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Stainless Steel and Carbon Steel Welding

08/13/2014 1:27 AM

When there is material break in piping/equipment's we use insulation gasket to avoid Galvanic corrosion. But we can weld carbon steel and stainless steel by using 9 chrome welding rod or by using any filler material for dissimilar materials. My question is if we can weld two dissimilar materials then why for Stainless steel pipes having larger dia we use same material (SS) supports. ( We can use C.S for cost saving)

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#1

Re: STAINLESS STEEL AND CARBON STEEL WELDING

08/13/2014 3:18 AM

I don't know why you do what you do. Perhaps your standards are telling you to do that. Why don't you talk to the individuals who wrote and published your standards?

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#2
In reply to #1

Re: STAINLESS STEEL AND CARBON STEEL WELDING

08/13/2014 3:27 AM

If we can weld both materials and technically it is correct than we can change or modify our standard drawings as per technical clarification to reduce cost.

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#3
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Re: STAINLESS STEEL AND CARBON STEEL WELDING

08/13/2014 3:29 AM

Then you need to be talking to the authors of your standard drawings and selling the idea to them instead of wasting time here. Perhaps they don't want rusty pipe supports under their stainless steel pipes - I don't know!

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#4

Re: Stainless Steel and Carbon Steel Welding

08/13/2014 9:48 AM

Sure- why not?

Assuming of course, that your customer is happy with that. Piping systems have to be compatible with both the internal environment (material conveyed) and the external environment. So a carbon steel support- especially welded to SS pipe- will likely result in base material dilution and reduced resistance to some materials. That would likely be fine in a dry cleaning operation but could be a nightmare when dealing with things like HCl or even saltwater (such as a desalination facility). Even having the carbon steel contacting- and possibly rubbing against- the SS can lead to rusting on the surface of the SS, as well as any galvanic potential issues.

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#5
In reply to #4

Re: Stainless Steel and Carbon Steel Welding

08/13/2014 10:47 AM

That is a good illustration as to why standards are necessary. Have a Team-point.

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#6

Re: Stainless Steel and Carbon Steel Welding

08/13/2014 2:23 PM

Not my field.

We had a thread a year or so ago with considerable detail given to similar issues. As I recall you don't actually get galvanic corrosion between atoms in an alloy but you aren't 100% clear of undesirable things happening in an alloy. Your welding of SS & CS is creating a new alloy by blending the SS alloy with the CS alloy.

Pipes and supports are not welded and therefore you are not creating an alloy with the two materials. I think that is a very important distinction. If you Google up "Practical Galvanic Series" by Charles M. Farman & E.A. Verchot (or other galvanic potential tables) you will see that even the exact same metal will have different galvanic potentials based upon slight issues such as the surface treatment. Your SS & CS will have small differences in their galvanic potential and therefore will be at risk of corrosion. This won't be as dramatic as with totally different metals but it will be present.

Does this mean you shouldn't do it? I don't know.

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#7

Re: Stainless Steel and Carbon Steel Welding

08/13/2014 10:44 PM

As JNB pointed out, rust will be an issue and rust is not the same as corrosion.

I agree supports should not be welded, but I would certainly paint all the CS used.

so the as- built drawings must show what was actually used if the prints aren't revised.

(Sent from my phart smone)

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#8

Re: Stainless Steel and Carbon Steel Welding

08/13/2014 11:04 PM

It not common practice to weld piping to supports due to the expansion/contraction differences of the different metals.

If the carbon steel and the stainless steel must be welded to each other, it is common practice to weld these with a stainless steel rod of the same alloy as the stainless steel piece. For example if carbon steel is welded to 304 stainless steel a 304, 308 or 316 rod would be used. If it CS to 316 Stainless, a 316 stainless rod would be used.

If a patch is to be made on the wall of the pipe, stainless can be used for the patch material on either CS or Stainless pipe.

This method can also be used for CS patches on CS pipe only in situations where CS is compatible with the material within the pipe, does not rust and put steel rust particles in the transferred materials.

Good Luck, Old Salt

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#9

Re: Stainless Steel and Carbon Steel Welding

08/14/2014 4:02 PM

A very simple reason appears to me. A little common sense will tell you that the most likely reason for the use of SS is corrosion resistance. When you weld it with CS, you've destroyed the corrosion resistance in that area. If this is a sanitary application, you will totally destroy that function and make the process people very unkind to you.

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