Nickel and nickel alloys are non-ferrous metals with high strength and toughness, excellent corrosion resistance, and superior elevated temperature properties. Products differ in terms of composition, grade, shape, dimensions, and features. Commercially pure, unalloyed, or very low alloy nickel does not contain or contains only very small amounts of alloying elements. By contrast, nickel alloys contain significant amounts of added elements or constituents. Clad or bimetal stock consists of two different alloys that are bonded integrally together. Metal matrix composites have a composite or reinforced metal or alloy matrix filled with a second component, which may be in particulate, chopped fiber, continuous filament, or fabric form. Other unlisted, specialty or proprietary nickel and nickel alloys are also available. These materials are often based on a unique alloy system, use a novel processing technology, or have properties tailored for specific applications.
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Many nickel and nickel alloys meet the compositional standards of the Unified Numbering System (UNS), a specification established by the American Society for Testing and Materials (ASTM), the Society of Automotive Engineers (SAE), and metal trade associations such as the American Iron and Steel Institute (AISI). The UNS assigns metals and alloys a lettered prefix and a five-digit number. Nickel and nickel alloys belong to the UNS N category and have designations such as UNS N. Other standards for nickel and nickel alloys include casting grades, European Norm (EN), American Society of Mechanical Engineers (ASME) standards, and U.S. military specifications (MIL-SPEC). QQ and QQS prefixes are used to designate specific MIL-SPEC metals.
Selecting nickel and aluminum alloys requires an analysis of dimensions, production processes, and performance features. Outer diameter (OD), inner diameter (ID), overall length, and overall thickness are important dimensions. Most materials are cast, wrought, extruded, forged, cold-finished, hot-rolled, or formed by compacting powdered metals or alloys. Performance features for nickel and nickel alloys include resistance to corrosion, heat, and wear.
Disclaimer: This information is provided &#;as is&#; and MSS makes no warranty of any kind with respect to the subject matter or accuracy of the information contained herein. MSS specifically disclaims all warranties, expressed, implied or otherwise, including without limitation, all warranties of merchantability and fitness for a particular purpose. In no event shall MSS be liable for any special, incidental, indirect or consequential damages of any kind or any damages whatsoever resulting from loss of use, data, profits, whether or not advised of the possibility of damage, and on any theory of liability, arising out of or in connection with the use of the information contained herein. This publication may include technical inaccuracies or typographical errors. Changes may be periodically made to the information herein.
Nickel Alloy Grades
Inconel, a robust nickel alloy, is available in wire mesh, perforated metal, expanded metal, and bar grating. Inconel wire mesh is renowned for its superior strength, resistance to extreme temperatures, and corrosion and oxidation resistance, making it ideal for high-stress applications like petrochemical, oil & gas, and chemical processing. Perforated Inconel metal offers high structural integrity, ensuring longevity in corrosive environments. Inconel expanded metal demonstrates increased tensile strength, making it perfect for architectural applications. Lastly, custom Inconel bar grating provides a durable, non-slip surface that remains stable even under intense conditions and is widely utilized in industrial platforms. Each form harnesses Inconel&#;s unique properties, delivering performance-enhanced solutions for diverse industry needs.
Inconel Grades
Inconel 601 offers enhanced resistance to high-temperature oxidation
Monel 400 Nickel Alloys
Monel 400 is a nickel-copper alloy known for its superior strength and excellent corrosion resistance, particularly in marine and chemical environments. With a composition of approximately 67% nickel and 23% copper, this alloy exhibits notable resistance to a wide range of corrosive conditions, including saltwater, acidic and alkaline substances. It also possesses high thermal conductivity and maintains its strength even at very low temperatures, making it a versatile material for numerous industries such as marine engineering, chemical processing, and oil & gas.
Incoloy 800 and Incoloy 825 are part of the renowned family of nickel-iron-chromium alloys known for their exceptional corrosion resistance and ability to withstand high temperatures. These alloys are meticulously designed to offer a robust combination of strength, durability, and oxidation resistance. The predominant elements in their composition&#;nickel, iron, and chromium&#;play crucial roles in enhancing their properties. Nickel provides remarkable resistance to both high temperatures and corrosive environments, making these alloys suitable for various demanding industrial applications. Chromium contributes to their oxidation resistance, while iron reinforces their structural integrity, adding to their overall toughness.
Incoloy 800, known for its stability and strength in high-temperature environments, is commonly used in applications where resistance to heat and corrosion is paramount. This includes the construction of heat exchangers, furnace components, and petrochemical processing equipment. Its ability to maintain structural integrity under high-temperature conditions makes it ideal for nuclear power plants and industrial heating elements.
In contrast, Incoloy 825 is particularly noted for its enhanced resistance to aqueous corrosion. It finds its applications in industries such as chemical processing, pollution control, and oil and gas recovery, where it is used for acid production equipment, oil well piping, and marine exhaust systems.
These alloys are available in Incoloy wire mesh, Incoloy perforated metal, Incoloy expanded metal, and Incoloy grating. Wire mesh and perforated metal are often utilized in filtration and separation processes, providing practical solutions in environments that demand durability and resistance to corrosive elements. Expanded metal and bar grating are employed for structural applications, offering strength and reliability in platforms, walkways, and stair treads, especially in settings that involve exposure to harsh chemicals or high temperatures.
Nichrome V is a specialized alloy composed primarily of nickel and chromium, typically containing around 80% nickel and 20% chromium. This unique combination endows the alloy with outstanding resistance to high temperatures and oxidation, making it an ideal material for applications that require enduring performance under heat stress. The high nickel content imparts excellent corrosion resistance and stability at elevated temperatures, while chromium enhances its oxidation resistance and contributes to its strength and durability.
Nichrome V is predominantly used in industries that demand high electrical resistance and thermal stability. One of its most common applications is in the manufacture of heating elements for industrial radiant heaters, electric furnaces, toasters, hair dryers, and other appliances that require consistent heat generation. The alloy&#;s ability to maintain its integrity and resist scaling even at temperatures up to °C makes it a preferred choice for such applications. Furthermore, its stability and reliability under thermal cycling conditions ensure long service life and efficiency, reducing maintenance costs and downtime.
Nichrome V woven wire mesh is particularly useful in the fields of filtration and separation, where it can withstand corrosive environments and high temperatures without degrading. Additionally, the mesh is utilized in the aerospace and automotive industries for applications such as mufflers and catalytic converters, where both heat resistance and structural integrity are essential. The exceptional properties of Nichrome V, combined with its availability in wire mesh form, make it a critical material for demanding applications that require resilience and reliability in harsh conditions.
Hastelloy C276 is a highly regarded nickel-molybdenum-chromium alloy known for its exceptional resistance to corrosion and high-temperature environments. The alloy&#;s composition includes a significant amount of nickel, which enhances its corrosion resistance, particularly against reducing agents. Molybdenum contributes to the alloy&#;s ability to withstand pitting and crevice corrosion, while chromium provides resistance to oxidizing media. These elements combine to make Hastelloy C276 one of the most reliable materials for applications requiring durability and robustness in harsh conditions.
Alloy 20, also known as Carpenter 20, is a nickel-iron-chromium alloy that is specifically designed to offer superior resistance to acid attack, particularly sulfuric acid. The alloy&#;s composition includes nickel, chromium, and molybdenum as its key elements. Nickel is crucial in enhancing its resistance to general corrosion, while chromium contributes to its oxidizing resistance. Molybdenum, on the other hand, provides added protection against pitting and crevice corrosion. This combination of elements makes Alloy 20 an excellent choice for applications that require durability in harsh chemical environments.
Nickel 200 is a commercially pure wrought nickel alloy, composed of at least 99.6% nickel. This high nickel content is pivotal in imparting several advantageous properties to the alloy, including excellent corrosion resistance, particularly in reducing environments. The purity of Nickel 200 ensures superior performance against a wide range of corrosive substances, such as alkalis and certain acids, making it a preferred choice in industrial settings where chemical exposure is a concern. Additionally, Nickel 200 exhibits remarkable mechanical properties, such as high ductility and toughness, even at sub-zero temperatures.
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Nickel-based alloys, as the name implies, are a type of casting materials primarily composed of nickel, combined with various other elements like chromium, molybdenum, iron, and copper. The exact composition varies, with nickel typically making up more than 50% of the alloy, depending on the specific application requirements and performance needs. These alloys are known for their exceptional corrosion resistance, heat resistance, and other unique properties that make them suitable for various applications. So, nickel based alloy casting is a common casting type in CFS Foundry.
The composition of nickel-based alloys can vary significantly based on the specific alloy and its intended use. However, the majority of these alloys contain over 50% nickel, with the remaining being a mixing of various elements. The primary elements are listed as below:
Elements Features Nickel The base element of these alloys, nickel, is valued for its corrosion resistance, heat resistance, and durability. Nickel also contributes to the alloy&#;s overall mechanical strength and toughness. Chromium Chromium is typically the second most abundant element in nickel-based alloys, often ranging from 15% to 20%. It enhances the alloy&#;s resistance to oxidation and corrosion, particularly at high temperatures. Chromium forms a protective oxide layer on the surface of the alloy, protecting it from various corrosive elements. Iron Iron is often added to nickel-based alloys to enhance their magnetic properties and increase their thermal expansion characteristics. It also contributes to the alloy&#;s overall mechanical strength. Molybdenum Molybdenum is another critical element in many nickel-based alloys. It enhances strength at high temperatures and improves resistance to pitting and crevice corrosion, especially in chloride environments. Cobalt Cobalt is used in some nickel-based alloys to increase their high-temperature strength and magnetic properties. Tungsten & Aluminium These elements are often added to create precipitate hardening nickel-based alloys. They enhance the alloy&#;s heat resistance and overall strength. Copper Copper is added to certain nickel-based alloys to improve their resistance to various acids and to enhance their thermal conductivity. It can also increase the alloy&#;s antimicrobial properties. Other Elements Additional elements like titanium, niobium, and silicon may also be added in small quantities to nickel-based alloys to impart specific properties. For instance, titanium and niobium can enhance an alloy&#;s weldability, and silicon can improve its oxidation resistance.Nickel-based alloys, known for their superior performance under extreme conditions, come in various types, each bringing unique properties to the table. Below are some of the most common types of nickel-based alloys:
Inconel: Inconel alloys are primarily composed of nickel, chromium, and iron. They exhibit exceptional resistance to high temperatures, oxidation, and carburization. These alloys are widely used in applications that operate under extreme heat and pressure, such as gas turbine components and heat-treating equipment.
Monel: Monel alloys are composed primarily of nickel (up to 67%) and copper, with small amounts of iron and other elements. They are known for their excellent corrosion resistance, especially to seawater and a range of acids and alkalis. Monel is often used in marine engineering, chemical and hydrocarbon processing, and in valves and pumps.
Hastelloy: Hastelloy is a family of alloys that are primarily made of nickel, molybdenum, and chromium. They are highly resistant to uniform attack and localized corrosion such as pitting and crevice corrosion, and they also withstand high-temperature environments. As such, they are used in chemical processing, aerospace, and industrial gas turbines.
Nimonic: Nimonic alloys are nickel-based, with additional elements such as titanium and aluminium. They maintain their strength at high temperatures and are resistant to corrosion and oxidation, making them suitable for use in jet engines and gas turbines.
Incoloy: Incoloy alloys are nickel-iron-chromium alloys that are designed for high-temperature applications and to resist oxidation, carburization, and other types of high-temperature corrosion. They are typically used in heating elements, heat-treat furnaces, and in petrochemical and chemical processing.
Nickel-Copper Alloys: These are made of nickel and copper, the most common being Alloy 400. With high corrosion resistance, especially in marine saltwater environments, they are used in various applications in the chemical, oil, and marine industries.
Nickel-based alloys are lauded for a range of properties that make them the go-to materials in many applications:
Heat Resistance
Nickel-based alloys are famous for their resistance to high temperatures. They can maintain their structural integrity under intense heat, making them ideal for use in high-temperature environments, such as in jet engines or power plants.
Corrosion Resistance
Another significant characteristic of nickel-based alloys is their superior corrosion resistance. They can resist oxidation and other types of corrosion, even in harsh environments. This makes them suitable for use in applications exposed to corrosive substances or extreme weather conditions.
Durability and Strength
Nickel-based alloys are highly durable and possess exceptional mechanical strength. They offer excellent tensile strength and toughness, even at elevated temperatures. This is a key factor behind their use in heavy-duty applications and in industries like aerospace, marine, and chemical processing.
Magnetic Properties
Certain nickel-based alloys, such as Permalloy, have high magnetic permeability, meaning they can easily form a magnetic field. This makes them useful in various electrical and electronic applications.
Thanks to their unique attributes, nickel-based alloys find applications in a host of industries:
The future of nickel-based alloys in casting is exceptionally bright and ripe with potential. The continual drive towards efficiency in high-performance sectors like aerospace, automotive, and energy shows a growing demand for materials capable of withstanding increasingly severe operating conditions.
Nickel-based alloys, with their unparalleled heat and corrosion resistance, are anticipated to take center stage in fulfilling these demands. Advancements in materials engineering are expected to lead to the development of new nickel alloys with improved characteristics. Enhancements in strength, creep resistance, and weldability will allow these materials to be used in even more extreme conditions.
Meanwhile, innovations in casting technologies promise greater efficiency and precision in the production of nickel-based alloy components. Techniques such as investment casting or 3D printing offer the potential for creating highly complex parts with minimal waste, and digital technologies can enable more precise control over the casting process.
Moreover, the drive towards sustainability is pushing the industry to develop more environmentally friendly casting processes. The recycling of nickel-based alloys can play a significant role in this, helping to reduce the environmental footprint of casting operations.
In conclusion, the future of nickel-based alloys in casting is expected to be defined by continuous innovation in both materials and processes, to meet the evolving demands of various high-performance industries.
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