This work investigates the feasibility of using friction stir welding (FSW) process as a groove filling welding technique to weld duplex stainless steel (DSS) that is extensively used by petroleum service companies and marine industries. For the FSW experiments, three different groove geometries without root gap were designed and machined in a DSS plates 6.5 mm thick. FSW were carried out to produce butt-joints at a constant tool rotation rate of 300 rpm, traverse welding speed of 25 mm/min, and tilt angle of 3o using tungsten carbide (WC) tool. For comparison, the same DSS plates were welded using gas tungsten arc welding (GTAW). The produced joints were evaluated and characterized using radiographic inspection, optical microscopy, and hardness and tensile testing. Electron back scattering diffraction (EBSD) was used to examine the grain structure and phases before and after FSW. The initial results indicate that FSW were used successfully to weld DSS joints with different groove designs with defect-free joints produced using the 60° V-shape groove with a 2 mm root face without root gap. This friction stir welded (FSWed) joint was further investigated and compared with the GTAW joint. The FSWed joint microstructure mainly consists of α and γ with significant grain refining; the GTWA weld contains different austenitic-phase (γ) morphologies such as grain boundary austenite (GBA), intragranular austenite precipitates (IGA), and Widmanstätten austenite (WA) besides the ferrite phase (α) in the weld zone (WZ) due to the used high heat input and 2209 filler rod. The yield strength, ultimate tensile strength, and elongation of the FSWed joint are enhanced over the GTAW weldment by 21%, 41%, and 66% and over the BM by 65%, 33%, and 54%, respectively. EBSD investigation showed a significant grain refining after FSW with grain size average of 1.88 µm for austenite and 2.2 µm for ferrite.

1 st Duplex stainless steel 2 nd repair 3 rd Friction stir welding 4 th Groove joint 5 th fusion welding This work focuses on studying the repairing capability of defected 6.5 mm-thick SAF 2205 duplex stainless steel (DSS) plates, welded using friction stir welding and repaired using fusion welding processes, shielded metal arc welding (SMAW), and gas tungsten arc welding (GTAW). A special tool made of tungsten carbide (WC) based material, with dimensions of 12 mm pin diameter, 5.5 mm pin length, and 20 mm shoulder diameter was used, the friction stir welding (F W PM V V angles, and 2mm root face, were used without root opening. The welded joints were inspected using both visual test (VT) and radiographic teste (RT). The mechanical properties, corrosion resistance, micrograph, microstructure, and the balance between ferrite and austenite phases, were investigated and analyzed for the repaired joints. It was significantly observed that, the repaired joints were sound with good quality, good mechanical properties, good interface between weld metal and base metal, good balance between ferrite and austenite phases, and their corrosion resistance is better than base metal.