to the reappearance of Cr2N precipitations.

  5. The sample that was welded without adding N2 (100% Ar) is significantly harder but shows less corrosion resistance due to the high ferrite phase content. On the other hand, the sample welded with 20% N2, despite having lower hardness, also exhibits low corrosion resistance because of the precipitation of Cr2N.

Acknowledgments

The researchers would like to thank the Deanship of Graduate Studies and Scientific Research at Qassim University for financial support (QU-APC-2025).

  1. Funding information: This study was financially supported (QU-APC-2025) by the Deanship of Graduate Studies and Scientific Research at Qassim University.

  2. Author contributions: Mohamed S. Melad: conceptualization, methodology, investigation, resources, writing – original draft & editing; Mohamed A. Gebril: supervision, visualization, investigation, review & editing, conceptualization; Farag M. Shuaeib: co-supervision, visualization, investigation, review & editing; Thabet M. Elrabei: resources, review & editing; Dawod Elabar: resources, review & editing; Farag I. Haider: resources, review & editing; Osama M. Irfan: funding acquisition and review. All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Conflict of interest: The authors state no conflict of interest.

  4. Data availability statement: All data generated or analysed during this study are included in this published article.

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Received: 2024-03-18
Revised: 2024-10-03
Accepted: 2025-04-10
Published Online: 2025-05-05

© 2025 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/rams-2025-0108
Keywords for this article
duplex stainless steel; TIG welding process; N2 shielding gas; Cr2N precipitations; micro-hardness; potentiodynamic polarization curve
Creative Commons
BY 4.0

Articles in the same Issue

  1. Review Articles
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  3. Technical development of modified emulsion asphalt: A review on the preparation, performance, and applications
  4. Recent developments in ultrasonic welding of similar and dissimilar joints of carbon fiber reinforcement thermoplastics with and without interlayer: A state-of-the-art review
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  100. Analyzing the viability of agro-waste for sustainable concrete: Expression-based formulation and validation of predictive models for strength performance
  101. Special Issue on Advanced Materials for Energy Storage and Conversion
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  103. Production of novel reinforcing rods of waste polyester, polypropylene, and cotton as alternatives to reinforcement steel rods
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