Suranaree University of Technology May-Aug 2007

Nickel and its alloys

Nickel and its alloys
Subjects of interest
Objectives/Introduction
Production of nickel and nickel alloys
Commercially pure nickel
Nickel-copper alloys (Monels)
Nickel-chromium alloys
Nickel-base superalloys
Single crystal castings of nickel-base
superalloys
Lecture 6
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Objectives
Objectives
This chapter provides fundamental knowledge of
different methods of productions of nickel alloys and the
use of various types of nickel alloys.
The influences of alloy composition and microstructure
on chemical and mechanical properties of nickel alloys will
be discussed in relation to its applications.
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Introduction
Introduction
Properties
Silvery shiny appearance
High toughness and ductility
Good high and low
temperature strength
High oxidation resistance
Good corrosion resistance
Ferro-magnetic
Relatively high cost
Not mixed with cheap
alloying elements.
Limitations
Nickel
Ni
Crystal structure FCC
Atomic number 28
Atomic weight 58.71
Density (g.cm
-3
) 8.89
Melting point (
o
C) 1455
28
58.71
FCC
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Applications
Applications
Applications required necessary corrosion or heat- resisting
properties and for special engineering applications.
Chemical plant, heat exchanger, reaction furnace, rotary kiln,
turbine blades.
Used as alloying elements in stainless steels, and in other
elements such as copper, cobalt, chromium, etc.
Aerospace flow bodies
www.immnet.com
Turbine blades
www.msm.cam.ac.uk
Heat exchangers Reaction furnace
Rotary kiln
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Production of nickel
Production of nickel
www.mii.org
First discovery of nickel mineral by the German was
mistakenly misunderstood to be rich-copper mineral.
There are three major types of nickel deposits (sources):
1) Nickel-copper sulphide
2) Nickel silicates
3) Nickel laterites and serpentines
Nickel laterite deposits
research.eas.ualberta.ca/ egg/nilaterite.jpg
Nickeline or niccolite
Serpentine deposits
home.arcor.de
Tapany Udomphol
Extraction of nickel
Extraction of nickel
Nickel-sulphide ore
(Fe, Cu)
Crushing
Grinding
Magnetic separation
Iron sulphide
(pyrrhotite
concentrate)
Iron ore
recovery plant
Froth flotation treatment
Nickel concentrate Copper concentrate
Remaining ore
(Ni, Cu)
Copper
smelter
Roasting
Smelting (Reverberatory furnace)
Bessemer matte
(Ni and Cu sulphides)
Recrystallisation
Cooling
Crushing & grinding
Crystals of Ni and Cu
sulphides.
Ni-Cu metallic alloy
Froth flotation
Copper sulphide Nickel sulphide
Different grade
of nickel oxides
Roasting
Nickel refinery
Pure nickel and
other nickel alloy
products
Suranaree University of Technology May-Aug 2007
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Classification of nickel alloys
Classification of nickel alloys
There are different types of nickel and nickel alloys;
1) Commercially pure nickel
2) Nickel-copper alloys (Monels)
3) Nickel-chromium alloys
4) Nickel-base superalloys
5) Nickel-iron superalloys
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Commercially pure nickel
Commercially pure nickel
High purity nickel contains 99.99% Ni.
Commercially pure nickel contains
99.5% Ni (+Co).
Microstructure consists of solid solution
phase in annealed condition.
Cold drawn Nickel 200 annealed
at 829
o
C
Properties
Good mechanical properties
and retains its strength at
elevated temperature.
Excellent resistance to most
corrosive environment.
Applications
Food processing equipment
Electrical & electronic parts
Caustic handling equipment.
100 x
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Nickel
Nickel
-
-
copper alloys (
copper alloys (
Monels
Monels
)
)
Ni and Cu form complete solid solution.
Most important Ni-Cu alloy contains
67%Ni and 33%Cu, called Monels.
Properties
Applications
High strength and toughness over
a range of temperature.
Good weldability
Excellent corrosion resistance
Microstructure of
cold drawn Monel
R405 and
annealed at 829
o
C,
showing solid
solution phase of
Ni-Cu with
sulphide stringers
(black)
Values, pumps, marine fixtures
and fasteners.
Chemical processing equipment.
Oil-well drill collars and
instruments.
Ni-Cu phase diagram
250 x
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Nickel
Nickel
-
-
chromium alloys
chromium alloys
Cr forms solid solution with Ni up to~30%
at RT. High corrosion resistance is due to
high Cr addition.
Inconel 600 (15.5%Cr, 8%Fe) is a
standard engineering alloy. Other Ni-Cr
alloys are Inconel 601 and 625 with
improved properties.
Ni-Cr phase diagram
Properties
Applications
High corrosion resistance at
high temperature.
High strength and workability.
Heat exchanger tubing
Chemical and food
processing equipment.
Furnace muffle.
Inconel 600, solution
heat-treated at
1200
o
C/1h+870
o
C/4h,
showing solid solution
phase with chromium
carbide precipitates at
GBs and some titanium
carbides and nitrides
within the grains
1500 x
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Nickel
Nickel
-
-
base
base
superalloys
superalloys
High temperature heat-resistance alloys, which can retain
high strengths at elevated temperatures.
Properties
Applications
Heat resistant and high strength at high
temperature (760-980
o
C).
Good corrosion resistance.
Good oxidation resistance.
There are three types of Ni-base superalloys; nickel base, nickel-
iron base and cobalt base. The alloys contain high Cr with Ti, Al to
from precipitates and additions of Mo, Co, Nb, Zr, B, Fe.
Microstructures are complex.
Aircrafts, space vehicles, rocket engines
Industrial gas turbines, high temp applications.
Nuclear reactors, submarines.
Steam power plants, petrochemical equipment.
www.stratcor.com
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Microstructure of nickel base
Microstructure of nickel base
superalloys
superalloys
The major phases present in the nickel-base superalloys:
1) 1) 1) 1) (gamma) phase the continuous matrix of FCC austenite.
2) 2) 2) 2) (gamma prime) phase the major precipitate phase
(more cubic shape).
3) Carbides various types, mainly M
23
C
6
and MC. M = metal.
Complex microstructure of astroloy
forging after heat treatments
10,000 x
Carbides
at GB
Note: GB carbides affect high-temp strength, ductility, creep.
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Nickel
Nickel
-
-
iron
iron
superalloys
superalloys
Fe is added to replace some of Ni as it has lower cost.lowering
the properties as compared with nickel base superalloy.
therefore it is used at lower temperatures.
Ni-Fe superalloys contains 25-45%Ni and 15-60%Fe.
Higher Ni content increases operating temp (upto 815
o
C), due to
improved stability but more costly.
Ex: Inconel 707, 718, 901.
Microstructure consists of
austenistic FCC matrix and can
be strengthened by solid solution
strengthening (Mo, Cr), and
precipitation hardening (Ti, Nb, Al)
by forming intermetallic phases.
15,000 x
Optical micrograph of
Inconel 901 after
precipitation hardening
SEM micrograph of Inconel 718
after exposure at 705
o
C/6,048
h, 37 ksi
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Single
Single
-
-
crystal castings of
crystal castings of
nickel
nickel
-
-
base
base
superalloys
superalloys
A major increase in strength and temperature capability of
superalloy casting has been much improve with the introduction of
columnar-grained and single crystal casting.
Diagram of setup
for single crystal
casting
www.nap.edu
Simulation of
evolution of grain
structure in a single
crystal casting.
Turbines blades are
cast using a spiral
starter
Competitive
grain
www.msm.cam.ac.uk
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
Applications of single
Applications of single
-
-
crystal castings of
crystal castings of
nickel
nickel
-
-
base
base
superalloys
superalloys
Used in production of aerofoils, gas turbine engines,
which allow the operating temperature range ~ 50
o
C higher
than normal materials.
Single crystal casting
of superalloy
www.grc.nasa.gov
Property
comparison
between
polycrystal,
columnar
crystal and
single crystal
(a) Polycrystal
(b) Columnar
crystal
(c) Single
crystal
Tapany Udomphol
Suranaree University of Technology May-Aug 2007
References
References
. a.a. +..+..+ . :-. u.uu+..a..a+a. ISBN
974-582-155-1.
Smith, W.F., Structure and properties of engineering
alloys, second edition, 1993, McGraw-Hill, ISB 0-07-59172-5.
www.cda.org.uk.
Heuner, U., Nickel alloys, 1998, Marcel Dekker, Inc., ISBN
0-8247-0440-1.
Tapany Udomphol