Evaluating the Effects of 309 and 2594 Filler Alloys on the Tensile Strength, Toughness, and Corrosion Resistance of Dissimilar Welds between Duplex S32550 and TP304 Using Multi-Process TIG and MMAW

Syukran; Winarto Winarto; Muhammad Anis

doi:10.48084/etasr.18167

Authors

Syukran Department of Metallurgical and Material Engineering, Faculty of Engineering, Universitas Indonesia, Depok, Indonesia
Winarto Winarto Department of Metallurgical and Material Engineering, Faculty of Engineering, Universitas Indonesia, Depok, Indonesia
Muhammad Anis Department of Metallurgical and Material Engineering, Faculty of Engineering, Universitas Indonesia, Depok, Indonesia

Volume: 16 | Issue: 3 | Pages: 35013-35021 | June 2026 | https://doi.org/10.48084/etasr.18167

Received: 14 February 2026 | Revised: 18 March 2026 | Accepted: 26 March 2026 | Online: 6 June 2026

Corresponding author: Winarto Winarto

Abstract

This study evaluates the influence of filler alloys ER309 and ER2594 on the tensile strength, impact toughness, and corrosion resistance of dissimilar welds between duplex S32550 and austenitic TP304, produced using a combined TIG and MMAW welding process. The results demonstrate that filler 2594 outperforms filler 309 across all evaluated properties. Welded joints fabricated with filler 2594 achieved a higher Ultimate Tensile Strength (UTS) of 537.48 MPa (72.8% joint efficiency), compared to 508 MPa (68.8% efficiency) for filler 309. Charpy impact testing at −40°C further demonstrated superior toughness for filler 2594 (56.47 J) compared to filler 309 (52.73 J), which is attributed to a more favorable ferrite–austenite phase balance and higher nitrogen content. Fracture during tensile testing consistently occurred in the Heat-Affected Zone (HAZ) of the TP304 base metal, identifying this region as the primary mechanical weakness of the joint. Corrosion performance, evaluated through potentiodynamic polarization in a 1% H₂SO₄ solution, revealed a significantly lower corrosion rate for Filler 2594 (1.21 mm/a) compared to filler 309 (19.24 mm/a), representing more than an order of magnitude improvement. This enhanced resistance is associated with the higher Pitting Resistance Equivalent Number (PREN) and improved passive film stability of filler 2594. Overall, the findings indicate that filler 2594 is the optimal choice for dissimilar welding of S32550 and TP304, providing superior tensile efficiency, improved low-temperature toughness, and excellent resistance to aggressive corrosive environments.

Keywords:

dissimilar welding, duplex S32550, TP304, filler 2594, filler 309, corrosion resistance, mechanical properties

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