Austenitic and ferritic stainless steel dissimilar weld metal evaluation for the applications as-coating in the petroleum processing equipment

Highlights: ► Ferritic and austenitic stainless steels dissimilar welds with different heat inputs were performed. ► Microstructure evolution and corrosion caused by heavy petroleum were analyzed. ► The dissimilar weld produced a duplex structure. ► The heat input changes the dilution which modified microstructure and petroleum corrosion resistance to some extent. - Abstract: The current study presents some fundamental observations on the effects of the welding heat input in the chemical composition, microstructure, hardness and petroleum corrosion resistance of the fusion zone, formed by the AWS E309MoL austenitic stainless steel covered electrode and the AISI 410S ferritic stainless steel, being a dissimilar welding procedure. Such welding configurations are widely used as an overlay of equipment in the petroleum and gas industries. The welds were performed with the application of three different levels in heat inputs (6, 9 and 12 kJ/cm). Samples of the weld metals were conventionally prepared for the microstructural characterization by light microscopy and scanning electron microscopy. A corrosion test with samples immersed in heavy oil heated at 300 °C, was carried out for a period of 60 h. The corrosion rate was determined by the weight loss given after the aforesaid test. The fusion zone microstructure has a typical δ-ferrite acicular morphology, from which the level of δ-ferrite was duly altered with the increases of the welding heat input, due to the variations in the composition of the weld metal caused by dilution. It was also concluded that the chemical composition and the weld metal microstructure had a slight influence in the material's corrosion rate. As a matter of fact, the corrosion rate of the weld metals evaluated herein, was considered satisfactory with few variations between the welding heat inputs duly applied