A Comparison of Sigma Phase Formation in Solubilized Hyper Duplex Stainless Steel and Super Duplex Stainless Steel Filler Metals

This study focuses on the kinetic analysis of sigma phase formation in filler metal wires on Super Duplex Stainless Steel (SDSS) and Hyper Duplex Stainless Steel (HDSS). Precipitation data reveal that in the solubilized microstructure, sigma phase kinetics are more prominent in SDSS. This increased susceptibility is attributed to the greater number of nucleation sites, which is facilitated by the larger interface area/volume and the higher chromium content in the ferrite. The difference in interface area/volume is significantly more influential in determining kinetics than the composition difference, with nucleation sites playing a central role. The sigma phase transformation in both materials was modeled using the JMAK kinetic law. The JMAK plots exhibit a transition in kinetic mechanisms, evolving from discontinuous precipitation to diffusion-controlled growth. In SDSS, the JMAK values indicate “grain boundary nucleation after saturation,” followed by “thickening of large plates.” In contrast, HDSS values point to “grain edge nucleation after saturation,” followed by “thickening of large needles.” The higher kinetics in SDSS are characterized by a smaller nucleation activation energy of 56.4 kJ/mol, in contrast to HDSS's 490.0 kJ/mol. CALPHAD-based data support the JMAK results, aligning with the maximum kinetics temperature of SDSS (875 °C to 925 °C) and HDSS (900 °C to 925 °C). Therefore, the JMAK sigma phase kinetics effectively describe the experimental data and its dual kinetics behavior, even though CALPHAD-based TTT calculations often overestimate sigma formation.