Monel® alloys are nickel-based alloys that contain between 29 and 33

percent copper. Initially created by metallurgist Robert Crooks Stanley and

patented in 1905 by the International Nickel Company. The metal was given the
name Monel in honor of the then-director of International Nickel. Not
surprisingly, Stanley later became Director of International Nickel.

By 1908, Monel was being used as a roofing material for Pennsylvania Station
in New York.

During the 1920's and later, Monel was used for countertops, sinks, appliances,
and roof flashing. While Monel was among the most popular metals on the
market through the 1940's, it was largely replaced by the more versatile
stainless steels from the 1950's onward.

Types of Monel

There are six types of Monel. All contain a large percentage of nickel (up to
67%), while some iron, manganese, carbon, and/or silicon. Small additions
of aluminum and titanium, which form the K-500 alloy, increase strength,
particularly at high temperatures, making it useful in aerospace applications.

Designation Cu % Al % Ti % Fe % Mn % Si % Ni %
Monel 400 28-34 - - 2.5 max. 2.0 max. - 63 min.
Monel 405 28-34 - - 2.5 max. 2.0 max. 0.5 max. 63 min.
Monel K-500 27-33 2.3-3.15 0.35-0.85 2.0 max. 1.5 max. - 63 min.

Uses for Monel

Monel® alloys are most often found in chemical plant equipment due to
their strong resistance to chemical corrosion.

They are also used in the aerospace industry. Products built with Monel
(particularly before the advent of stainless steel) include heat exchangers,
screw machine products, wind instruments, piping systems, fuel and water
tanks, kitchen sinks, and roofing.

Advantages and Disadvantages

Advantages:

Monel® alloys have a great deal to offer.

Prior to the 1950's, they were the "go to" choice for many critically important
industries. It could also be easily welded, soldered, and brazed. This is because
of its:
  high corrosion resistance to acids and alkalis
 high mechanical strength
 good ductility (easy to shape and form)
 resistance to alkalis
 relatively low cost
 availability in different forms including hot and cold-rolled sheets, plates,
rods, bars, and tubes
 attractive appearance and finishes, including a gray-green patina similar
to copper

Disadvantages:

While Monel has a number of advantages, it is far from the perfect metal. The
machinability of these alloys is poor because of their tendency to quickly work-
harden.

 While surface discoloration in the form of a patina may be attractive in

some circumstances, it can create problems in others.
 While it is resistant to corrosion, it can become pitted if exposed to salt
water.
 While it is corrosion resistant under many circumstances, it can corrode
when exposed to certain substances. For example, nitric oxide, nitrous
acid, sulfur dioxide, and hypochlorites are all substances that can corrode
Monel.
 The presence of Monel can lead to galvanic corrosion. In other words, if
aluminum, zinc, or iron are used as fasteners for Monel and then exposed
to certain conditions, the metal fasteners will quickly corrode.
Applications:

Monel 400 is a material in a variety of applications, and is applied in many

industrial areas.
1. Feed-water and steam generator in power plants;
2. Brine heaters and evaporator bodies in seawater desalination plants;
3. Pumps and values used in the manufacture of chlorinated hydrocarbons;
4. Cladding for crude oil distillation columns;
5. Splash-zone sheathing in offshore structures;
6. Plants for uranium refining and isotope separation in the production of nuclear
fuel;
7. Propeller and pump shafts for seawater service.