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Stainless Steel Fabrication

Stainless Steel Welding Fabrication

Experienced Stainless Steel Fabricator for Contract Fabrication

Contents

Stainless Steel Welding and Fabrication

Why Stainless Steel Matters

  • Corrosion Resistance: Stainless steel resists rust and corrosion, making it durable in wet and harsh environments.

  • Strength and Durability: It is strong and can handle heavy loads, extreme temperatures, and wear.

  • Hygiene: Its smooth, easy-to-clean surface makes it ideal for food, medical, and cleanroom applications.

  • Aesthetic Appeal: Stainless steel has a sleek, modern look that’s popular in design and architecture.

  • Low Maintenance: It requires minimal upkeep and stays functional and attractive over time.

  • Recyclability: It’s environmentally friendly and 100% recyclable without losing quality.

  • Versatility: Used in construction, healthcare, energy, automotive, and everyday products like cookware.

Applications of Stainless Steel

Water Treatment and Supply
Desalination plants and water pipes.
Tanks and components for sewage and wastewater treatment.
Aerospace and Defense
Aircraft components like fuel tanks and engine parts.
Military and defense equipment needing high durability.
Consumer Goods
Home appliances like refrigerators, dishwashers, and washing machines.
Jewelry, watches, and personal accessories.
Chemical and Petrochemical Industries
Storage tanks, valves, and pipelines resistant to chemicals.
Reactors and processing equipment for corrosive environments.
Energy and Power Generation
Components in wind turbines, nuclear reactors, and solar panels.
Oil and gas pipelines and offshore platforms.
Heat exchangers and boilers.
Medical and Healthcare
Surgical instruments and medical implants.
Hospital furniture and equipment (beds, trolleys, and sterilizers).
Hygienic surfaces in labs and pharmaceutical facilities.
Construction and Architecture
Roofing, cladding, and handrails.
Decorative elements and modern interiors.
Food and Beverage Industry
Food processing equipment (mixers, tanks, and pipes).
Kitchen appliances, cutlery, and cookware.
Brewery and dairy equipment.
Stainless Steel Machining
Stainless Steel Welding
Stainless Steel Tanks
Stainless Steel for Water Equipment

Stainless Steel Fabrication Operations

Stainless steels, especially austenitic grades, can be fabricated using standard techniques. They are capable of being

  • Folded
  • Bent
  • Cold and hot forged
  • Deep drawn
  • Spun
  • Roll formed.

Despite requiring more force than carbon steels due to high strength and work hardening rates, they are highly ductile.

Austenitic stainless steels can undergo heavy cold forming, making them suitable for various applications.

  • Work Hardening
    • Austenitic stainless steels can only be strengthened through work hardening.
    • Martensitic stainless steels can be hardened via quench-and-temper treatment, similar to carbon steels.
    • Ferritic stainless steels harden solely through cold working, but their rates are low compared to austenitic grades.
  • Cold Working Properties
    • Austenitic grades like 301, 302, and 304 can achieve high tensile properties through cold drawing.
    • Tensile properties in larger sections become impractical due to surface hardening.
    • Higher work hardening rates in austenitic grades result in higher magnetic permeability.
    • Ferritic and martensitic alloys have limited cold working capabilities, with martensitic grades commonly heat treated for optimization.
  • Effect of Temperature
    • Work hardening decreases at higher temperatures, resulting in reduced strength and increased ductility.
    • This characteristic is utilized in certain applications such as deep drawing and warm heading.
  • Forming Speed
    • More severe deformation is possible at slower forming speeds for stainless steels, unlike carbon steels.
    • Stainless steel processing is generally slower compared to carbon steel, suggesting the need to slow down for challenging forming operations.

Welding and joining stainless steel requires understanding both the welding process and the steel’s reaction to heat and mechanical stress. The weld must not only be structurally sound but also maintain essential properties like strength, toughness, and corrosion resistance.

A key concern with welding stainless steel, unlike carbon steel, is protecting its chromium content from oxidation to ensure it remains effective against corrosion and does not form oxides that could weaken the weld.

Stainless steel is welded in different industries and in various techniques depending on the work requirement. Most common techniques of welding stainless steel are TIG welding and MIG welding.

TIG Welding (Gas Tungsten Arc Welding)

The TIG welding process is one of the most frequently applied stainless steel welding methods; it is of high quality, versatile, and long-lasting.

TIG Welding has low heat input therefore suitable for thin materials.It involves a tungsten electrode and an inert shield of argon gas which might be mixed with other gasses like helium, hydrogen or nitrogen.

MIG Welding (Gas Metal Arc Welding)

MIG welding is a semi-automatic operation which has got strong union of the stainless steel components. It utilises Argon-rich shielding gas combined with a wire electrode. MIG welding has the advantage of being able to provide a pulsed current supply which enables easy welding of stainless steel projects that are complex

Considerations for Stainless Steel Welding

  • Stainless steel has a much slower heat input compared with carbon steel and is also at a greater risk from distortion, burn-through and oxidation
  • Setting up properly with clean is vital to avoid ferrous contamination
  • The selection of the filler material is not an easy task as it will need to match the class of the base material
  • The Various types of stainless steel have their call for techniques to tackle. Austenitic, Martensitic and Ferritic have unique requirements and call for particular skills or thermal controls.

Selection of Welding Method

Most appropriate welding method to use on stainless steel depends upon material thickness desired finish complexity of the job, as well as, cost accounting.

With thin materials in mind TIG is applied mostly during precision work but MIG offers its availability for any thickness.

Stainless steels are rarely placed in service in the hot rolled or forged condition. Annealing or other forms of heat treatment are desirable to obtain the full advantages of the corrosion resistance and mechanical properties of the steels. Standard heat treating equipment may generally be used.

The 4xx series of Ferritic and martensitic stainless steels are annealed by heating to above the critical temperature followed by slow cooling below this temperature to obtain minimum hardness and maximum ductility. These steels can also be annealed by an isothermal heat treatment below the critical temperature.

Some steels of the 4xx series may be hardened by heating to above the critical temperature and rapidly cooling. This hardening operation is generally followed by a tempering or stress relieving treatment.

The 2xx and 3xx series of austenitic stainless steels are annealed by heating to a temperature sufficiently high to put the carbides into solution and rapidly cooling from that temperature to retain the carbides in solution. The austenitic types when maintained at the temperature range of 425 to 900C may cause the precipitation of chromium carbides, as a separate phase, in the grain boundaries. Associated with such carbide precipitation is a severe loss of corrosion resistance in some corrosive media.

Heat Treatment

Heat Treatment

Stainless steel fabrication involves various mechanical and chemical finishing processes to enhance both the appearance and functionality of the material. These finishes can be broadly categorized into mechanical and chemical treatments.

Mechanical Finishes

Mechanical finishes involve physically altering the surface of stainless steel to achieve specific textures and appearances. Some common mechanical finishing methods include:

  • Grinding: This process uses abrasive wheels to remove surface imperfections, resulting in a smoother finish
  • Polishing: Finer abrasives are used progressively to achieve a smooth, reflective surface. This method is key to creating mirror-like finishes
  • Brushing: Wire brushes or abrasive bands are employed to create a unidirectional satin finish, which is popular for hiding fingerprints and minor scratches on household appliances.

Chemical Finishes

Chemical finishes alter the surface of stainless steel through chemical reactions. These processes include:

  • Acid Pickling: The stainless steel is immersed in an acid solution to remove scale, rust, and other surface contaminants. This provides a clean foundation for further finishing processes
  • Passivation: A thin layer of acid removes free iron from the surface, enhancing corrosion resistance. This is often done after polishing or grinding
  • Electropolishing: This process involves immersing the stainless steel in an electrolyte bath where it acts as an anode, removing a layer of metal and smoothing the surface. It results in a uniform, highly reflective, and smooth finish

Both mechanical and chemical finishes play crucial roles in enhancing the corrosion resistance, cleaning ease, and longevity of stainless steel fabrications

The choice of finish depends on the specific application requirements, balancing factors such as aesthetics, functionality, and environmental exposure.

Stainless Steel Mechanical Finish

Stainless Steel Mechanical Finish

Stainless Steel Machine Frame
Stainless Steel Fabricated Parts

Fabrication of Stainless Steel Grades

Grade 304 (L)   UNS NO : S30400 (S30403)     Euronorm : 1.4301 ( 1.4307)

Grade 304 is the most widely used austenitic, chromium-nickel stainless steel. Its corrosion resistance is somewhat higher than that of Type 302. It is essentially nonmagnetic when annealed and can become slightly magnetic when cold worked. The alloy has excellent fabricability and weldability.

This alloy serves a wide range of applications. It resists rusting in architectural applications. It is resistan to food processing environments, except for high-temperature conditions involving high acid and chloride contents and it resists organic chemicals and a wide variety of inorganic chemicals.

Type 304H is a modification of Type 304 in which the carbon content is controlled to a range of 0.04 to 0.10 to provide improved high temperature strength to parts exposed to temperatures above 425C

Corrosion Resistance of Grade 304
  • 304 has excellent corrosion resistance in various environments and when in contact with different corrosive media.
  • Pitting and crevice corrosion can occur in environments containing chlorides.
  • Stress corrosion cracking can occur above 60°C.
Heat Resistance of Grade 304
  • 304 has good resistance to oxidation in intermittent service up to 870°C and in continuous service to 925°C.
  • For continuous use at 425- 860°C, 304L is recommended due to its resistance to carbide precipitation.
  • Where high strength is required at temperatures above 500°C and up to 800°C grade 304H is recommended. This material will retain aqueous corrosion resistance.
Fabrication
  • Fabrication of all stainless steels should be done only with tools dedicated to stainless steel materials.
  • Tooling and work surfaces must be thoroughly cleaned before use.
  • These precautions are necessary to avoid cross contamination of stainless steel by easily corroded metals that may discolour the surface of the fabricated product.
Machinability
  • 304 has good machinability.
  • During the machining cutting edges must be kept sharp. Dull edges cause excess work hardening.
  • Cuts should be light but deep enough to prevent work hardening by riding on the surface of the material.
  • Chip breakers should be employed to assist in ensuring swarf remains clear of the work.
  • Low thermal conductivity of austenitic alloys results in heat concentrating at the cutting edges. This means coolants and lubricants are necessary and must be used in large quantities.
Welding
  • Fusion welding performance for type 304 stainless steel is excellent both with and without fillers.
  • Recommended filler rods and electrodes for stainless steel 304 is grade 308 stainless steel.
  • For 304L the recommended filler is 308L.
  • Heavy welded sections may require post-weld annealing.
Grade 303  UNS NO : S30300    Euronorm : 1.4305

Grade 303 stands out as the most easily machinable among all austenitic stainless steel grades, owing to the inclusion of Sulphur in its composition. While Sulphur enhances machinability, it concurrently diminishes corrosion resistance and marginally reduces toughness. In comparison to grade 304, the corrosion resistance of type 303 is inferior. However, its toughness remains superior, similar to other austenitic grades.

Corrosion Resistance

The addition of Sulphur to the composition serves as points of initiation for pitting corrosion. This consequently reduces the corrosion resistance of 303 stainless steel compared to 304. Nonetheless, its corrosion resistance remains satisfactory in mild environments.

In chloride-rich environments exceeding 60°C, 303 stainless steel is vulnerable to pitting and crevice corrosion. Therefore, it is unsuitable for applications in marine environments.

Heat Resistance

303 stainless steel demonstrates commendable resistance to oxidation when subjected to intermittent temperatures up to 760°C. Additionally, it maintains good oxidation resistance when continuously utilized up to 870°C. However, it’s important to note that continuous use within the range of 425-860°C is not advised due to the susceptibility of 303 stainless steel to carbide precipitation.

Fabrication
  • Fabrication of all stainless steels should be done only with tools dedicated to stainless steel materials.
  • Tooling and work surfaces must be thoroughly cleaned before use.
  • These precautions are necessary to avoid cross contamination of stainless steel by easily corroded metals that may discolour the surface of the fabricated product.
Welding

The inclusion of Sulphur in 303 stainless steel leads to subpar weldability. In instances where welding is necessary, it is recommended to utilize filler rods or electrodes made of grades 308L and 309 stainless steels. To ensure optimal corrosion resistance, it is essential to anneal the welds.

Grade 316 UNS NO : S31600 Euronorm : 1.4401

Grade 316 holds the second position, following 304, in terms of commercial significance among austenitic grades.

The addition of molybdenum in 316 stainless steel enhances its corrosion resistance, particularly evident in combating pitting and crevice corrosion in chloride-rich environments.

316L, being the low carbon version of 316 stainless steel, is resistant to sensitization caused by grain boundary carbide precipitation, making it suitable for heavy gauge welded components, typically over 6mm thick.

For applications involving high temperatures, it is recommended to use either the high carbon variant, 316H stainless steel, or the stabilized grade 316Ti stainless steel.

The austenitic structure of 316 stainless steel ensures excellent toughness, even at extremely low temperatures.

Stainless steel grade 316Ti contains a small proportion of titanium, typically around 0.5%. Titanium atoms serve to stabilize the structure of 316 at temperatures exceeding 800°C, thereby preventing carbide precipitation along grain boundaries and safeguarding the metal against corrosion.

The primary advantage of 316Ti lies in its ability to withstand higher temperatures for extended durations without experiencing sensitization (precipitation). Moreover, 316Ti maintains physical and mechanical properties akin to standard grades of 316.

Corrosion Resistance

Grade 316 stainless steel showcases outstanding corrosion resistance when confronted with various corrosive environments and substances. Often labeled as “marine grade” stainless steel, it should be noted that it is not resistant to warm sea water. Exposure to warm chloride environments can lead to pitting and crevice corrosion in Grade 316. Moreover, Grade 316 is susceptible to stress corrosion cracking when temperatures exceed approximately 60°C.

Heat Resistance

Grade 316 exhibits commendable resistance to oxidation, capable of intermittent service up to 870°C and continuous service up to 925°C. Nonetheless, prolonged utilization within the range of 425-860°C is discouraged, especially if maintaining corrosion resistance in water is essential. In such cases, Grade 316L is preferred due to its resistance to carbide precipitation.

For applications necessitating high strength at temperatures surpassing 500°C, Grade 316H is recommended.

Fabrication
  • Fabrication of all stainless steels should be done only with tools dedicated to stainless steel materials.
  • Tooling and work surfaces must be thoroughly cleaned before use.
  • These precautions are necessary to avoid cross contamination of stainless steel by easily corroded metals that may discolour the surface of the fabricated product.
Welding

The fusion welding performance of 316 stainless steel is exceptional, whether with or without fillers. Recommended filler rods and electrodes for both 316 and 316L are identical to the base metal, namely 316 and 316L, respectively. In some cases, post-weld annealing may be necessary for heavy welded sections. Grade 316Ti can serve as an alternative to 316 for heavy section welds.

However, oxyacetylene welding has not proven to be effective for joining 316 stainless steel.

Grade 321 UNS NO : S32100    Euronorm : 1.4541

Stainless steel 321 is a stabilized version of stainless steel 304. It combines an 18/8 blend of chromium and nickel with titanium to guard against intergranular corrosion following heat treatment. This alloy is designed to withstand temperatures ranging from 800 to 1500°F and exhibits high strength and resistance to various forms of corrosion, including aqueous environments.

Type 321 is commonly used in heavy welding components and dynamic environments subjected to fluctuations.

However, the inclusion of titanium imposes limitations on certain fabrication methods, as it renders the metal non-consumable for certain welding techniques. Despite this drawback, stainless steel 321 boasts excellent formability, eliminates the need for post-weld annealing, and maintains toughness across a wide temperature range.

The alloy retains its strength even when exposed to cryogenic temperatures and is often preferred over Type 304 for its enhanced resistance to creep and rupture. However, both alloys may be susceptible to stress corrosion cracking.

Corrosion Resistance

321 stainless steel (1.4541) demonstrates excellent corrosion resistance under normal temperatures but is primarily engineered for high-temperature performance. The significant titanium content, at least five times the carbon percentage (maximum 0.7%), imparts grade 321 with exceptional creep strength, resistance to chromium carbide precipitation, and robust resistance to oxidation and intergranular corrosion up to 850°C under dry air service conditions. However, exposure to other corrosive compounds such as water and sulfur compounds in hot atmospheres can notably reduce the maximum service temperature.

The overall characteristics of this material make it an outstanding and relatively cost-effective choice for numerous applications. Nonetheless, it is susceptible to pitting and crevice corrosion in warm chloride environments, as well as stress corrosion cracking above approximately 60°C. It is generally deemed resistant to potable water with chloride levels up to around 200 mg/L at ambient temperatures, decreasing to about 150 mg/L at 60°C.

Heat Resistance

These grades exhibit excellent oxidation resistance, capable of intermittent service up to 900°C and continuous service up to 925°C. They perform admirably within the 425-900°C range, especially in scenarios where subsequent aqueous corrosive conditions are encountered.

321H, distinguished by higher hot strength, is particularly well-suited for high-temperature structural applications.

Fabrication
  • Fabrication of all stainless steels should be done only with tools dedicated to stainless steel materials.
  • Tooling and work surfaces must be thoroughly cleaned before use.
  • These precautions are necessary to avoid cross contamination of stainless steel by easily corroded metals that may discolour the surface of the fabricated product.
Welding

321 stainless steel exhibits excellent weldability through all standard fusion methods, whether with or without filler metals. AS 1554.6 pre-qualifies welding of 321 and 347 using Grade 347 rods or electrodes. Additionally, a high silicon version of 347 is also pre-qualified for welding of 321. Notably, a post-weld heat treatment is not required for this process.

Grade 310 UNS NO : S31000      Euronorm : 1.4845

Grade 310 Stainless Steel is categorized as an austenitic stainless steel renowned for its outstanding high temperature properties, coupled with commendable ductility and weldability. It finds prevalent use in elevated temperature applications owing to its elevated chromium and nickel content, which confer robust corrosion resistance, exceptional resistance to oxidation, and superior strength even at temperatures reaching up to 2100°F. Its high chromium and nickel content render it superior to both 304 and 309 stainless steel in most environments.

Corrosion Resistance

Grade 310 stainless steel offers excellent corrosion resistance, facilitated by its high chromium content, which enables robust resistance to aqueous corrosion. It exhibits exceptional resistance at normal temperatures and maintains good resistance even in oxidizing and carburizing atmospheres.

Heat Resistance

Grade 310 stainless steel demonstrates good resistance to oxidation, capable of intermittent service in air at temperatures up to 1040°C and continuous service up to 1150°C. It also exhibits resilience against thermal fatigue and cyclic heating. This alloy finds widespread application in environments where sulphur dioxide gas is present at elevated temperatures.

However, continuous use within the range of 425-860°C is not advisable due to potential carbide precipitation, especially if subsequent aqueous corrosion resistance is required. Typically, Grade 310 is utilized at temperatures starting from about 800 or 900°C, surpassing the effectiveness of both 304H and 321 stainless steel at higher temperatures.

Fabrication

Grade 310 stainless steel is widely utilized in the heat treatment and process industries due to its suitability for high temperatures and corrosive environments. It is frequently fabricated into intricate structures and can be easily roller-formed, stamped, and drawn. However, it is important to note that Grade 310 tends to work harden, so any severe forming operations should be followed by an annealing process to relieve stress and restore ductility.

Welding

Austenitic stainless steel is commonly acknowledged for its weldability. It is generally regarded to have weldability on par with that of 304 and 304L stainless steel grades. However, special attention should be given to compensate for its higher coefficient of thermal expansion to prevent warping and distortion during welding processes.

Grade 253 Ma    UNS NO : S31000      Euronorm : 1.4835

253MA is a grade renowned for its exceptional performance at high temperatures while maintaining ease of fabrication. It withstands oxidation at temperatures up to 1150°C and can outperform Grade 310 in atmospheres containing carbon, nitrogen, and sulphur.

One of the advantages of 253MA is its relatively low nickel content, which makes it more effective in reducing sulphide atmospheres compared to high nickel alloys and Grade 310. Additionally, the high silicon, nitrogen, and cerium contents contribute to the steel’s oxide stability, elevated temperature strength, and resistance to sigma phase precipitation.

Thanks to its austenitic structure, this grade exhibits excellent toughness, even at cryogenic temperatures.

Corrosion Resistance

While not specifically engineered for aqueous corrosion resistance, the high chromium and nitrogen content in 253MA endows the grade with pitting resistance comparable to that of 316 stainless steel. However, it’s crucial to note that 253MA contains a high carbon content, rendering it highly susceptible to sensitization from both welding and service exposure.

Heat Resistance

253MA exhibits high strength at elevated temperatures, making it a preferred choice for structural and pressure-containing applications operating at temperatures above approximately 500°C and up to about 900°C. Its strength at these elevated temperatures surpasses that of alternatives like Grade 310.

However, it’s important to note that 253MA is susceptible to sensitization within the temperature range of 425-860°C. While this isn’t typically an issue for high-temperature applications, it can lead to reduced aqueous corrosion resistance.

Fabrication

Stainless steel 253 MA can be easily fabricated using standard commercial procedures. When compared to carbon steel, stainless steels are tougher and have a tendency to work harden quickly. However, this tendency can be minimized by employing positive feeds and slow speeds, along with ample cutting fluid during the fabrication process.

Welding

253MA demonstrates excellent weldability with all standard fusion methods, utilizing matching filler metals. AS 1554.6 pre-qualifies welding of 253MA with Grade 22.12HT rods or electrodes. Alternatively, Grade 309 fillers can be employed if lower creep strength is acceptable. It is recommended to use pure argon shielding gas during the welding process.

Grade 904L  UNS NO : N08904      Euronorm : 1.4539

 

Grade 904L stainless steel is classified as a non-stabilized austenitic stainless steel with a low carbon content. This high-alloy stainless steel is enriched with copper to enhance its resistance to strong reducing acids, such as sulphuric acid. Additionally, it boasts resistance to stress corrosion cracking and crevice corrosion. Notably, Grade 904L is non-magnetic and offers excellent formability, toughness, and weldability.

However, it’s worth noting that Grade 904L contains high levels of costly elements like molybdenum and nickel. Consequently, many applications that historically utilized Grade 904L have transitioned to low-cost duplex stainless steel 2205.

Corrosion Resistance

Grade 904L stainless steels exhibit outstanding resistance to warm seawater and chloride attack. The exceptional resistance of grade 904L to stress corrosion cracking is attributed to its high nickel content. Furthermore, the addition of copper enhances resistance to sulphuric acid and other reducing agents, both in aggressive and mild conditions.

The corrosion resistance of grade 904L falls between super austenitic grades with a 6% molybdenum content and standard 316L austenitic grades. However, it is less resistant to nitric acid compared to grades 304L and 310L, which lack molybdenum. To achieve maximum stress corrosion cracking resistance in critical environments, grade 904L requires solution treatment after cold working.

Heat Resistance

Grade 904L stainless steels provide good oxidation resistance. However, it’s important to note that the structural stability of this grade deteriorates at elevated temperatures, especially beyond 400°C.

Fabrication

Grade 904L stainless steels are characterized by high purity and low sulphur content, making them suitable for machining using standard methods. These grades can be easily bent to a small radius under cold conditions. While subsequent annealing is generally unnecessary, it should be considered when fabrication occurs under severe stress corrosion cracking conditions.

Welding

Welding of grade 904L stainless steels can be carried out using all conventional methods. Pre-heat and post-weld heat treatments are not necessary for this grade. However, it’s important to note that grade 904L may be prone to hot cracking in constrained weldments. Grade 904L electrodes and rods are typically employed for welding grade 904L steels in accordance with AS 1554.6 standards.

Stainless Steel Fabrication Piping

Duplex Stainless Steels

Duplex stainless steels are highly corrosion-resistant and work-hardenable alloys. They typically contain elevated levels of chromium, ranging from 18% to 28%, and lower to moderate amounts of nickel, varying between 1.5% and 8%. The remarkable corrosion resistance and superior mechanical properties of duplex stainless steels stem from their chemical composition and balanced microstructure, which comprises approximately equal volume percentages of ferrite and austenite. This duplex nature imbues duplex stainless steels with properties characteristic of both austenitic and ferritic stainless steels.
Due to their duplex structure, duplex stainless steels are generally tougher than ferritic stainless steels. In some instances, the strength of duplex stainless steels can be double that of austenitic stainless steels.

Duplex welding

Advantages of Duplex Steels

  • Duplex Stainless Steels offer advantageous traits from ferritic and austenitic material such as elevated strength and commendable corrosion resistance.

  • Strength is notably heightened, approximately twice that of austenitic.

  • They exhibit higher resistance to pitting and crevice corrosion.

  • Exceptional resistance to stress-corrosion cracking.

  • Demonstrates good erosion and fatigue resistance.

  • Weldability is satisfactory, accompanied by enhanced heat transfer capabilities.

  • Their elevated chromium, molybdenum, and nitrogen contents, coupled with a duplex structure, confer numerous advantages over 300 series austenitic grades.

Applications of Duplex Steels

Pressure vessels, reactor tanks and heat exchangers
Desalination plants and seawater systems
Water transmission pipes
Rotors, impellers and shafts in industrial equipment
Pulp and Paper industry
Absorber towers, FGD systems for air pollution control
Phosphoric acid production
Biofuels plants
Oil and Gas Applications
Stainless Steel Welded Components
Stainless Cut and Bended Parts

Fabrication of Duplex Steels

The processes commonly used to cut austenitic stainless steels and carbon steels can generally be applied to duplex stainless steels as well. However, adjustments in parameters may be necessary to accommodate the differences in mechanical properties and thermal response of duplex stainless steels. These adjustments help ensure optimal cutting performance and quality when working with duplex stainless steels.

  • Sawing: Cutting duplex stainless steels requires adjustments in parameters due to their high strength, work hardening rate, and absence of chip-breakers. This includes using powerful machines, coarse-toothed blades, slow-to-moderate cutting speeds, heavy feeds, and generous coolant flow. Cutting speeds and feeds should be similar to those for austenitic stainless steel.
  • Punching: Punching duplex stainless steels is difficult due to their high strength, rapid work hardening, and resistance to tearing. It’s suggested to treat them as if they were twice the thickness of austenitic stainless steel.
  • Laser Cutting: Duplex stainless steels can be processed using standard laser cutting equipment with minimal adjustments. The higher thermal conductivity and low sulphur content may marginally affect optimal parameters. The Heat Affected Zone (HAZ) from cutting is narrow and can be removed during normal machining or welding preparation.
  • Machining: Duplex stainless steels typically boast yield strengths approximately twice that of non-nitrogen alloyed austenitic grades, and their initial work hardening rate is generally comparable to that of common austenitic grades. However, the chips formed during machining duplex stainless steel are strong and abrasive to tooling, particularly for the more highly alloyed duplex grades. Additionally, because duplex stainless steels are produced with minimal sulfur content, there is little aid for chip breaking. Due to these factors, duplex stainless steels are typically more challenging to machine compared to 300-series austenitic stainless steels with similar corrosion resistance. Machining duplex stainless steels requires higher cutting forces, and more rapid tool wear is typical. This increased difficulty in machinability, especially noticeable when using carbide tooling, underscores the need for careful consideration and adjustments during machining operations.

Welding Duplex Steels

Stainless Steel Welding

Duplex stainless steels exhibit very good resistance to hot cracking due to their high ferrite content, making hot cracking rarely a concern when welding these steels. Instead, the primary concerns with duplex stainless steels lie in the heat-affected zone (HAZ), rather than the weld metal itself. HAZ issues can include loss of corrosion resistance, toughness, or post-weld cracking. To mitigate these problems, welding procedures should prioritize minimizing the total time spent at temperature in the “red hot” range, rather than focusing solely on managing heat input for individual passes. Experience has demonstrated that this approach can lead to welding procedures that are both technically and economically optimal.

Quality Control in Stainless Steel Fabrication

QC Method Purpose Process Tools/Techniques Used
Visual Inspection Identify obvious surface defects (e.g., scratches, cracks). Inspect parts during and after fabrication for imperfections or inconsistencies in surface finish. Magnifying lenses, direct visual inspection.
Dimensional Inspection Verify parts meet size and shape requirements. Measure thickness, length, and angles using precision tools to ensure compliance with design specifications. Calipers, micrometers, coordinate measuring machines (CMM).
Weld Quality Inspection Ensure strong and reliable welds. Inspect welds for defects (e.g., porosity, cracks), and verify joint integrity. Visual inspection, NDT, bend testing.
Material Certification Verify material quality and specifications. Provide certification documents detailing material origin, grade, and chemical composition. Material certificates, traceability records.
Corrosion Testing Ensure the material’s corrosion resistance. Simulate environmental exposure (e.g., salt spray, immersion) to evaluate resistance to corrosion. Salt spray tests, immersion tests.
Surface Finish Inspection Ensure surface smoothness and aesthetics. Inspect for surface imperfections such as scratches, dents, and discoloration. Visual inspection, surface roughness measurement tools.

Stainless Steel Finishes

  A- Mechanical Finishes

Grinding

  • Grinding is a foundational technique used to refine welded seams and remove imperfections.

  • Grinding wheels, flap discs, and abrasive belts are primarily used.

  • Proper grinding ensures welded components have no sharp edges or irregularities that could lead to stress points or corrosion.
Stainless Steel Grinding

Polishing

  • Polishing is a surface finishing method aimed at enhancing surface quality.

  • It uses finer abrasives, such as polishing compounds and wheels

  • Polishing can be performed manually, with machines, or using robots since it demands less precision compared to grinding or deburring.
Stainless Steel Polishing

Brushing

  • Brushing achieves a visually appealing grain that enhances the surface’s modern appeal.
  • It is especially effective in environments where wear and tear are common  as it hides fingerprints and scratches.
  • Brushing ensures a low roughness to the metal, smoothen the surface and block contamination.
Stainless Steel Brushing

Comparison of Mechanical Finishes

Technique Purpose Key Features Applications
Grinding
  • Smoothens weld seams and removes roughness.
  • Prepares surfaces for additional finishing or coatings.
  •  Uses abrasive wheels, belts, or flap discs for precise material removal.
  • Produces flat, uniform surfaces or contours.
  • Versatile – from coarse grinding for weld cleanup to fine grinding for aesthetics.
  • Welded joints: Ensures safety and seamless appearance.
  • Structural components: Removes imperfections before painting or coating.
  • Industrial machinery: Improves surface integrity and resistance to corrosion.
Polishing
  • Enhances surface smoothness, durability, and appearance.
  • Improves hygiene and ease of cleaning.
  • Progressively finer abrasives yield satin, semipolished, or mirror finishes.
  • Creates a reflective or smooth, matte surface depending on the requirement.
  • Adds resistance to corrosion and wear.
  • Foodgrade equipment: Smooth surfaces prevent bacterial growth.
  • Decorative products: Reflective finishes for highend appeal.
  • Pharmaceutical and medical devices: Mirror finishes for easy sterilization.
Brushing
  • Creates a consistent, linear matte texture for a clean and modern look.
  • Hides fingerprints and minor scratches.
  • Achieved with abrasive belts or brushes applied in a single direction.
  • Durable and resistant to daily wear and tear.
  • Kitchen appliances: Satin finishes for a sleek, professional look.
  • Architectural elements: Handrails, balustrades, and panels.

  B- Chemical Finishes

Pickling

  • An acid treatment known as pickling is used to remove a thin layer (1 to 3 µm) of material from stainless steel surfaces that have been exposed to high temperatures, such as during welding or heat treatment.
  • When applied in moderation, pickling does not harm the surface or affect its cleanability.

  • If applied too aggressively, it can strip away up to 8 µm of material, potentially damaging the surface and lowering corrosion resistance.

  • While pickling is often associated with post-welding treatments, it can also be used to clean surfaces by eliminating fabrication residues, including iron oxides.

  • Certain types of stainless steel are not suitable for lengthy immersion times in a strong acid pickle for austenitic grades, as they are susceptible to acid attack

Stainless Steel Welding and Fabrication

Electropolishing

  • Electropolishing is an electrochemical process that smooths the surface without physical contact, differentiating it from mechanical polishing.
  • The process involves anodically dissolving 20-40 microns of the surface using low voltages and high currents
  • The result is a smoother surface, improved corrosion resistance, and the removal of contaminants, though it will not eliminate deep scratches or imperfections.
  • Benefits of electropolishing include improved corrosion resistance, better surface reflectivity, and enhanced cleaning ability.
  • It is particularly useful for components with complex shapes where mechanical polishing would be difficult.

  • Electropolishing reduces surface stresses, lowers bacterial growth, and increases the durability of components, making it especially valuable in industries such as food processing and high-vacuum applications.

Stainless Steel Electropolishing

Passivation

  • Stainless steel naturally forms a protective chromium oxide layer when exposed to oxygen, which provides inherent corrosion resistance.
  • This self-passivation occurs automatically when the material is exposed to air or water.
  • However, in certain cases, especially after welding, a passivation treatment may be necessary to ensure the surface is thoroughly cleaned and free of contaminants.
  • To begin the process, any scale or contamination must be removed, often through pickling with a nitric-hydrofluoric acid mixture.
  • Passivation itself usually involves the use of nitric acid, which not only facilitates the formation of the protective oxide layer but also helps remove light iron contamination.
Stainless Steel Passivation

Comparison of Chemical Finishes

Feature Pickling Passivation Electropolishing
Purpose Removes corrosion-prone material and contaminants from the surface. Enhances the naturally formed protective oxide layer to improve corrosion resistance. Smoothens the surface, removes contaminants, and improves corrosion resistance.
Process Involves the use of acid (usually nitric or hydrochloric acid) to remove a thin layer (1 to 3 µm) from the surface. Treats the material with acid (typically nitric acid) to promote the formation of a chromium oxide layer. An electrochemical process that dissolves material anodically, using acids like phosphoric and sulfuric acids.
Surface Finish Can leave some roughness if over-applied; primarily removes oxides and impurities. Often results in a clean and slightly more passive surface, but may not significantly alter surface smoothness. Produces a smooth, shiny, and reflective surface, reducing roughness and imperfections.
Effect on Corrosion Resistance Improves resistance by removing layers of contamination and oxide. Enhances the material’s inherent corrosion resistance by increasing the thickness and quality of the chromium oxide layer. Greatly improves corrosion resistance by removing surface contaminants and defects, creating a more uniform and smooth surface.
Depth of Material Removal Removes a thin layer (typically 1 to 3 µm), but can remove more if over-applied. Minimal material removal, mainly focusing on enhancing the oxide layer. Removes 20-40 microns of material from the surface. Results in a much smoother and more uniform surface, enhancing reflectivity and ease of cleaning.
Cost Generally less expensive compared to other treatments. Moderate cost due to the chemicals used and the need for thorough cleaning before application. Can be more expensive due to the specialized equipment and electrolytes involved.
Common Applications Post-welding treatments to remove oxidation, heat tint, and scale. Also used to clean surfaces of iron oxides and fabrication residues. Typically used after welding or heat treatment to ensure a clean, contaminant-free surface that will form a stable passive layer. Ideal for components that require smoothness, high corrosion resistance, and better cleaning ability, often used in food, medical, and pharmaceutical industries.
Stainless Steel Weldment

Contamination During Stainless Steel Fabrication

Stainless steels can be readily fabricated by conventional manufacturing methods, but their fabrication characteristics are different from those of the carbon and alloy steels.

Among the most important differences which must be recognized are the relatively high hot strengths of these alloy steels, which affect forging, the high toughness and work hardening rates of some types, which affect machining and cold forming, and the high thermal expansion of the austenitic types, which affects weldment distortion.

stainless steel welding

stainless steel welding

The two most common fabrication deficiencies which affect later service are;

  • Surface contamination with carbon and alloy steels
  • Improper post fabrication cleaning.

Stainless steels must have clean surfaces to provide optimum corrosion resistance. It is important to note than even minor, invisible contamination from non-stainless steels can later cause unsightly staining when exposed to moisture, and often may lead to more serious corrosion.

Such contamination can come from high pressure contact with low alloy steels, from wire brushing with non-stainless brushes, from grinding with wheels previously used for carbon steels or even from airborne particles in a shop which also fabricates carbon steel.

Contamination of stainless steel surfaces can be minimized by utilizing careful procedures, including use of covered or plated dies and corrosion resisting handling equipment, but complete prevention of contamination is very difficult in shops which fabricate a variety of non-stainless metals. It is often the best practice to provide for an acid treatment to remove any contaminating particles after fabrication when staining or corrosion in service cannot be accepted.

Post fabrication cleaning may be necessary for three basic purposes:

  • To remove oxide scale resulting from welding hot working or heat treatment operations
  • To remove contaminating metallic particles
  • To remove general shop soils.

Oxide scales are most frequently removed by mechanical means (wire brushing with a stainless steel brush or blasting with clean sand or aluminium oxide grit) or by acid descaling (pickling). For faster descaling, pickling may be preceded by mechanical descaling.

Novelty Structures Polished Stainless Steel

Grease, oil, lubricants, paint and other soils may be removed from stainless steels by alkaline cleaners, emulsion or solvent cleaners, vapour degreasing or other suitable means, as described in the standards. Such cleaning may be required before processing steps, such as heat treatment or acid descaling, or as a final cleaning to prevent product contamination. Cleaning solutions containing chlorine or chlorides should be avoided, or used only with extreme caution. There are documented cases of serious service failures which resulted from cleaning with chloride-containing solutions.

The trend to use of clean-in-place systems is favourable if cleaning is done with good control, especially of the final rinsing operation. Failure to rinse thoroughly can lead to severe corrosion damage.

Stainless Steel Fabrication Case Studies

Practical Project Lessons, Causes and Workshop Improvements at Novelty Structures

Case Study 1: The Rust Mystery on 'Clean' Stainless Equipment

Background

During a facility equipment upgrade, a batch of new stainless steel components supplied by Novelty Structures developed noticeable brown rust spots shortly after exposure to moisture. The material certificates confirmed that the parts were made from the specified high-grade stainless steel, ruling out the supply of an incorrect material.

Conceptual close-up of iron-particle rust marks on a brushed stainless steel surface

Stainless steel surface contamination

Incident & Root Cause Analysis

Our investigation into workshop practices identified two sources of contamination:

  • Shared Finishing Tools: An abrasive disc used for final surface finishing had previously been used on carbon steel parts. This transferred tiny iron particles onto the stainless steel surface. When exposed to moisture in the air, these particles quickly rusted.
  • Airborne Dust and Sparks: Clean, finished stainless steel assemblies had been temporarily stored on open racks next to an active carbon steel grinding station. Grinding dust and hot sparks settled directly onto the finished surfaces.

Corrective Action Plan

Problem Area Root Cause Implemented Solution
Tooling Control Grinding discs and wire brushes had been shared between metals. We introduced dedicated, colour-coded abrasives reserved for stainless steel work.
Shop Layout & Storage Finished parts had been stored near carbon steel grinding areas. We created separate stainless steel storage areas away from sparks and required protective covers.
Quality Control Rust spots had been polished away without checking the cause. We required checks after handling and confirmed whether marks came from contamination or corrosion of the stainless steel before treatment.

LESSON LEARNED: A tool suitable for stainless steel can contaminate the surface if it has previously been used on carbon steel. We learned that dedicated tools must be combined with separate storage to prevent contamination.

Case Study 2: The Mismatched Equipment Covers

Background

An equipment manufacturer wanted to eliminate recurring paint maintenance and corrosion problems in a harsh operating environment by replacing painted mild-steel enclosure covers with 304 stainless steel. At Novelty Structures, we reused the existing laser-cutting drawings for the flat sheets and the programmed bending machine settings. However, during trial assembly, the folded edges did not line up with the adjoining parts.

Conceptual stainless steel cover with folded edges misaligned at the adjoining frame

                                 Equipment cover fit

The Technical Challenge

The trial showed why we needed to account for the different ways stainless steel and mild steel behave during bending:

  • Higher Forming Force: Stainless steel required more force to produce the same bend radius.
  • Greater Spring back: The bends opened slightly more after the bending pressure was released. This movement is known as springback.
  • Flat Sheet Dimensions: Reusing the flat cutting patterns without adjusting the allowance for how stainless steel bends changed the final dimensions.

Implementation Protocol

To correct the fit, we introduced a four-step process to check and adjust the setup:

STEP 1

Tooling Trial

(Test grade & thickness)

STEP 2

Geometry Audit

(Measure angle & radius)

STEP 3

Pattern Adjustment

(Recalculate flat blank)

STEP 4

Trial Fit-Up

(Verify full assembly)

TAKEAWAY: Keep the required finished shape and dimensions on technical drawings, but ask fabricators to check the flat cutting patterns and bending machine settings again whenever the material grade changes.

Case Study 3: The Warped Washdown Panels

Background

For a food production facility, Novelty Structures upgraded washdown panels from painted carbon steel to 304 stainless steel to improve hygiene and corrosion resistance. The panels included welded stiffeners and mounting brackets. We used the established welding sequence developed for carbon steel. After welding, however, the stainless steel panels had bowed and distorted badly, preventing them from sitting flat when mounted.

Technical Breakdown

Response to Heat: Austenitic stainless steels, including 304, expand around 50% more than carbon steel for the same temperature rise and conduct heat away more slowly.

Why the Panels Warped: Heat stayed near the welds for longer, causing those areas to expand and then shrink as they cooled. This pulled the panels out of shape.

Conceptual bowed stainless steel panel with welded supports above a flat surface

Washdown panel distortion

Standard Operating Procedure (SOP) & Preventive Controls

  • Controlled Welding: We reduced the heat input and used a staggered welding sequence with gaps between welds to spread the effects of heating and cooling more evenly.
  • Checks After Cooling: We required flatness and dimensional tolerances to be checked after the panels had cooled and were released from their holding fixtures. This showed their true shape without clamps holding them in place.
  • Clear Assembly Drawings: We provided the fabrication team with complete assembly drawings and details of how the parts fitted together, highlighting the dimensions that had to be maintained.

Case Study 4: Overcoming Specification Ambiguity to Cut Rework Costs

Background

On custom stainless steel fabrication orders at Novelty Structures, unclear requirements had led to budget overruns, disagreements and delayed deliveries. Expensive cosmetic polishing had been applied across entire components, including hidden structural areas. Meanwhile, thin, flexible panels had passed workshop inspection but failed to fit during installation on site.

Conceptual stainless steel enclosure showing different surface finishes beside assembly sketches

Surface finish and inspection

Standardised 5-Point Fabrication Protocol

We introduced five clear specification requirements for all future procurement drawings:

Specification Rule Common Pitfall Standardized Requirement
1. Surface Zoning Applying a high polish to hidden structural parts. We marked visible, product-contact and hidden surfaces clearly on drawings.
2. Finish Criteria Using vague terms such as ‘polished’ or ‘cleaned’. We specified surface roughness (Ra), passivation treatment after fabrication to support corrosion resistance, and inspection methods.
3. Pre-Assembly Access Being unable to weld or clean internal joints after assembly. We checked access before closing assemblies and agreed checks at intermediate stages.
4. Restrained vs. Free Measuring flexible parts while clamped in holding fixtures. We defined whether dimensions applied to free-standing parts or parts held in the specified installed position.
5. Reference Sample Inconsistent quality across repeat orders. We kept the first approved unit (‘golden sample’) with its drawing revision, finish records and material certificates.

How can we help you ?

Stainless steel fabrication is widely used across various industries and its success depends on the careful selection of a stainless steel fabricator.

Novelty Structures provides high-quality stainless steel fabrication services tailored to demanding industrial needs.

Contact our team to further discuss your needs.

FAQ

What is stainless steel fabrication?2024-12-26T23:25:49+00:00

Stainless steel fabrication refers to the process of creating stainless steel structures, components, or products by cutting, bending, welding, and assembling various pieces of stainless steel material. It’s commonly used in industries like construction, food processing, aerospace, and automotive due to stainless steel’s durability, corrosion resistance, and aesthetic appeal.

What are the main advantages of stainless steel over other metals?2024-12-26T23:26:20+00:00
  • Corrosion Resistance: Stainless steel is much more resistant to rust, corrosion, and staining compared to other metals like carbon steel or aluminum.
  • Non-reactive: It doesn’t react with food, beverages, or chemicals, making it perfect for medical, food, and beverage industries.
  • Long-lasting: Its durability ensures it lasts longer without the need for frequent replacement or repairs.
What is the difference between MIG and TIG welding for stainless steel?2024-12-26T23:26:56+00:00
  • MIG (Metal Inert Gas) welding: Faster and easier to learn, MIG welding is commonly used for thicker pieces of stainless steel and high-production environments. It requires a continuous wire feed and uses a shielding gas.
  • TIG (Tungsten Inert Gas) welding: Provides more precise and cleaner welds, making it ideal for thinner stainless steel. It requires more skill but offers superior control, especially for intricate or high-quality applications.
Can stainless steel be painted or coated?2024-12-26T23:27:39+00:00

Yes, while stainless steel is often used for its natural appearance, it can be painted or coated for additional protection or aesthetic purposes. Common coatings include:

  • Powder Coating: Adds color and enhances durability.
  • PVD (Physical Vapor Deposition): Adds decorative colors like gold, black, or bronze while retaining stainless steel’s durability.
  • Epoxy Coatings: Used in harsh environments for additional corrosion protection.
Is stainless steel magnetic?2024-12-26T23:28:13+00:00

It depends on the type of stainless steel:

  • Austenitic stainless steels (e.g., 304 and 316): Typically non-magnetic in their annealed state but can become slightly magnetic after cold working.
  • Ferritic and Martensitic stainless steels (e.g., 430 and 410): Magnetic due to their higher iron content and crystalline structure.
What challenges arise during stainless steel fabrication?2024-12-26T23:28:53+00:00

Some challenges include:

  • Work Hardening: Stainless steel tends to harden when worked, which can make cutting and forming more difficult.
  • Thermal Expansion: It has a high rate of thermal expansion, which must be managed during welding to prevent warping.
  • Corrosion during Fabrication: Improper handling, such as using contaminated tools, can introduce rust or surface damage.
  • Precision Welding: Welding stainless steel requires precise temperature control to avoid overheating, discoloration, or weakening.
How does stainless steel compare to aluminum in fabrication?2024-12-26T23:29:55+00:00
  • Corrosion Resistance: Stainless steel is generally more corrosion-resistant than aluminum.
  • Strength: Stainless steel is stronger and more durable but also heavier.
  • Weight: Aluminum is lighter, making it ideal for applications where weight is a concern.
  • Cost: Aluminum is typically less expensive but may require more maintenance over time.
  • Applications: Aluminum is commonly used in lightweight structures, while stainless steel is preferred for strength, durability, and hygienic requirements.
What is the difference between cold-rolled and hot-rolled stainless steel?2024-12-26T23:30:33+00:00
  • Cold-Rolled Stainless Steel: Rolled at room temperature, it has a smooth surface, precise dimensions, and increased strength. It’s used for applications requiring tight tolerances and a polished finish.
  • Hot-Rolled Stainless Steel: Rolled at high temperatures, it’s easier to form and is more cost-effective, but it has a rougher surface and less precision. It’s often used for structural or heavy-duty applications.
How do you prevent warping during stainless steel fabrication?2024-12-26T23:31:04+00:00

To prevent warping:

  • Proper Welding Techniques: Use controlled heat input and alternate welds on opposite sides.
  • Clamping: Secure the stainless steel firmly during welding or cutting.
  • Cooling: Allow the material to cool naturally or apply controlled cooling methods.
  • Stress Relief Treatments: After fabrication, stress-relieving processes can help minimize residual stress.
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Novelty Steel offers Turkish steel fabrication solutions to various industries with broad scope of applications.

For all inquiries please contact : [email protected]

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