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A Deep Dive into Super Duplex Zeron 100: Features & Uses
Published on 25 May, 2025
When high performance meets extreme durability, one alloy that stands out in demanding environments is Super Duplex Zeron 100. Developed for applications where corrosion resistance and strength are non-negotiable, Zeron 100 has become a go-to material in sectors like offshore oil & gas, desalination, marine engineering, and chemical processing. In this blog, we take a closer look at what makes Zeron 100 a superior super duplex stainless steel and why it's the material of choice for critical industrial operations.
What is Super Duplex Zeron 100?
Super Duplex Zeron 100 is a highly alloyed stainless steel with a mixed microstructure of austenite and ferrite. It offers exceptional resistance to corrosion, especially in environments containing chlorides or aggressive chemicals. With higher chromium, molybdenum, and nitrogen content compared to standard duplex steels, Zeron 100 exhibits enhanced mechanical properties and corrosion resistance.
Key Features of Zeron 100
| Feature | Details |
| Chemical Composition | Approx. 25% Cr, 7% Ni, 3.6% Mo, 0.7% Cu, 0.2% N |
| Tensile Strength | Typically over 750 MPa |
| Yield Strength | Approximately 550 MPa |
| Corrosion Resistance | Excellent resistance to pitting, crevice, and stress corrosion cracking |
| PREN Value | > 40 (Pitting Resistance Equivalent Number) |
| Operating Temperature | -50°C to +300°C |
| Weldability | Good, with recommended filler metals and procedures |
| Impact Strength | High impact resistance even at sub-zero temperatures |
Advantages of Using Zeron 100
1. Superior Strength: Stronger than austenitic or standard duplex steels, reducing material thickness in design.
2. Corrosion Resistant: Performs reliably in harsh environments including seawater, acids, and brine solutions.
3. Long-Term Cost Efficiency: Extended lifespan and reduced maintenance needs due to its durability.
4. Thermal Stability: Maintains structural integrity under high pressure and temperature fluctuations.
Common Industrial Applications
Zeron 100 is used extensively in sectors where durability and corrosion resistance are mission-critical:
1. Oil & Gas: Subsea pipelines, risers, manifolds, and pressure vessels
2. Desalination Plants: High-pressure pumps, piping, and evaporation components
3. Chemical Processing: Reactors, tanks, and acid-handling systems
4. Marine Engineering: Shafts, propellers, and seawater cooling systems
5. Mining: Slurry handling and equipment exposed to aggressive chemicals
Zeron 100 vs Other Duplex Steels
| Property | Zeron 100 | Duplex 2205 | Austenitic 316L |
| Strength | Very High | Moderate | Low |
| Corrosion Resistance | Excellent | Good | Moderate |
| Chloride Resistance | Superior | Moderate | Low |
| Cost Efficiency | High (Long Term) | Medium | Low (Short Term) |
| Operating Temperature | -50°C to 300°C | -45°C to 250°C | -196°C to 870°C |
If you're working in a highly corrosive or mechanically demanding environment, Super Duplex Zeron 100 is one of the most reliable and cost-effective material choices available today. With its excellent mechanical properties, long lifespan, and broad application range, Zeron 100 helps industries achieve optimal performance and safety standards.
Always ensure you procure Zeron 100 from certified metal suppliers who offer material traceability, Mill Test Certificates (MTCs), and expert consultation. Because in challenging environments, the right material isn't optional — it's essential.
Need help sourcing Zeron 100? Contact our team at Online Fittings for expert guidance and high-quality alloy solutions.
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Online Fittings is a privately held stockiest and distributors of Stainless Steel and Alloy Steel, the head office in Mumbai.Our company's vision is to understand our customers requirements and meet them fully to their entire satisfaction by way of high quality, competitive price and prompt service.
