HEAT AND CORROSION RESISTANT CASTINGS:

THEIR ENGINEERING PROPERTIES

AND APPLICATIONS

Publication No 266

NiDl
Distributed by the
Nickel Development Institute,
courtesy of Inco Limited
 Contents
Pages
Part I. Heat-Resistant Alloy Castings ........................................................... 4-26
Introduction ....................................................................................................... 4
Typical Casting Compositions of Heat-Resistant Alloy Castings, Table I ...... 4

Effect of Constituents ........................................................................................ 5

Groups of Heat-Resistant Alloy Castings ...................................................... 6-8

Chromium-Iron Alloys (HA, HC, HD)
Chromium-Nickel-Iron Alloys (HE, HF, HH, HI, HK, IN-519, HL)
Nickel-Chromium-Iron Alloys (HN, HP, HT, HU, HW, HX)
Chromium-Nickel Alloys (50Cr-50Ni, IN-657)

Selecting the Proper Alloy ................................................................................. 8

Heat-Resistant Alloy Casting Design ................................................................ 9

High-Temperature Mechanical Properties ................................................... 9-15

High-Temperature Corrosion Resistance .................................................. 14,16

Room Temperature Properties ....................................................................... 16

Industrial Applications of Heat-Resistant Alloy Castings

Aeronautical ................................................................................................. 17
Cement ........................................................................................................ 17
Glass & Enameling ................................................................................. 17-18
Heat Treating .......................................................................................... 18-21
Petroleum, Petrochemical Refining &Chemical ...................................... 22-24
Power Plants ............................................................................................... 25
Steel Mill Equipment .................................................................................... 26
Smelting & Refining Equipment ................................................................... 26

2
Part II. Corrosion-Resistant Alloy Castings .......................................................... 27-47
Introduction ............................................................................................................... 27
Typical Casting Compositions of Corrosion-Resistant Alloy Castings, Table V .... 27

Room Temperature Properties ................................................................................. 28

Effect of Constituents ........................................................................................... 29-30

Corrosive Attack ................................................................................................... 30-31

Groups of Corrosion-Resistant Alloy Castings ..................................................... 31-33

Martensitic Alloys (CA-15, CA-40, CA-6NM, CA-6N)
Ferritic and Duplex Alloys (CB-30, CC-50, CD-4MCu)
Austenitic Alloys (CE-30, CF types, CG-8M, CH-20, CK-20, CN-7M, CN-7MS,
IN-862)
Precipitation Hardenable Alloys (CB-7Cu-1, CB-7Cu-2)
Nickel-Base Alloys (CZ-100, M-35, CY-40, Alloy 625, CW-12M, N-12M, Ni-Si)

Corrosion Data ..................................................................................................... 34-37

Industrial Applications of Corrosion-Resistant Alloy Castings .............................. 38-48

Aeronautical .......................................................................................................... 38
Architectural .......................................................................................................... 38
Chemical & Petroleum ....................................................................................... 39-40
Process Industries Equipment ........................................................................... 41-44
Hydraulics .............................................................................................................. 45
Marine ................................................................................................................... 44
Power–Nuclear & Conventional ........................................................................ 45-48

Part Ill. Fabrication Data for Heat & Corrosion-Resistant Alloy Castings .... 49-52
Machining ............................................................................................................. 49-51
Welding ................................................................................................................. 51-52

3
 Part I
Heat-Resistant Alloy Castings

The heat-resistant casting alloys are those composi-
tions that contain at least 12% chromium which are
capable of performing satisfactorily when used at tem-
peratures above 1200 ºF. As a group, heat-resistant
compositions are higher in alloy content than the
corrosion-resistant types. The heat-resistant alloys are
composed principally of nickel, chromium and iron to-
gether with small percentages of other elements. Nickel
and chromium contribute to the superior heat resistance
of these materials. Castings made of these alloys must
meet two basic requirements:
1. Good surface film stability (oxidation and corro-
sion resistance) in various atmospheres and at the
temperature to which they are subjected.
2.Sufficient mechanical strength and ductility to meet
high temperature service conditions.
The heat-resistant alloys are listed in Table I along with
their chemical compositions and designations.
Commercial cast heat-resistant alloys can be identified
by designations of the Alloy Casting Institute, now a
division of the Steel Founders' Society of America, and
the American Society for Testing and Materials.* Some
of these materials are also listed in the Aerospace Mate-
*See ASTM Specification A 297
rial Specifications (AMS) of the Society of Automotive
Engineers, United States Government Military Specifi-
cations (MIL), the Society of Automotive Engineers
Specifications and the Unified Numbering System
(UNS) developed by the Society of Automotive Engi-
neers and the American Society for Testing and Mate-
rials. Standard ACI designations are listed in Table I.
The Alloy Casting Institute designations use "H" to
indicate alloys generally used in applications where the
metal temperature exceeds 1200 ºF. The second letter
indicates the nominal nickel content, increasing from A
to X.
The chemical compositions of the heat-resistant cast-
ing alloys are not the same as those of the wrought
alloys. Therefore, Table I lists only the nearest wrought
alloy AISI type number. Alloy Casting Institute designa-
tions or their equivalents should always be used when
identifying castings.
The SAE specification designations use the nearest
wrought composition (AISI type number) and prefix it
with the number 70 ºFor heat-resistant castings: for ex-
ample, 70310 is equivalent to HK. In the Unified Num-
bering System, the Jxxxx number series is assigned to
cast steels.

TABLE I
Compositions of Heat-Resistant Alloy Castings

Alloy CHEMICAL COMPOSITION, %

Nearest
Casting Alloy ASTM UNS
AISI
Institute Type Specification No. Ni Cr C Mn Si Mo Other
Type
Designation max max max
HA 8-10Cr A217 – – – 8-10 0.20 max 0.35-0.65 1.00 0.90-1.20 Fe bal
HC 28Cr A297 446 J92605 4 max 26-30 0.50 max 1.00 2.00 0.5 Fe bal
HD 28Cr-6Ni A297 327 J93005 4-7 26-30 0.50 max 1.50 2.00 0.5 Fe bal
HE 28Cr-9Ni A297 312 J93403 8-11 26-30 0.20-0.50 2.00 2.00 0.5 Fe bal
HF 19Cr-9Ni A297 302B J92603 9-12 19-23 0.20-0.40 2.00 2.00 0.5 Fe bal
HH 25Cr-12Ni A297, A447 309 J93503 11-14 24-28 0.20-0.50 2.00 2.00 0.5 Fe bal
HI 28Cr-15Ni A297 – J94003 14-18 26-30 0.20-0.50 2.00 2.00 0.5 Fe bal
HK 25Cr-20Ni A297, A351 310 J94224 18-22 24-28 0.20-0.60 2.00 2.00 0.5
Fe bal
A567
1
IN-519 24Cr-24Ni – – – 23-25 23-25 0.25-0.35 1.00 1.00 – Cb 1.4-1.8; Fe bal
HL 30Cr-20Ni A297 – J94604 18-22 28-32 0.20-0.60 2.00 2.00 0.5 Fe bal
HN 25Ni-20Cr A297 – J94213 23-27 19-23 0.20-0.50 2.00 2.00 0.5 Fe bal
HP 35Ni-26Cr A297 – J95705 33-37 24-28 0.35-0.75 2.00 2.00 0.5 Fe bal
HP-50WZ 35Ni-26Cr – – – 33-37 24-28 0.45-0.55 2.00 2.50 – W 4-6; Zr 0.1-1.0; Fe bal
HT 35Ni-17Cr A297, A351 330 J94605 33-37 15-19 0.35-0.75 2.00 2.50 0.5 Fe bal
HU 39Ni-18Cr A297 – J95405 37-41 17-21 0.35-0.75 2.00 2.50 0.5 Fe bal
HW 60Ni-12Cr A297 – – 58-62 10-14 0.35-0.75 2.00 2.50 0.5 Fe bal
HX 66Ni-17Cr A297 – – 64-68 15-19 0.35-0.75 2.00 2.50 0.5 Fe bal
Chromium
Nickel 50Cr-5ONi A560 – – bal 48-52 0.10 max 0.30 1.00 – Fe 1.0 max
IN-6571 50Cr-48Ni – – – bal 48-52 0.10 max 0.30 0.50 – Cb 1.4-1.7; N 0.16 max;
Fe 1.0 max
1
INCO Designation

4
EFFECT OF CONSTITUENTS
Nickel
Nickel is present in cast heat-resistant alloys in others in the United States, Japan and Britain. Alteration
amounts up to 70%. Its principal function is to strengthen of the carbide morphology from lamellar to discrete
and toughen the matrix. Microstructurally, nickel particles seems to be the important factor; HP-50WZ
promotes the formation of austenite which is stronger (Table I) and IN-657 (Tables I through IV) are examples
and more stable at elevated temperatures than ferrite. of commercial alloys with improved property levels.
Nickel contributes to resistance to oxidation, car-
burization, nitriding and thermal fatigue.
INFLUENCE OF MICROSTRUCTURE
Chromium The iron-chromium-nickel heat-resistant alloys de-
The chromium content in heat-resistant alloys varies signed for service up to 1200 ºF often have mixed
from approximately 10 to 30%. Chromium imparts resis- ferriteaustenite matrices. However, alloys intended for
tance to oxidation (scaling) at elevated temperatures, service above 1200 ºF are austenitic. The compositions
and to sulfur-containing atmospheres. Also, chromium of these alloys are generally adjusted to prevent the for-
carbides precipitate in the matrix and contribute to high- mation of ferrite which has a detrimental effect on high-
temperature creep and rupture strength. In some alloys, temperature creep-rupture strength. Long-time expo-
chromium increases resistance to carburization. It also sure at high temperatures, e.g., 1500 ºF, can result in
improves the resistance of the alloys to the action of transformation of ferrite to the sigma phase with signifi-
many other corrosive agents at normal and elevated cant loss of toughness at room temperature. Thus, in
temperatures. It promotes the formation of ferrite in the these alloys, the high-temperature strength is based
microstructure. primarily on the solid solution strengthening of the aus-
tenite by the addition of nickel, chromium and certain
Other Elements minor elements.
Carbides also contribute to strengthening these al-
Nickel and chromium have the greatest effect on the
loys. As noted previously, these alloys have carbon
properties of heat-resistant castings but the minor alloy-
contents ranging from 0.20 to 0.75%. In the as-cast
ing elements also influence the properties.
condition, the microstructures consist of carbides dis-
Carbon content ranges from 0.20 to 0.75%. It pro- persed in an austenite matrix which also contains dis-
motes dispersion-strengthening through the formation of solved carbon. By interfering with dislocation move-
carbide in the structure. Increasing the carbon content ment, these precipitated carbides assist in strengthen-
improves the high-temperature strength and creep ing the alloy. During long service at elevated tempera-
resistance of the heat-resistant alloys at the expense of tures in the range 1000 to 1800 ºF, additional chromium
lower ductility. carbides precipitate in finely divided form and also as-
Silicon has a beneficial effect on the high- sist in strengthening the alloys. At temperatures some-
temperature corrosion resistance and on resistance to what above 1800 ºF, the primary carbides have a ten-
carburization. In amounts greater than 2%, it lowers the dency to coalesce and the secondary carbides to redis-
high-temperature creep and rupture properties and, in solve in the matrix. Nickel and chromium retard this
general, the silicon content is limited to 1.5% in castings tendency.
intended for service above 1500 ºF. Silicon promotes the
formation of ferrite.
Manganese, although important in melting opera-
GROUPS OF HEAT-RESISTANT
tions, has little or no effect on the mechanical properties ALLOY CASTINGS
or corrosion resistance when present in moderate The heat-resistant alloys can be classified according
amounts. to composition and metallurgical structure into three
Molybdenum improves the high-temperature creep broad groups:
and rupture strength by promoting stabilization of car- 1. Chromium-iron alloys: HA, HC, HD.
bides. In some instances, it also increases high- 2. Chromium-nickel-iron alloys: HE, HF, HH, HI, HK,
temperature corrosion resistance. It slightly increases IN-519, HL.
resistance to carburization. 3. Nickel-chromium-iron alloys: HN, HP, HT, HU, HW,
Work to improve the creep and stress rupture proper- HX.
ties of the heat resisting chromium-nickel-iron alloys In addition, chromium-nickel heat-resistant alloys in-
through the addition of small amounts of tungsten, zirco- clude 50Cr-50Ni and IN-657.
nium, titanium, columbium, nitrogen, or combinations of
them, has been pursued for several years under Steel A general discussion of each group is followed by a
Founders' Society of America sponsorship and by discussion of each alloy.

5

CHROMIUM-IRON ALLOYS
This group consists of alloys in which chromium pre-
dominates with up to 30% chromium and up to 7% nickel.
These alloys are ferritic and have relatively low hot
strength. They are seldom used in critical loadbearing
parts at temperatures above 1400 ºF, but have found use
in applications involving uniform heating and certain
atmospheric conditions, such as high-sulfur atmospheres.
The alloys in this group include the HA, HC and HD types.
HA (9Cr)
Type HA is a chromium-molybdenum-iron alloy that is
resistant to oxidation up to about 1200 ºF. The molyb-
denum content contributes desirable strength properties
to the alloy at these moderate temperatures. Typical
uses are furnace rollers, Lehr rolls, refiner fittings and
trunnions.
HC (28Cr-4Ni max)
The HC type is limited to applications where strength
is not a consideration or for moderate load-bearing
service around 1200 ºF. It provides excellent resistance
to oxidation and flue gases containing sulfur at tempera-
tures as high as 2000 ºF. It is also used where high nickel
content tends to crack hydrocarbons through catalytic
action. Due to the low nickel content, the ductility and
impact toughness are very low at room temperatures
and the creep strength is very low at elevated tempera-
tures. Typical uses are boiler baffles, furnace grate
bars, kiln parts, recuperators, salt pots and tuyeres.
HD (28Cr-6Ni)
The HD type has the best hot strength, weldability
and high-temperature corrosion resistance of the
chromium-iron group. HD can be used for load-bearing
applications up to 1200 ºF, and where only light loads
are involved up to 1900 ºF. It is suitable for use in high-
sulfur atmospheres. Long exposures to temperatures in
the range 1300 to 1500 ºF may in some cases result in
considerable hardening, accompanied by a severe loss
of room temperature ductility through the formation of
the sigma phase. Typical applications are roaster fur-
nace rabble arms and blades, salt pots and cement kiln
ends.
CHROMIUM-NICKEL-IRON ALLOYS
These alloys are characterized by good high- rails and rollers, tube supports and cement and lime kiln
temperature strength, hot and cold ductility, and resis- ends. Type I alloy is used where hot ductility is more
tance to oxidizing and reducing conditions. They are important than hot strength, and is preferred for welding.
useful for atmospheres high in sulfur, particularly under
reducing conditions. These alloys contain 8 to 22%
nickel and 18 to 32% chromium, and may have either a face corrosion under the various conditions encoun-
partial or a completely austenitic microstructure. They tered in industry, but are seldom used for carburizing
include types HE to HL.
HE (28Cr-9Ni)
This type has excellent high-temperature corrosion erally recommended for severe cyclic service such a
6
resistance and is frequently recommended for service in
sigh-sulfur atmospheres where alloys containing higher
nickel cannot be used. Because of its high alloy content,
it is suitable for use up to 2000 ºF. The alloy has moder-
ately high hot strength and excellent ductility. It is widely
used for parts such as conveyors in furnaces, recupera-
tors, coke oven exhaust castings, roasting furnace cen-
ter shafts and tube support castings. Prolonged expo-
sure at temperatures around 1500 ºF may promote for-
mation of the sigma phase with consequent low ductility
at room temperature.
HF (19Cr-9Ni)
This type is comparable to the popular wrought
corrosion-resisting 18-8 compositions and is suitable for
use up to around 1600 ºF. It approaches the HH grade
in many properties and combines moderately high hot
strength and ductility. Its microstructure is essentially
austenitic. Typical uses include burnishing and coating
rolls, furnace dampers, annealing furnace parts, etc.
HH (25Cr-12Ni)
This type is one of the most popular of the heat-
resistant alloys and accounts for about one-fifth of all
heat-resistant casting production. This alloy contains
the minimum quantities of chromium and nickel to sup-
ply a useful combination of strength and corrosion resis-
tance for elevated temperature service above 1600 ºF.
The chromium range is high enough to assure good
scaling resistance up to 2000 ºF in air or normal
products of combustion. Sufficient nickel is present,
aided by carbon, nitrogen and manganese, to maintain
austenite as the major phase; however, the
microstructure is sensitive to composition balance. For
high ductility at 1800 ºF, a two-phase structure of
austenite and ferrite is appropriate but such a structure
has lower creep strength If high creep strength is
needed and lower ductility can be tolerated, a
composition balanced to be completely austenitic is
desirable.
Alloy HH is covered by ASTM specification A 447
which recognizes two types. Type I is partially ferritic
and Type II predominately austenitic. Type I has a max-
imum magnetic permeability of 1.70 and Type II of 1.05.
Because of its high creep strength and relatively low
ductility, Type II is useful in parts subject to high constant
load conditions in the range from 1200 to
1800 ºF Some typical uses are for furnace shafts, beams,
Both types of HH alloy have good resistance to sur-
applications because of embrittlement caused by ab-
sorption of carbon. Experience has indicated that HH
alloys can withstand repeated temperature changes or
differentials reasonably well; however, they are not gen-
HI (28Cr-15Ni) HN (25Cr-20Ni)
This alloy is resistant to oxidation up to 2150 ºF. Its This alloy has properties somewhat similar to the
composition is such that it is more likely to be completely more widely used HT alloy but has better ductility. It is
austenitic than the lower alloys of this group, hence it used for highly stressed components in the
has more uniform high-temperature properties. This 1800-2000 ºF range. It has also given satisfactory ser-
type is used for billet skids, conveyor rollers, furnace vice in several specialized applications, notably brazing
rails, lead pots, retorts for magnesium production, fixtures at temperatures up to 2100 ºF. Among its appli-
hearth plates and tube spacers. cations are chain, furnace beams and parts, pier caps,
brazing fixtures, radiant tubes, tube supports and torch
nozzles.
HK (25Cr-20Ni)
The HK alloy provides one of the most economical
combinations of strength and surface stability at tem- HP (35Ni-26Cr)
peratures up to and above 1900 ºF and accounts for This alloy is related to the HN and HT types but
almost half of the heat-resistant alloy tonnage. contains more nickel than the HN alloy and more chro-
It can be used in structural applications up to 2100 ºF mium than the HT alloy. This composition makes the HP
but is not recommended where severe thermal shock is a alloy resistant to both oxidizing and carburizing atmo-
factor. It is used for parts where high creep and rupture spheres at high temperatures and provides high stress-
strengths are needed such as steam methane reformer rupture properties in the range 1800-2000 ºF. It is used
tubing, ethylene pyrolysis tubing, gas turbines, furnace for ethlene pyrolysis tubing, steam methane reformer
door arches and chain, brazing fixtures, cement kiln tubing, heat treating fixtures and radiant tubes. Several
nose segments, rabble arms and blades, radiant tubes, proprietary modifications containing columbium and/or
retorts and stack dampers. tungsten are also being used.

IN-519 (24Cr-24Ni-1.5Cb) HT (35Ni-17Cr)

This alloy is a modification of HK alloy in which the About one-seventh of the total production of heat-
25-20 base has been altered, the carbon content has resistant castings is HT alloy because of its value in
been reduced and columbium (niobium) has been resisting thermal shock, its resistance to oxidation and
added. As a result, the high-temperature stress-rupture carburization at high temperatures, and its good
strength has been improved. It is used for centrifu- strength at heat treating furnace temperatures. Except
gally-cast catalyst tubes in steam-hydrocarbon re- in high-sulfur gases, it performs satisfactorily up to
former furnaces. 2100 ºF in oxidizing atmospheres and up to 2000 ºF in
reducing atmospheres. It is used for load-bearing mem-
bers in many furnace applications, retorts, radiant tubes,
HL (30Cr-20Ni) cyanide and salt pots, hearth plates and trays quenched
This alloy has excellent resistance to oxidation at with the work.
temperatures over 2000 ºF, and is resistant to corrosion
in flue gases containing a moderate amount of sulfur up HU (39Ni-18Cr)
to 1800 ºF. It is used where higher strength is required This type has an exceptionally high combination of
than obtainable with lower nickel content alloys. Leading creep strength and ductility up to 2000 ºF and is used
applications are for radiant tubes, furnace skids and where high hot strength is required. It is suited for severe
stack dampers where excessive scaling must be service conditions involving high stress and rapid thermal
avoided, such as in enameling furnace carriers and cycling. HU alloy has good resistance to corrosion by
fixtures. either oxidizing or reducing hot gases containing
NICKEL-CHROMlUM-IRON ALLOYS moderate amounts of sulfur. Typical uses are heat treat-
ing salt pots, quenching trays, fixtures and gas dissocia-
The nickel-chromium-iron alloys are fully austenitic
tion equipment.
and contain 25 to 70% nickel and 10 to 26% chromium.
They can be used satisfactorily up to 2100 ºF because
no brittle phase forms in these alloys. They have good HW (60Ni-12Cr)
weldability and are readily machinable if proper tools The HW alloy performs satisfactorily up to 2050 ºF in
and coolants are used. The specific types of alloys in strongly oxidizing atmospheres and up to 1900 ºF in
this group are HN, HP, HT, HU, HW and HX. oxidizing or reducing products of combustion, provided
These austenitic heat-resistant alloys have good hot that sulfur is low or not present in the gas. The adherent
strength and good resistance to carburization and thermal nature of its oxide scale makes HW alloy suitable for
fatigue. They are used widely for load-bearing appli- enameling furnace service where even small flecks of
cations and for castings subject to cyclic heating and dislodged scale could ruin the work in process. High-
large temperature differentials. They will withstand re- temperature strength, resistance to thermal fatigue and
ducing and oxidizing atmospheres satisfactorily but high- resistance to carburization, are obtainable with this alloy
sulfur atmospheres should be avoided. and its high electrical resistivity suits it for electrical

7
heating elements. Other applications are cyanide pots, CHROMIUM NICKEL ALLOYS
gas retorts, hardening fixtures (quenched with the work), Chromium-Nickel Alloy (50Cr-50-Ni)
hearth plates, lead pots, muffles and other parts in
This alloy was developed to improve the resistance of
cyaniding and carburizing operations.
heat-resistant alloys to fuel oil ash. It is widely used
worldwide (and in fact is specified almost exclusively in
HX (66Ni-17Cr) Europe) for resistance to oil ash corrosion in power
The high-alloy content of this grade confers high re- plants, petroleum refinery heaters and marine boilers at
sistance to hot gas corrosion even in the presence of temperatures up to about 1650 ºF. Its applications in-
some sulfur and permits it to be used for severe service clude such parts as sidewall and roof hanger supports in-
applications where corrosion must be minimized at tem- furnace radiant sections, tube sheets, re-radiation cone
peratures up to 2100 ºF. It is used to great advantage tips in vertical furnaces and for burner parts.
where maximum and widely fluctuating temperatures are
encountered because of its ability to withstand cycling IN-657 (50Cr-48Ni-1.5Cb)
without cracking or severe warping. Thus, a leading
This more recent development is a columbium
application is for quenching fixtures. It is also useful in
(niobium) modification of the 50Cr-50Ni alloy also with
carburizing and cyaniding equipment. Typical applica-
high resistance to fuel oil ash corrosion but with creep
tions in which it gives excellent service include nitriding,
and stress-rupture properties superior to those of the
carburizing and hardening fixtures (quenched with the
50Cr-50Ni alloy. IN-657 is used in petroleum refinery
work), heat-treating boxes, retorts and burner parts. heaters, marine and land-based boilers in such applica-
tions as convection section tube sheets; it is produced
by several U.S. and European foundries under license
from Inco.*

SELECTING THE PROPER ALLOY

The selection of the proper cast alloy for a given properties that must be matched with them. Some of
high-temperature application requires knowledge of these properties are listed below and are discussed
various factors and the related mechanical and physical later under "Alloy Casting Design."

Operating Conditions Related Property

1. Anticipated service and maximum Short-time tensile properties
temperature of operation Creep strength
Stress-rupture properties
Hot ductility
2. Type and size of maximum load Short-time tensile properties
Creep strength
Stress-rupture properties
Hot ductility
3. Temperature cycling Thermal fatigue properties
a. Range of temperature cycling
b. Frequency of temperature cycling
c. Rate of temperature change
4. Type of atmosphere or other corrosive Oxidation resistance
conditions Carburization resistance
Sulfidation resistance
Surface stability
5. Size and shape of part Temperature gradients
6. Further processing, such as welding Fabrication data
and machining
7. Abrasive or wear conditions –
8. Cost –
9. Ease of replacement –

The governing economic consideration in the selec-
tion of heat-resistant alloy castings is the cost per hour
at operating temperatures. Equipment downtime can
result in a loss of production that is far more expensive
than the cost of the alloy involved. Ease of replacement
must also be considered in the selection of the alloy.
With rare exceptions, the use of heat-resistant alloys is
justified at all temperatures above 1200 ºF.
In selecting heat-resistant alloys for castings, the sig-
nificant properties that must be considered are shown in
Tables II, III and IV.

*Trademark of the Inco family of companies.

8
 HEAT-RESISTANT ALLOY CASTING DESIGN
The properties listed in Table II and Figures 1 through plication of these properties in casting design together
4, inclusive, are the basis for the design of heat-resistant with other design considerations that are not amenable
alloy castings. This selection is concerned with the ap- to tabulation.

TABLE II
Room Temperature Mechanical Properties of Heat-Resistant Alloy Castings
Type I Type II IN- 50Cr- IN
PROPERTY HA HC HD HE HF HH HH HI HK 519 HL HN HP HT HU HW HX 50Ni 657
Tensile Strength, ksi
1 4
As-Cast 95 70 85 95 92 85 80 80 75 75 82 68 71 70 70 68 65 80 87
2
Aged 107 115 – 90 100 86 92 90 85 – – – – 75 73 84 73 – –
Yield Strength
(0.2% offset), ksi
1 3 4 3
As-Cast 65 65 48 45 45 50 40 45 50 35 52 38 40 40 40 36 36 50 54
2
Aged 81 80 – 55 50 55 45 65 50 – – – – 45 43 52 44 – –
Elongation in 2 in., %
1
As-Cast 23 2 16 20 38 25 15 12 17 25 19 13 11.5 10 9 4 9 15 28
2
Aged 21 18 – 10 25 11 8 6 10 – – – – 5 5 4 9 – –
Brinell Hardness
As-Cast 180 1 190 190 200 165 185 180 180 170 – 192 160 – 180 170 185 176 – –
Aged 220 2 - – 270 190 200 200 200 190 – – – – 200 190 205 185 – –

Aging Treatment - 24 hours – 24 hours 24 hours 24 hours 24 hours 24 hours 24 hours – – – – 24 hours 48 hours 48 hours 48 hours – –
at at at at at at at at at at at
1400 ºF 1400 ºF 1400 ºF 1400 ºF 1400 ºF 1400 ºF 1400 ºF 1400 ºF 1800 ºF 1800 ºF 1800 ºF
Furnace Furnace Furnace Furnace Furnace Furnace Furnace Air Air Furnace Air
Cooled Cooled Cooled Cooled Cooled Cooled Cooled Cooled Cooled Cooled Cooled
Modulus of Elasticity 29 29 27 25 28 27 27 27 27 23 27 27 27 27 27 25 25 – 30
in Tension, ksi x 103
1
Annealed
2
Normalized at 1825 ºF and tempered at 1250 ºF.
3
0.2% Proof Stress
4
Minimum

HIGH-TEMPERATURE MECHANICAL
PROPERTIES
In common with all metals, the load-carrying ability of
heat-resistant casting alloys decreases as the tempera-
ture increases. However, the fall-off in strength is less
pronounced than it is with less highly alloyed materials.
At elevated temperatures, metals under stress are
subject to slow plastic deformation as well as to elastic
deformation. Therefore, time becomes a critical factor
and conventional tensile tests do not furnish values that
are useful in design. The data required are those indica-
ting the load which will produce no more than an allow-
able percentage of elongation at a specified tempera-
ture in a given period of time. Thus, the factors of time
and deformation as well as stress and temperature are
involved in high-temperature strength properties.
Creep Strength
The slow plastic deformation that occurs under load
at elevated temperatures is known as creep. In the
design of furnace parts, experience indicates that a
creep rate of 0.0001% per hr is satisfactory for compari-
son of alloys, and Table III shows the data on this basis.
This is sometimes expressed as 1 % creep in 10,000 hr.
It should be kept in mind that when creep is expressed
in the latter terms it does not mean that this rate of creep
can be expected to continue in every instance for 10,000
hours without failure.
Figure 1 and Table III compare the creep strengths
of representative heat-resistant alloy castings.
Creep values that are obtained under constant load
and constant temperature conditions are applicable to
design, however, safety factors should always be incor-
porated. The safety factor will depend on the degree to
which the application is critical.
Stress-Rupture Properties
Stress-rupture properties determined under constant
load at constant temperature are useful in approximating
the life of the alloy (time to fracture) under the specific
conditions and also for comparing alloys which are
subject to loading that might produce failure in a
relatively short time.

9
 TABLE III
Elevated Temperature Properties of Heat-Resistant Alloy Castings

Type l Type II
PROPERTY HA HC HD HE HF HH HH HI HK IN-519 HL HN HP HT HU HW HX 50Cr-50Ni IN-657
Short-Time
Tensile
Strength, ksi, at
1000 ºF 67 – – – – – – – – – – – – – – – – 446 866
4 4
1200 ºF – – – – 60 – 60.5 – – – – – – 42.4 – – 45 40 79
1400 ºF – – 36 – 38 33 37.4 38 37.5 391 50 – 43 35 40 32 – 361 681
2 2 2
1600 ºF – – 23 – 21 18.5 21.5 26 23.3 23 30.4 20.2 26 18.8 19.6 19 20.5 18 36
3
1800 ºF – – 15 – – 9 10.9 – 12.4 15 18.7 11.9 14.5 11 10 10 10.7 – –
2000 ºF – – – – – – 5.5 – 5.6 – 6.2 7.5 6 – – – – –
Short-Time Yield
Strength (0.2%
Offset), ksi, at
6
1000 ºF 42 – – – – – – – – – – – – – – – – – 36
4
1200 ºF – – – – 31.5 – 32.2 – – – – – – 28 – – 20 – 46
1 1
1400 ºF – – – – 25 17 19.8 – 24.4 20 – – 29 26 – 23 – – 29
2 2
1600 ºF – – – – 15.5 13.5 16 – 14.7 13 – 14.5 17.5 15 – 15 17.5 – 15
3
1800 ºF – – – – – 6.3 7.3 – 8.7 9 – 9.6 11.0 8 6.2 8 6.9 – –
2000 ºF – – – – – – – – 5.0 – – 4.9 6.2 – – – – – –
Elongation in
2 in., %, at
1000 ºF – – – – – – – – – – – – – – – – – 126 166
1200 ºF – – – – 10 – 14 – – – – – – 5 – – 8 44 154
1400 ºF – – 14 – 16 18 16 6 12 321 – – 15 10 – – – 31 151
1600 ºF – – 18 – 16 30 18 12 16 432 – 37 27 26 20 – 48 52 192
1800 ºF – – 40 – – 45 31 – 42 373 – 51 46 28 28 40 40 – –
2000 ºF – – – – – – – – 55 – – 55 69 – – – – – –
Creep Stress
0.0001%/hr, ksi, at
1000 ºF 16 – – – – – – – – – – – – – – – – – –
1200 ºF 3.1 – – – 18 – 18 – – – – – – – – – – – 184
1400 ºF – 1.3 3.5 4 6.8 3 6.3 6.6 10.2 8.61 7.0 – – 8 8.5 6 6.4 – 6.51
1600 ºF – 0.75 1.9 2.4 3.9 1.7 3.9 3.6 6.0 4.52 4.3 6.3 5.8 4.5 5.0 3 3.2 – 2.52
1800 ºF – 0.36 0.9 1.4 – 1.1 2.1 1.9 2.5 1.83 2.2 2.4 2.8 2 2.2 1.4 1.6 – 0.53
2000 ºF – – 0.2 0.4 – 0.3 0.8 0.8 0.65 – – 1.0 1.0 0.5 0.6 – 0.6 – –
2150 ºF – – – – – – – 0.15 – – – – – 0.15 – – – – –
Stress to Rupture
in 100 hr, ksi, at
1000 ºF 37 – – – – – – – – – – – – – – – – – –
1200 ºF – – – – 33 – 35 – – – – – – – – – – – 304
1400 ºF – 3.3 10 11 13.5 14 14 13 15.5 141 15.0 – – 16 15 10 13 – 14.51
1600 ºF – 1.7 5 5.3 7.2 6.4 6.8 7.5 9.2 92 9.2 11 10 8.9 8 6 6.7 – 7.22
1800 ºF – 0.85 2.5 2.5 – 3.1 3.2 4.1 4.7 53 5.2 5.6 5.9 4.4 4.5 3.6 3.5 – 3.83
2000 ºF – – – – – 1.5 1.4 1.9 2.2 – – 2.9 2.8 2.1 – – 1.7 – 1.65
1 4
1470 ºF 1290 ºF
2 5
1650 ºF 2010 ºF
3 6
1830 ºF 1110 ºF

Stress-rupture properties are a valuable adjunct to
creep-strength values in the selection of heat-resistant
casting alloys and in the establishment of allowable
design stresses. Figures 2, 3, and 4 compare the stress-
rupture properties of representative casting alloys for
various time periods. Frequently, designers of furnaces
and furnace tubing use the 100,000-hour stress-rupture
properties with some factor of safety. A comparison of
Figures 1 and 2 shows that, in general, stress-rupture
tests rank the alloys in much the same order as the
creep tests.
Ductility
An accurate comparison of hot ductility of heat-
resistant casting alloys is difficult since there is no gen-
erally accepted reference test. Total elongation values
on both creep and stress-rupture tests are often used
as criteria. Also, the elongation in short-time high-
temperature tensile tests is commonly used in specifica-
tions as an indication of high-temperature ductility. In
many applications where castings are handled at normal
temperatures, room temperature ductility is a con-
sideration. Heat treating to remove sigma phase by
heating castings to 1800 ºF and cooling to below 1200 ºF
improves ductility.

10
Figure 1– Creep Strength of Heat-Resistant Alloy Castings (HT curve is included in both
graphs for ease of comparison).

11
 Figure 2 –1,000-Hour Stress-Rupture Properties of Heat-Resistant Alloy Castings (HT curve is
included in both graphs for ease of comparison).

12
Figure 4–100,000-Hour Stress-Rupture Properties of Several Heat-Resistant Alloy Castings.

13
Short-Time Tensile Properties mining the life of castings in service. For this reason, the
Short-time hot-tensile tests in which the test speci- heat-resistant casting user should consult with the pro-
men is held at the test temperature for one hour and ducers in the early stages of design in order to obtain the
then pulled at temperature, cannot be relied upon to benefit of their experience with similar applications.
indicate how heat-resistant alloys will behave in service.
The values obtained are as much as five or six times DESIGN DATA
the limiting creep stress values, and, therefore, greatly
over-evaluate load-carrying ability over long periods of The curves shown in Figure 5 are constructed to
time. Nevertheless, short-time tensile tests can be help- indicate the values of allowable stress that result from
ful in evaluating resistance to momentary overloads and applications of code criteria to the short-time tensile,
are included in some specifications. The short-time creep, and stress-rupture properties of the heat-
mechanical properties for the standard heat-resistant resistant alloys, HF, HH-II, HK and HN. The ASME
alloys are given in Table Ill. Boiler Code allowable stresses for wrought composi-
tions are included in two of the graphs to offer a compari-
Thermal Fatigue son.
In many high-temperature applications, intermittent
or widely fluctuating temperatures (cyclic heating) are HIGH-TEMPERATURE CORROSION
encountered, and therefore the ability of the various
heat-resistant casting alloys to withstand such thermal RESISTANCE
fatigue service must be considered. High-temperature equipment is exposed to many dif-
Thermal fatigue failure involves cracking caused by ferent atmospheres and corrosive conditions and an
heating and cooling cycles. Crazing and checking of important requirement of heat-resistant alloys is surface
heat-treating fixtures are typical examples. Such fail- film stability. No single alloy will show satisfactory resis-
ures are the result of many reversals of thermal stresses tance to all of the high-temperature environments.
in the part as contrasted to common mechanical fatigue High-temperature corrosive conditions may involve
failures, which are caused by externally applied loads. simple oxidizing or reducing atmospheres or they may be
Very little experimental thermal fatigue information is complicated by sulfur compounds in the products of
available on which comparison of the various alloys can combustion. Oxidizing flue gases are slightly more cor-
be based, and no standard test as yet has been rosive than air if the sulfur concentration is low. Corro-
adopted. Field experience indicates that, usually, resis- sive attack by reducing flue gases is similar to that of an
tance to thermal fatigue is improved with increasing oxidizing gas if the sulfur content is not greater than 100
nickel content. Columbium-modified ACI alloys have ppm. At higher sulfur concentrations, attack by reducing
been employed successfully where a high degree of gas is much more severe. The high nickel alloys, types
thermal fatigue resistance is desired such as in reformer HN to HW, give good service under oxidizing and reduc-
outlet headers. ing conditions if the sulfur content of the gas is low.
Types HH and HL, for example, should be considered
Temperature Gradients for service in sulfur-bearing atmospheres.
Non-uniform heating or cooling causes temperature Cyclic heating under reducing conditions increases
gradients and the attendant unequal dimensional metal loss in alloys containing from 10 to 50% nickel.
changes result in stresses within the casting, These Under oxidizing conditions, cyclic heating has little ef-
stresses may be accompanied, particularly at high tem- fect in alloys containing more than 20% nickel.
peratures, by some degree of plastic deformation. The Different corrosive conditions are encountered with
magnitude of the stress and/or the amount of the plastic equipment in contact with fused salts or molten metals.
deformation will depend on the temperature differential Types HT to HX should be considered for service under
within the casting. these conditions. Still other conditions are met in the
Heat-resistant alloys inherently have high coefficients chemical, petroleum, and petrochemical industries
of thermal expansion and low heat conductivity, both where new processes with new corrosive conditions are
properties tending to produce temperature and stress constantly under development.
differences between various regions of a casting. The In the heat-treating industry, only the high nickel-
unequal stresses set up within the casting tend to distort chromium alloys give satisfactory service under nitriding
or fracture it; thus, maximum articulation should be de- conditions. Another important process in the heat-
signed into elevated temperature parts by making them treating industry is carburization, which is considered in
of a number of small components that are free to expand some detail below.
and contract. All sharp corners and abrupt changes in
section are to be avoided. Carburization Resistance
Proper design, taking all thermal conditions into con- When heat-resistant castings are used as muffles,
sideration, is as important as alloy composition in deter- holding fixtures or baskets for work being carburized,

14
Figure 5–Design Data for Four Heat-Resistant Steels.

15
 the castings also pick up carbon. The same effect oc-
curs in any high-temperature carbon-bearing atmo-
sphere under reducing conditions. Some alloys absorb
from 0.30 to 2% carbon within a period of several
months when used in a carburizing application. A large
increase in carbon pickup leads to volume changes
which can cause warpage and distortion. The additional
carbon also leads to difficulties if repair welding of the
casting is necessary. Increasing the nickel content re-
duces the effect of increased carbon content on the
mechanical properties of heat-resistant alloys. Hence,
the nickel-chromium-iron grades HP to HX are preferred
because they withstand thermal fatigue and shock load-
ing at higher carbon levels than alloys with less nickel.
Resistance to carbon penetration increases as the
nickel content increases and to some extent as the
chromium content increases. Therefore the high nickel
types HP to HX are all good in this respect with the HW
and HX types, being highest in nickel content, rating as
excellent.
The high chromium types are generally not suitable
for service under carburizing conditions unless other
requirements dictate their selection. In such cases, sili-
con content should be kept on the high side. Carburiza-
tion resistance of types HH and HK is improved with
silicon content above 1.6%.
ROOM TEMPERATURE PROPERTIES
The room temperature properties of the various
alloys shown in Table II have little relationship to high-
temperature behavior. These properties are useful only
for acceptance purposes and for instances where the
nature of the service requires good strength at room
temperature.
Acceptance tests of a particular composition at room
temperature are used only with the supposition that the
alloy will behave at elevated temperatures in the same
way that the same composition has behaved previously
in the same application.
The room temperature properties after aging are
given as an indication of the structural stability of the
alloy after high-temperature exposure.
The physical properties of the heat-resistant alloys
are given in Table IV.

TABLE IV
Physical Properties of Heat-Resistant Alloy Castings

Type
Type l II IN- 50Cr- IN
Property HA HC HD HE HF HH HH HI HK 519 HL HN HP HT HU HW HX 50Ni 657
Density, lb/cu in. 0.279 0.272 0.274 0.277 0.280 0.279 0.279 0.279 0.280 0.286 0.279 0.283 0.284 0.286 0.290 0.294 0.294 0.291a 0.288
Mean Coefficient of
Linear Thermal Expansion,
-6
in./in./° F x 10
70 - 212 ºF 6.1 - - - - - - - - 7.21 - - - 7.9 - 7.0 - - 5.91
70 - 1000 ºF 7.1 6.3 7.7 9.6 9.9 9.5 9.5 9.9 9.4 9.12 9.2 9.3 9.2 8.8 8.8 7.9 7.8 7.42
70- 1200 ºF 7.5 6.4 8.0 9.9 10.1 9.7 9.7 10.0 9.6 - 9.4 9.5 9.5 9.1 9.0 8.2 8.1 -
70 - 1400 ºF - 6.6 8.3 10.2 10.3 9.9 9.9 10.1 9.8 9.33 9.6 9.7 9.8 9.3 9.2 8.5 8.5 8.33
70 - 1600 ºF - 7.0 8.6 10.5 10.5 10.2 10.2 10.3 10.0 9.44 9.7 9.9 10.0 9.6 9.4 8.7 8.8 8.34
70 - 1800 ºF - 7.4 8.9 10.8 10.6 10.5 10.5 10.5 10.2 9.55 9.9 10.1 10.3 9.8 9.6 9.0 9.2 8.25
70 - 2000 ºF - 7.7 9.2 11.1 10.7 10.7 10.7 10.8 10.4 - 10.1 10.2 10.6 10.0 9.7 9.3 9.5 -
1200 - 1600 ºF - 8.7 10.3 12.2 11.5 11.4 11.4 11.0 - - 10.5 - 11.4 10.8 10.5 10.0 10.7 -
1200 - 1800 ºF - 9.3 10.6 12.5 - 11.7 11.7 12.0 11.4 - 10.7 11.0 11.9 11.0 10.6 10.3 11.3 -
Specific Heat,
Btu/Ib/° F at 70 ºF 0.11 0.12 0.12 0.14 0.12 0.12 0.12 0.12 0.13 0.11 0.12 0.11 0.11 0.11 0.11 0.11 0.11 - 0.11
Specific Electrical
Resistance,
microhm-cm at 70 ºF 70 77 81 85 80 75-85 75-85 85 90 978 94 99.1 102 100 105 112 116 - 988
Thermal Conductivity,
Btu/hr/sq ft/ft/°F
At 212 ºF 15.0 12.6 12.6 8.5 8.3 8.2 8.2 8.2 7.9 8.2 8.2 7.5 7.5 7.0 7.0 7.2 7.2 - 8.2
6 6
At 1000 ºF 15.7 17.9 17.9 12.4 12.3 12.0 12.0 12.0 11.8 12.9 12.2 11.0 11.0 10.8 10.8 11.1 11.1 13.4
At 1400 ºF - - - 14.6 14.6 14.1 14.1 14.1 14.2 - 14.7 13.2 13.2 12.9 12.9 13.3 13.3 -
7 7
At 1500 ºF - 20.3 20.3 - - - - - - 14.8 - - - - - - - 15.5
At 2000 ºF - 24.2 24.2 18.2 - 17.5 17.5 17.5 18.6 - 19.3 17.0 17.0 16.3 16.3 17.0 17.0 -
Melting Point (approx), ºF 2750 2725 2700 2650 2550 2500 2500 2550 2550 2490 2600 2500 2450 2450 2450 2350 2350 - 2400
Magnetic Permeability Ferro- Ferro- Ferro- 1.3-2.5 1.00 1.0-1.9 1.0-1.05 1.0-1.7 1.02 - 1.01 1.10 1.02-1.25 1.10-2.00 1.10- 16.0 2.0 - -
Magnetic Magnetic Magnetic 2.00
1 6
68- 212 ºF 1110 ºF
2 7
68- 930 ºF 1470 ºF
3 8
68-1470 ºF 75 ºF
4
68-1650 ºF aCalculated
5
68-1830 ºF

16
 Industrial Applications
of Heat-Resistant Alloy Castings

AERONAUTICAL Typical Applications

The high temperatures encountered in aircraft power plants Jet engine rotors Afterburner parts
and afterburners have been controlled by the use of heat- Jet engine rings Gun blast tubes
resistant alloy castings.

CEMENT
In kiln processes, heat, corrosion and abrasion are con-
stantly attacking operating equipment. High-alloy castings
resist high temperatures, corrosive gases and abrasives and
reduce breakage, shut-down time and rapid wear.

Typical Applications
Burner nozzles Kiln end rings
Conveyors Kiln feed chutes
Cooler lifters Kiln shell segments
Dampers Slurry feed pipes
Kiln chains
CONTINUOUS CAST CHAIN
Alloy: HH (25Cr-12Ni)
Weight: 50 Ib
Use: Cement Kiln

GLASS AND ENAMELING

In the glass, pottery and enameling industries, handling
equipment must have sufficient strength at elevated tempera-
tures to resist bending and warpage. The alloys used must LEHR ROLLS
Alloy: HF (19Cr-9Ni)
resist scaling or flaking to prevent contamination of the prod-
Weight: 1040 Ib
uct. Some heat-resistant cast alloys have both these charac- Size: 8 in. O.D., 6 in. I.D., 168 in. long
teristics and they are used extensively. Use: Supports glass without bending at operating temperature of
1500 ºF.
Typical Applications

Trays Brick supports

Molds Suspension bars
Fixtures Hearth plates
Hangers Kilns and furnaces
Burning tools Lehr rolls

17
Glass and Enameling (Cont'd.)

MUFFLER ASSEMBLIES
Alloy: HT (35Ni-15Cr)
Size: Each casting 24 in. long, wall thickness ¼ in.
Use: Handle hot gases (1750-1800 ºF) of glassmaking furnace.

ENAMELING FURNACE FLOOR IRONS

Alloy: HT (35Ni-15Cr)
Weight: 575 Ib (large casting)
Use: Operates at 1800 ºF

HEAT TREATING
The advantages of high-alloy castings have been frequently
demonstrated in heat-treating equipment. High temperatures,
heavy loads, thermal shock and the continuous operation of
heat-treating furnaces require the use of heat-resistant alloy
castings for long uninterrupted service and low maintenance
and operating costs. The uses of high-alloy castings in heat-
treating operations are extensive.

Typical Applications
Trays Roller conveyors
Boxes and baskets Screw conveyors
Retorts Skid rails
Fixtures Hot fans
Conveyor belts and chains Molten metal pots
Furnace hearths Furnace muffles
Furnace hearth supports Radiant tubes
Roller rails Dampers
Grates Heat exchangers

SHAFT FIXTURE ON TRAY

Alloy: HU (39Ni-15Cr)
Weight: 87 Ib
Use: Carburizing furnace

18
Heat Treating (Cont'd.)

GEAR FIXTURE ON TRAY

Alloy: HU (39Ni-18Cr)
Weight: 75 Ib TRAY WITH CRISS-CROSS FIXTURE
Use: Carburizing furnace Alloy: HU (39Ni-18Cr)
Weight: 56 Ib
Use: Carburizing furnace

RIVETLESS CHAIN
Alloy: HW (60Ni-12Cr)
Weight: 5 lb each
Size: 5 in. x 6 in. x 1¾in.
Use: Convey parts through hardening
furnace operating at 1650 ºF.

TRAY ARTICULATED TRAY WITH TUBULAR FIXTURE

Alloy: HU (39Ni-18Cr) Alloy: HX (66Ni-17Cr)
Weight: 40 lb Weight: 178 lb
Use: Roller rail furnace Use: Solution treat aircraft parts (water quenched).

19
GRID WITH LIFTING LOOPS TUBULAR GRID ROLLER TRAY
Alloy: HU (39Ni-18Cr) Alloy: HT (35Ni-17Cr)
Weight: 265 lb Weight: 164 lb
Use: Pit furnace top support Use: Malleablizing furnace

TUBULAR BASE WITH GRIDS

Alloy: HT (35Ni-17Cr)
Weight: 1170 lb
Use: Pit furnace base support

SIDE HEARTH LINK BELT

Alloy: HH (25Cr-12Ni)
Weight: According to size
Size: 3 in., 4 in., or 6 in. pitch
Use: Convey parts through continuous furnaces
operating at 1600 to 1800 ºF

20
 PIT FIXTURE WITH SPACER GRIDS
Alloy: HT (35Ni-17Cr)
Weight: 1173 Ib
Use: Carburizing furnace
PIT FIXTURE CAGE
Alloy: HX (66Ni-17Cr)
Weight: 930 Ib
Use: Solution treat space parts.

PIT FURNACE RING

Alloy: HX (66Ni-17Cr)
Weight: 849 Ib
Use: Solution treat space parts (water quenched).

TRAY WITH TWO CRISS-CROSS FIXTURES

Alloy: HU (39Ni-18Cr)
Weight: 115 Ib
Use: Carburizing furnace

21
PETROLEUM, PETROCHEMICAL REFINING AND CHEMICAL
The heat-resistant grades of high-alloy castings are used high output operation under severe corrosive and temperature
extensively in the petroleum refining industry. High-pressure conditions.
and high-temperature refining units depend on high-alloy sup-
ports, tubes, headers and other castings which can withstand
excessive heat and corrosion. Metal parts used in refineries
and rectifying plants are subject to extreme temperatures, Typical Applications
heavy loadings, and corrosive liquids and gases. Among heat-
Beams and channels Tube sheets
resistant alloy casting grades are those that assure protection Pumps Tubes
from deterioration caused by heating and cooling cycling and Valves Tube supports and wall ties
resist corrosive media at temperatures up to 2000 ºF. HK-40 Pistons Heater tubes
and IN-519 are used extensively for catalyst tubes in steam- Retorts Fittings
hydrocarbon reforming furnaces. The chromium-nickel alloys, Roof tube hangers Burners and nozzles
50Cr-50Ni and IN-657, show excellent resistance to fuel oil Dampers
ash attack and are used extensively in Europe to resist this
material.
High-alloy castings serve many applications in the chemical
equipment field where heat-resistant castings are permitting

U-BEND RETURN
Alloy: HK-40 (25Cr-20Ni)
Weight: 45 Ib
Size: 4 in. O.D. x 10 in. center to center
Use: Ethylene converter furnace
CAST WELDING WYE
Alloy: HP (35Ni-26Cr)
Weight: 74 lb
Size: 14 in. long, 10 in. center to center
Use: Pyrolysis furnace FLANGES AND REDUCERS
Alloy: HF with 5-15% ferrite (19Cr-9Ni)
Weight: 1500 lb (flanges)
Use: High temperature piping in
petrochemical plant.

22
 FURNACE TUBE ASSEMBLIES
Alloy: HP (35Ni-26Cr)
Weight: 500 lb per assembly
Size: 3.75 in. O.D. x 3.12 in. I.D. x 20 ºFt
long Use: Coil, radiant section, pyrolysis
furnace

WELD ELBOW
WITH TRUNNION PAD
Alloy: HK-40 modified with Cb (25Cr-20Ni-Cb)
Weight: 23 Ib
Size: 4 in. O.D. x 3 in. ID
Use: Ethylene converter furnace

VERTICAL TUBULAR BEAM

WITH LOOSE ACCESSORIES
Alloy: HK (25Cr-20Ni)
Weight: 153 Ib
Use: Petrochemical tube support
TUBE SUPPORT
Alloy: HH (25Cr-12Ni)
Weight: 15 Ib
Use: Petrochemical industry

23
 TUBE SUPPORTS
Alloy: HH (25Cr-12Ni)
Weight: 6 Ib
Use: Petrochemical industry

SIDE SUPPORTS AND TUBE SHEETS

Alloy: HK (25Cr-20Ni)
Weight: Sheets, 170 lb; supports, 407 lb

HORIZONTAL TUBULAR BEAM WITH ACCESSORIES HORIZONTAL TUBULAR BEAM WITH ACCESSORIES
Alloy: HK (25Cr-20Ni) Alloy: HK (25Cr-20Ni)
Weight: 253 Ib Weight: 299 Ib
Use: Petrochemical tube support Use: Petrochemical tube support

24
REDUCING ELBOW
Alloy: HK-40 (25Cr-20Ni)
Weight: 10 Ib
Size: I.D. reduction 4½ in. to 1½ in.
Use: Reformer tube assemblies BURNER DIFFUSER
Alloy: HX (66Ni-17Cr)
Weight: 27 Ib
Use: Petrochemical industry

CENTRIFUGALLY-CAST
FURNACE TUBE
Alloy: HK-40 (25Cr-20Ni)
Weight: 245 Ib
Size: 4 in. O.D. x 3 in. I.D. x 156 in. long
Use: Furnace tube section

BURNER NOZZLES
POWER PLANTS Alloy: HE (29Cr-9Ni)
Weight: 10 to 15 lb each
Because of the higher operating temperatures being used Use: Burners operating at temperatures up to 1800 ºF
in superheater and boiler units, extensive use is being
made of heat-resistant cast alloys. The proper use of
high-alloy castings avoids costly shutdowns and reduces
maintenance requirements

Typical Applications

Tube supports Nozzles

Hanger bolts Beams
Brick and tile supports Burner diffusers
Dampers Valve bodies

25
STEEL MILL EQUIPMENT
The advantages of heat-resistant alloy castings have been
demonstrated by the steel industry in many high-temperature
applications. These alloys are capable of operation at high
speeds, temperatures and loads and provide reliable opera-
tion for long periods, thus reducing equipment upkeep and
operating costs.

Typical Applications
FURNACE DRUM
Baffles Retorts Alloy: HK-40 (25Cr-20Ni)
Furnace beams and rails Radiant tubes Weight: 10,000 Ib
Conveyor parts Recuperators Size: 60 in. major O.D.
Furnace doors and frames Skid rails
Use: Turn-down roll in steel mill furnace for normalizing sheet.
Dampers Muffles

GUIDES
Alloy: HH (25Cr-20Ni)
Weight: 2 and 14 Ib
Use: Steel rod mill guides

REFRACTORY-LINED BLOWPIPES
Alloy: HP (35Ni-26Cr)
Weight: 600 Ib (pipe)
Size: 10 in. O.D. barrel with 14 in. O.D. bell ends
Use: Steel mill blast furnace

SMELTING AND REFINING EQUIPMENT Typical Applications

Many years ago, this industry recognized the savings that Rabble arms Feed spouts
were possible if high-alloy castings were properly utilized. In
Plows Hearth plates
the sintering and smelting of ores, high temperatures, acid
Rabbles Lute rings
gases and abrasion contribute to the destruction of furnace,
Air arms Grate
hearth, kiln and sintering machine parts. Heat-resistant alloy
Chains Seal plates
castings reduce operating and maintenance costs by provid-
ing durability and heat resistance. Dampers Furnace tubes

COOLER GRATES GRATE BARS

Alloy: HH (25Cr-12Ni) Alloy: HH (25Cr-12Ni)
Weight: 20 to 40 Ib Weight: 12 Ib
Use: Iron ore pelletizing and cement kiln Use: Iron ore sintering and pelletizing furnace

26
 Part ll
Corrosion-Resistant Alloy Castings

The corrosion-resistant casting alloys are those com- VI, the physical properties in Table VII and the heat
positions capable of performing satisfactorily in a large treating temperatures in Table VIII.
variety of corrosive environments. They are composed Commercial cast corrosion-resistant alloy can be
principally of nickel, chromium and iron; sometimes also identified by the designations of the Alloy Casting Insti-
containing other elements. Castings made of these al- tute, now a division of the Steel Founders' Society of
loys offer two basic advantages: America, and the American Society for Testing and
1. Facility of the production of complex shapes at Materials.* Some of these materials are also listed in the
low cost. Aerospace Material Specifications (AMS) of the Society
2. Ease of securing rigidity and high strength-to- of Automotive Engineers, the United States Govern-
weight ratios. ment Specifications (MIL and QQ), the Society of Auto-
Some typical alloy compositions are given in Table V, motive Engineers Specifications and the Unified Num-
the room temperature mechanical properties in Table bering System (UNS) developed by the Society of Auto-
motive Engineers and the American Society for Testing
and Materials.
TABLE V
Compositions of Corrosion-Resistant Alloy Castings

AISI CHEMICAL COMPOSITION, %

Alloy Casting ASTM (or other)
Institute Alloy (or other) Wrought UNS Ni Cr Mo Cu C Mn Si Other
Designation Type Specification Comparative No. Max Max Max

CA-15 12Cr A296, A487 410 J91150 1.0 11.5-14.0 0.5 – 0.15 1.00 1.50 Fe bal
CA-40 12Cr A296 420 J91153 1.0 11.5-14.0 0.5 – 0.20-0.40 1.00 1.50 Fe bal
CA-6NM 12Cr-4Ni A296,A487 – J91540 3.5-4.5 11.5-14.0 0.40-1.0 – 0.06 1.00 1.00 Fe bal
CA-6N1 12Cr-7Ni A296 – – 6.0-8.0 10.5-12.5 – – 0.06 0.50 1.00 Fe bal
CB-30 20Cr A296 442 J91803 2.0 18-22 – – 0.30 1.00 1.50 Fe bal
CB-7Cu-1 17Cr-4Ni A747 17-4PH2 – 3.6-4.6 15.5-17.7 – 2.5-3.2 0.07 0.70 1.00 Cb 0.20-0.35; N 0.05
max; Fe bal
CB-7Cu-2 15Cr-5Ni A747 15-5PH2 – 4.5-5.5 14.0-15.5 – 2.5-3.2 0.07 0.70 1.00 Cb 0.20-0.35: N 0.05
max; Fe bal
CC-50 28Cr A296 446 J92615 4.0 26-30 – – 0.50 1.00 1.50 Fe bal
CD-4MCu 26Cr-5Ni A296 – – 4.75-6.0 25-26.5 1.75-2.25 2.75-3.25 0.04 1.00 1.00 Fe bal
CE-30 29Cr-9Ni A296 312 J93423 8-11 26-30 – – 0.30 1.50 2.00 Fe bal
CF-3 19Cr-10Ni A296, A351 304L J92500 8-12 17-21 – – 0.03 1.50 2.00 Fe bal
CF-8 19Cr-9Ni A296, A351
MIL-S-867 304 J92600 8-11 18-21 – – 0.08 1.50 2.00 Fe bal
CF-20 19Cr-9Ni A296 302 J92602 8-11 18-21 – – 0.20 1.50 2.00 Fe bal
CF-3M 19Cr-10Ni A296, A351 316L J92800 9-13 17-21 2.0-3.0 – 0.03 1.50 1.50 Fe bal
CF-8M 19Cr-10Ni A296, A351 316 J92900 9-12 18-21 2.0-3.0 – 0.08 1.50 1.50 Fe bal
CF-8C 19Cr-10Ni A296, A351 347 J92710 9-12 18-21 – – 0.08 1.50 2.00 Cb 8XC min, 1.0 max
or Cb-Ta 9XC min,
1.1 max; Fe bal
CF-16F 19Cr-10Ni A296 303 J92701 9-12 18-21 1.50 – 0.16 1.50 2.00 Se 0.20-0.35; Fe bal
CG-8M 19Cr-10Ni A296
MIL-S-867 317 J93000 9-13 18-21 3.0-4.0 – 0.08 1.50 1.50 Fe bal
CH-20 25Cr-12Ni A296, A351 309 J93402 12-15 22-26 – – 0.20 1.50 2.00 Fe bal
CK-20 25Cr-20Ni A296, A351
AMS 5365 310 J94202 19-22 23-27 – – 0.20 1.50 2.00 Fe bal
CN-7M 20Cr-29Ni A296, A351 – J95150 27.5-30.5 19-22 2.0-3.0 3.0-4.0 0.07 1.50 1.50 Fe bal
IN-8623 – – – – 23-25 20-22 4.5-5.5 – 0.07 1.50 1.00 Fe bal
CW-12M1 – A296, A494 – – bal 15.5-20.0 16.0-20.0 – W 5.25 max; V 0.40
0.12 1.00 1.50
max; Fe 7.50 max
CY-401 Ni-Cr-Fe A296, A494 INCONEL4
alloy 600 – bal 14.0-17.0 – – 0.40 1.50 3.00 Fe 11.0 max
Alloy 6253 – – – – bal 20-23 8.0-10.0 – 0.06 1.00 0.75 Cb 3.15-4.50;
Fe 5.0 max
1
CZ-100 Ni A296, A494 Nickel 200 – bal – – 1.25 1.0 1.50 2.00 Fe 3.0 max
M-351 Ni-Cu A296, A494 MONEL4
QQ-N-288 alloy 400 – bal – – 26.0-33.0 0.35 1.50 2.00 Fe 3.50 max
1
N-12M Ni-Mo A296, A494 – – bal 1.00 26.0-33.0 – 0.12 1.00 1.00 V 0.60 max; Fe 6.0 max
– Ni-Si – – – bal 1.00 – 2.4 – 0.50-1.25 8.5-10.0 W 1 max
1 3
ASTM designation INCO designation
2 4
Trademark of Armco Steel Corporation Trademark of the INCO family of companies

Note: ASTM A.296 will be replaced by two new standards, A 743 and A 744 in the 1978 Annual Book of ASTM Standards. A 743 will cover the martensitic and ferritic types and A 744 the
austenitic types. A 296 will appear in the 1978 Book of Standards but will be dropped in the 1979 Book.

*See ASTM Specification A 296

27
 TABLE VI
Room Temperature Mechanical Properties of Corrosion-Resistant Alloy Castings
CA- CA CB- CB- CD- CF- IN- CW- Alloy CZ-
PROPERTY CA-15 CA-40 6NM -6N CB-30 7Cu-1 7Cu-2 CC-50 4MCu CE-30 CF-3 CF-8 CF-20 CF-3M CF-8M F-8C 16F CG-8M CH-20 CK-20 CN-7M 862 12M CY-40 625 100 M-35 N-12M
1 1 5 6 7 12a 12a 8a 9 10 11 11 11 11 11 11 11 11 11 11 11 6 10 6 10 10
Tensile 200 220 120 140 95 170 170 70 108 95 77 77 77 80 80 77 77 82 88 76 69 60 72 65-90 70 50-65 65-85 726
Strength, 1352 1502 15012b 15012b 95 8b 9711
ksi 1153 1403 14512c 14512c
1004 1104 13512d 13512d
12512e 12512e
Yield 1501 1651 1005 1356 607 14512a 14512a 65 8a 829 4510 3611 3711 3611 3811 4211 3811 4011 4411 5011 3811 3211 25 466 32-5010,13 406 15-3010,13 30-4010,13 466
Strength 1152 1252 14012b 14012b 60 8b 6311
(0.2% offset) 1003 1133 11512c 11512C
ksi 754 674 11012d 11012d
9712e 9712e

Elongation 71 11 245 156 157 512a 512a 2 8a 259 1510 6011 5511 5011 5511 5011 3911 5211 4511 3811 3711 4811 40 46 20-1010 206 30-1510 50-2510 66
in 2 in., % 172 102 912b 912b 15 8b 1811
223 143 912c 912c
304 184 912d 912d
1012e 1012e
90–
Brinell 3901 4701 2695 – 1957 37512a 37512a 212 8a 2539 19010 14011 14011 16311 15011 156–17011 14911 15011 17611 19011 14411 13011 130 – 150–20010 – 10 125–17010 –
130
Hardness 2602 3102 31112b 31112b 193 8b 19011
2253 2673 27712c 27712c
1854 2124 26912d 26912d
26912e 26912e
Modulus of 29 29 29 29.5 29 28.5 – 29 29 25 28 28 28 28 28 28 28 28 28 29 24 – – 23 – 21.5 23 –
Elasticity,
ksi x 103

9
1 Solution annealed at 2050 ºF. Water quenched from 1900 ºF.
Air cooled from 1800 ºF. Tempered at 600 ºF. 10
2 As cast
Air cooled from 1800 ºF. Tempered at 1100 ºF. 11
3 Water quenched from 2000-2050 ºF.
Air cooled from 1800 ºF. Tempered at 1200 ºF. 12
4 a PH heat treatment H900, minimum values.
Air cooled from 1800 ºF. Tempered at 1400 ºF.
5 b PH heat treatment H1025, minimum values.
Air cooled from above 1750 ºF. Tempered at 1100-1150 ºF.
6 c PH heat treatment H1075, minimum values.
Minimum
7 d PH heat treatment H1100, minimum values.
Annealed at 1450 ºF. F.C. to 1000 ºF, then air cooled.
8a
e PH heat treatment H1150, minimum values.
Under 1% Ni 13
0.5% extension
b Over 2% Ni with 0.15 Nitrogen, minimum

TABLE VII
Physical Properties of Corrosion-Resistant Alloy Castings
CA- CB- CB- CD- CF- CF- CF- CF- CF- CG- CH- CK- CN- CW- Alloy- CZ- N- IN-
PROPERTY CA-15 CA-40 6NM CA-6N CB-30 7Cu-1 7Cu-2 CC-50 4MCu CE-30 CF-3 CF-8 20 3M 8M 8C 16F 8M 20 20 7M 12M CY-40 625 100 M-35 12M 862
Density, Ib/cu in. 0.275 0.275 0.278 0.280 0.272 0.280 0.269a 0.272 0.280 0.277 0.280 0.280 0.280 0.280 0.280 0.280 0.280 0.280 0.279 0.280 0.289 0.292a 0.336 a 0.300 0.305 0.301 0.312 0.334a
Specific Heat,
Btu db/°F at 70 0.11 0.11 0.11 - 0.11 0.11 - 0.12 0.11 0.14 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.11 - - 0.11 0.10 0.13 0.13 -
ºF
Mean Coefficient
of Linear Thermal
Expansion,
in./in./°F x 106
70 - 212 ºF 5.5 5.5 6.0 5.7 6.0 - 5.9 6.3 - 9.0 9.0 9.6 8.9 8.9 9.3 9.0 8.9 8.6 8.3 8.6 - - - 7.1 - - -
70 - 1000 ºF 6.4 6.4 7.0 6.21 6.5 6.4 6.9 9.6 10.0 10.0 10.4 9.7 9.7 10.3 9.9 9.7 9.5 9.4 9.7 - 7.8 -
70 - 1200 ºF - - - - - 7.0 9.9 - 10.2 - - - - - - - - - - 8.2 -
70 - 1300 ºF 6.7 6.7 - 6.7 - - - - - - - - - - - - - - - -
70 - 1400 ºF - - - - - - 10.2 - - - - - - - - - - 8.9 8.5 8.9
70 - 1600 ºF - - - - - - 10.5 - - - - - - - - - - - - 8.8 -
Specific
Electrical
Resistance
microhm
cm at 70 ºF 78 76 78 - 76 77 - 77 75 85 76.2 76.2 77.9 82 82 71 72 82 84 90 89.6 - - 116 129 21 53 -
Thermal
Conductivity,
Btu/hr/sq
ft/ft/°F
at 212 ºF 14.5 14.5 14.5 - 12.8 9.9 - 12.6 8.8 8.5 9.2 9.2 9.2 9.4 9.4 9.3 9.4 9.4 8.2 7.9 12.1 - - 8.7 6.3 34 15.5 -
at 1000 ºF 16.7 16.7 16.7 14.5 17.9 13.4 12.4 12.1 12.1 12.1 12.3 12.3 12.8 12.3 12.3 12.0 11.8 - 10.0
Melting Point _ _
(approx), ºF 2750 2725 2750 - 2725 2750 - 2725 2700 2650 2650 2600 2575 2600 2550 2600 2550 2550 2600 2600 2650 - - 2600 2460 2600 2400 -
Magnetic Ferro- Ferro- Ferro- Ferro Ferro- - Ferro- Ferro- over 1.20- 1.00- 1.50- 1.50- 1.20- 1.00- 1.50- 1.01-
–
Permeability Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic 1.5 3.00 1.30 1.01 3.00 250 1.80 2.00 3.00 1.71 1.02 1.10 1.00

1
70-600 ºF
2
Data from wrought equivalent
aCalculated

28
 The Alloy Casting Institute and ASTM designations
use "C" to indicate alloys used primarily for their
corrosion-resistant properties. The second letter indi-
cates the nominal nickel content, increasing from A to Z.
The S.A.E. specifications use the nearest wrought
composition (AISI type number) and prefix it with the
number 60 ºFor corrosion-resistant castings; for exam-
ple, 60304 is equivalent to CF-8. In the Unified Num-
bering System, Jxxxx number series has been assigned
to cast steels.
The chemical compositions of the corrosion-resistant
casting alloys are not the same as those of the wrought
alloys. Therefore, Table V lists only the nearest AISI or
other wrought comparative. Alloy Casting Institute des-
ignations or their equivalent should always be used to
identify castings.

TABLE VIII
Heat Treatment of Corrosion-Resistant Alloy Castings

Alloy Casting
Institute Designation Anneal at Harden at Temper at Quench
CA-15 1450-1650 ºF 1800-1850 ºF 600 ºF, max or 1100-1500 ºF -
CA-40 1450-1650 ºF 1800-1850 ºF 600 ºF, max or 1100-1500 ºF -
CA-6NM 1450-1500 ºF 1900-1950 ºF 600 ºF, max or 1100-1500 ºF -
1 2
CA-6N 1900 ºF - 800 ºF air cool
CB-30 1450 ºF, min - - air cool
CB-7Cu-1 1925 ºF - 900-1150 ºF3 air cool
3
CB-7Cu-2 1925 ºF - 900-1150 ºF air cool
CC-50 1450 ºF, min - - air or furnace cool
CD-4MCu 2050 ºF, min4 - - -
CE-30 2000-2050 ºF - - water, oil or air
CF-3 1900-2050 ºF - - water, oil or air
CF-8 1900-2050 ºF - - water, oil or air
CF-20 2000-2100 ºF - - water, oil or air
CF-3M 1900-2050 ºF - - water, oil or air
CF-8M 1950-2100 ºF - - water, oil or air
CF-8C 1950-2050 ºF - - water, oil or air
CF-16F 1950-2050 ºF - - water, oil or air
CG-8M 1900-2050 ºF - - water, oil or air
CH-20 2000-2100 ºF - - water, oil or air
CK-20 2000-2150 ºF - - water, oil or air
CN-7M 2050 ºF, min - - water, oil or air
IN-862 2150 ºF - - water
CW-12M 2200-2250 ºF - - water
CY-40 - - - -
Alloy 625 2150 ºF - - water
Cz-100 - - - -
M-35 - - - -
N-12M 2100-2150 ºF - - water

1
Reheat to 1500 ºF, air cool
2
Aging Temperature
3
Precipitation hardened
Temperature Condition
900 ºF H 900
925 ºF H 925
1025 ºF H1025
1075 ºF H1075
1100 ºF H1100
1150 ºF H1150
*Held 3 hours, slowly cooled to 1400-1750 ºF, cooled in water, oil or air.

EFFECT OF CONSTITUENTS
Chromium
A chromium content of at least 11.5% is required to
provide surface passivity under oxidizing conditions and
to form an inert adherent surface film rich in chromium
oxide which is highly resistant to attack. A higher chro-
mium content broadens the range of oxidizing condi-
tions under which passivity is maintained. The chro-
mium content of corrosion-resistant castings ranges
from 12 to 28% in the ACI alloys.
Nickel
The addition of nickel supplements the passivating
effect of chromium under oxidizing conditions and also
increases the resistance of the alloys to attack under
reducing conditions. Nickel in sufficient concentration
results in a desirable austenitic structure and preserves
this structure through the many heat treatments to
which castings may be subjected during production and
subsequent fabrication. In the higher nickel alloys,
nickel provides increased resistance to most reducing

29
 environments. It also provides improved resistance to
those chemical compounds to which nickel is particu-
larly resistant. These are typified by strong alkalies and
halogen compounds. In corrosion-resistant castings,
the nickel content ranges from 1 to 96%.
Molybdenum
Molybdenum has specific beneficial effects in improv-
ing resistance to sulfuric, phosphoric and hydrochloric
acids. It also reduces the tendencies toward pitting in
sea water and other chloride solutions. In the ACI alloys,
the molybdenum content ranges from none to 30%.
Other Elements
Although chromium, nickel and molybdenum have
the greatest influence on the properties of corrosion-
resistant castings, other alloying elements also have
their effects.
Carbon can have a detrimental effect on corrosion
resistance by combining with chromium to form a car-
bide. This undesirable effect can be eliminated by:
(a) Holding the carbon content below 0.03%.
(b) Introducing columbium or titanium to form car-
bides of these elements instead of the harmful
chromium carbide.
(c) Heating the alloy to a temperature sufficiently
high to dissolve the carbon and cooling rapidly
enough to hold the carbon in solution.
Columbium is added as a stabilizer to prevent precipi-
tation of chromium carbides.
Copper acts in the same manner as molybdenum to
improve resistance to sulfuric and phosphoric acids.
Selenium in small quantities improves machinability
but it reduces corrosion resistance somewhat.
Silicon also contributes to resistance to reducing
acids such as sulfuric, but impairs resistance to nitric
acid. The silicon content of cast corrosion-resistant alloys
is higher than that of the wrought alloys because this
element contributes the fluidity required to obtain
satisfactory casting characteristics. However, silicon is a
promoter of ferrite formation and, as a consequence,
tends to cause the formation of small amounts of ferrite in
the austenitic matrix. As one result, silicon increases the
resistance of cast corrosion-resistant alloys to chloride
ion stress-corrosion cracking.
CORROSIVE ATTACK
Corrosion is a complex phenomenon in which numer-
ous variables influence not only the severity but also the
type of attack. Therefore, it is not possible to make
specific recommendations for alloy selection in a gen-
eral publication. Certain limitations on the use of
corrosion-resistant alloy castings and suggestions for
counteracting them are discussed below. Table IX is
included to serve as a guide in selecting candidate
alloys for an environment. Where corrosion data on cast
30
alloys were sparse, data on the wrought counterpart
were included on the assumption that corrosion rates for
both cast and wrought alloys would be similar.
Pitting Corrosion
Stainless steels are subject to localized loss of pas-
sivity and subsequent pitting by the action of chloride
ions which penetrate the passive surface films. The
incidence of such pitting is determined by the competi-
tion between the chloride ions which destroy passivity
and dissolved oxygen or other oxidizing substances
which passivate the surface. It is affected also by the
composition of the alloy and the exposure conditions.
Favorable factors are the presence of molybdenum and
a high nickel content represented, for example, by the
51% Ni-17% Mo-16.5% Cr compositions which is usu-
ally resistant to pitting by chloride solutions even under
adverse conditions. Favorable environmental factors are
a plentiful supply of oxygen or other oxidizing agent or,
conversely, no oxygen at all, a high alkalinity and low
temperature, a medium to high flow rate and freedom
from deposits. The most unfavorable condition is repre-
sented by exposure beneath deposits to a stagnant
solution containing some dissolved oxygen. Turbulence
associated with high velocity flow is generally beneficial.
Sensitization
When an austenitic stainless steel containing more
than 0.03% carbon, which is not stabilized by the pres-
ence of columbium or titanium, is heated in the 900-
1400 ºF range, chromium carbide will precipitate at the
grain boundaries. The localized depletion of chromium
may make the alloy susceptible to intergranular attack in
environments in which it ordinarily shows good
resistance. Sensitization can usually be avoided by
keeping the carbon content at 0.03% or less, by adding
small quantities of columbium or titanium, or by heating
to 2000 ºF for one hour per inch of thickness followed by
quenching in water.
Magnetic Properties
The Alloy Casting Institute grades containing up to
4% nickel are all magnetic, as is the CE-30 grade. AIl
other grades fall within the austenitic alloy class, be-
cause of their compositions, and are substantially non-
magnetic. A small amount of magnetic ferrite is desir-
able to facilitate weld repair although this ferrite may not
be detected by a magnet. Occasionally, when the chro-
mium is on the high side of the specification and the
nickel is on the low side, an unbalanced condition will
develop in austenitic alloys that results in the formation
of a two-phase alloy composed of austenite and ferrite
The presence of ferrite in the structure will cause the
alloy to be slightly magnetic. This two-phase structure
will have corrosion resistance in practically all environ-
ments equivalent to that of the single-phase austenitic
structure. An exception is in ammonium carbamate so-
lutions such as are encountered in urea production.

Stress-Corrosion Cracking
Under the combined effects of tensile stress and cor-
rosion by specific environments (most commonly con-
centrated chlorides), certain stainless steel composi-
tions are subject to stress-corrosion cracking. Nickel
has the greatest effect on resistance to this form of
attack. Resistance to such cracking is improved by in-
creasing the nickel content above the 8% level of the
common CF-8 grade.
Although cast austenitic stainless steels are often
considered to be similar to their wrought counterparts,
there is a difference. There is usually a small amount of
GROUPS OF CORROSION-RESISTANT ALLOY CASTINGS
The iron-base corrosion resistant alloys can be clas-
sifed according to composition and metallurgical struc-
ture into four broad groups:
1. Martensitic Alloys: CA-15, CA-40, CA-6NM,
CA-6N
2. Ferritic and Duplex Alloys: CB-30, CC-50,
CD-4MCu
3. Austenitic Alloys: CE-30, CF types, CG-8M,
CH-20, CK-20, CN-7M, CN-7MS, IN-862
4. Precipitation Hardenable Alloys: CB-7Cu-1,
Cb-7Cu-2
In addition, nickel-base corrosion-resistant alloys in-
clude nickel, high nickel-copper alloys, high nickel-
chromium alloys and other proprietary alloys.
MARTENSITIC ALLOYS
CA-15 (12Cr-1Ni)
This alloy contains the minimum content required to
attain surface passivity under oxidizing conditions. It
has good resistance to many mildly corrosive environ-
ments that are oxidizing in character. It also has good
resistance to velocity effects in solutions for which it is
suitable. The alloy is used widely for seats and discs in
valves in steam service and for parts of turbines ex-
posed to high velocity steam
CA-40 (12Cr-1Ni)
This is the cutlery type of stainless steel which, by
virtue of its higher carbon content, can be hardened to a
greater depth than type CA-15. It has good corrosion
resistance to many environments, is tough and has
good resistance to abrasion. It is used for chipper
blades, cutter blades, cylinder liners, grinding plugs,
shredder sleeves and steam turbine parts.
CA-6NM (12Cr-4Ni)
This is an iron-chromium-nickel-molybdenum alloy
that is hardenable by heat treatment. In general corro-
sion resistance, it is similar to CA-15 and has been
widely substituted for CA-15 because of easier process-
ing through the foundry cleaning room. Among uses are
compressor wheels, diaphragms, hydraulic turbine
ferrite present in austenitic stainless steel castings, in
contrast with the single-phase austenitic structure of the
wrought alloys. The presence of ferrite in the castings is
desirable to facilitate weld repair but also increases
resistance to stress-corrosion cracking. There have
been only a few stress-corrosion cracking failures with
cast stainless steels in comparison with the approxi-
mately equivalent wrought compositions. The principal
reasons for this resistance are apparently (a) lower
stresses, (b) silicon added for fluidity is also beneficial
from the standpoint of stress-corrosion cracking and (c)
sand castings are usually tumbled or sandblasted to
remove molding sand and scale which probably tends to
put the surface in compression.
parts, impulse wheels and pumps and valves for boiler
feedwater service.
CA-6N (12Cr-7Ni)
This is a higher nickel content modification of CA-15
which has an excellent combination of strength, tough-
ness and weldability. It has moderately good corrosion
resistance.
FERRITIC AND DUPLEX ALLOYS
CB-30 (20Cr-2Ni)
Because of its higher chromium content, this alloy has
better resistance to corrosion in many oxidizing environ-
ments than the CA alloys. The addition of 2% nickel
enhances corrosion resistance and increases tough-
ness. It also has good abrasion resistance. Uses in-
clude pump parts, turbine parts and valve trim.
CC-50 (28Cr-4Ni)
Alloys containing about 28% chromium and up to 4%
nickel are resistant to a number of highly oxidizing me-
dia such as hot nitric acid. They are also used in han-
dling corrosives such as acid mine waters which are
oxidizing and may be mildly abrasive. Among applica-
tions are cylinder liners, digester parts, pump casings
and impellers.
CD-4MCu (26Cr-5Ni-3Cu-2Mo)
As cast, this alloy has a duplex ferrite and austenite
structure. Because of its low carbon content, there are
only small amounts of chromium carbides distributed
throughout the matrix, but for maximum corrosion resis-
tance, these carbides must be dissolved by suitable heat
treatment. Although the alloy can be precipitation
hardened, the ACI recommends that this alloy be used
only in the solution annealed condition. It is highly resis-
tant to attack by some concentrations of sulfuric and
hydrochloric acids and is exceptionally resistant to
stress-corrosion cracking in chloride-containing solu-
tions or vapors. It has also shown outstanding resis-
tance to such mixtures as nitric-adipic acid slurries and
wet process phosphoric acid slurries. Uses include
compressor cylinders, pump impellers, digester valves
and feed screws.
31
 AUSTENITIC ALLOYS
CE-30 (29Cr-9Ni)
This alloy also is resistant to a number of highly
oxidizing corrosives and is particularly used for pumps,
valves and fittings handling sulfite liquors in the paper
industry and some acid slurries in the metallurgical in-
dustries. Because of its high chromium content, the
alloy can be made with a higher carbon content than the
CF type alloy without suffering the injurious effects of
carbide precipitation. For the same reason, it may be
used in place of the CF alloys where they must be
welded without subsequent heat treatment. While often
used in the as-cast condition, ductility and corrosion
resistance of the CE alloy may be improved somewhat
by quenching from about 2000 ºF. Uses include digester
necks and fittings, circulating systems, fractionating
towers, pump bodies and casings.
CF Alloys (19Cr-9Ni)
The austenitic alloys containing about 19% chro-
mium, 9% nickel and less than 0.20% carbon constitute
by far the most widely used group of corrosion-resistant
stainless alloys. These alloys are used for handling a
wide variety of corrosive solutions in the chemical, tex-
tile, petroleum, pharmaceutical, food and numerous
other process industries. In the chemical industry, they
are particularly useful in handling oxidizing solutions
such as nitric acid and peroxides and mixtures of acids
such as sulfuric and phosphoric with oxidizing salts
such as ferric, cupric, mercuric and chromic salts.
These stainless alloys are resistant to most organic
acids and compounds as encountered in the food, dairy
and pharmaceutical industries. They also are resistant
to most waters including mine, river, boiler and tap
waters. They are resistant to sea water under the high
velocity conditions associated with pumping but are
subject to severe pitting attack in stagnant or slow mov-
ing sea water.
The limitation of the CF alloys is that most halogen
acids and halogen acid salts tend to destroy their sur-
face passivity. Thus, they are subject to considerable
attack in such media as hydrochloric acid, acid chloride
salts, wet chlorinated hydrocarbons, wet chlorine and
strong hypochlorites.
For best resistance to corrosion, this alloy is produced
in the low carbon CF-3 and CF-8 grades and should be
solution annealed to prevent intergranular attack in
severely corrosive media. Heat treated CF-3 castings can
be field welded or hot formed without subsequent re-
solution annealing, a major advantage in many appli-
cations.
Columbium (niobium) or columbium plus tantalum
are sometimes added to produce carbide-stabilized CF-
8C alloy which, after heat treating, can be field welded or
used at elevated temperatures without the precipitation of
chromium carbides and resultant susceptibility to
intergranular attack of chromium depleted regions.
The addition of molybdenum as in grades CF-3M and
CF-8M considerably increases the resistance of the
CF-alloys to such corrosive media as sulfuric, sulfurous
32
and phosphoric acids and to certain hot organic acids
such as formic, acetic and lactic acids. Molybdenum
also improves resistance to pitting in chloride salt solu-
tions and sea water.
Grade CF-16F is similar to grades CF-8 and CF-20
to which small amounts of selenium have been added to
improve the machinability. The corrosion resistance of
this alloy is somewhat inferior to that of the CF-20 alloy
but is adequate for many purposes.
Controlled Ferrite Types
The strength of the CF alloys cannot be improved by
heat treatment but these alloys can be strengthened by
increasing the ferrite phase at the expense of the aus-
tenite phase in these duplex microstructures. This fact
has led to the introduction of controlled ferrite types,
designated with an "A" suffix in some CF alloys, i.e.,
CF-3A and CF-8A, for applications where higher
strength is desired than is obtainable in the CF-3 and
CF-8 types. Minimum tensile strengths for these con-
trolled ferrite types are 7 to 10 ksi higher than for the
regular types. The increased ferrite content generally
improves the resistance of the alloy to stress-corrosion
cracking in addition to increasing the strength. Because
of the thermal instability of the higher ferrite microstruc-
ture, however, the controlled ferrite types are not con-
sidered suitable for service at temperatures above
650 ºF (CF-3A) or 800 ºF (CF-8A).
CG-8M (19Cr-8Ni)
The high molybdenum content of this alloy (3-4%)
gives it improved resistance to hot sulfurous and or-
ganic acids and to dilute sulfuric acid. It also has great
resistance to pitting. Uses include dyeing equipment,
flow meter components, pump parts and propellers.
CH-20 (25Cr-12Ni)
With a carbon content of less than 0.20%, this alloy is
similar in corrosion resistance to the CE-30 composi-
tion. It is used for specialized applications in the chemi-
cal and paper industries. Uses include digester fittings,
roasting equipment, valves and pump parts.
CK-20 (25Cr-20Ni)
This alloy is somewhat similar to the CE and CH types
but has higher nickel content. It is sometimes made with a
columbium, or columbium plus tantalum addition, to
minimize the effect of carbide precipitation. It is used in
the pulp and paper industry to handle sulfite solutions.
Uses include digesters, filter press plates and frames,
mixing kettles and return bends.
CN-7M (29Ni-20Cr)
This designation covers a group of complex nickel
chromium-copper-molybdenum alloys containing more
nickel than chromium. The increased nickel content
together with the addition of copper and molybdenum
give the alloy especially good resistance to sulfuric acid
and to many reducing chemicals. It has good resistance
to dilute hydrochloric acid and to hot chloride salt solu-
tions. The alloy also has excellent resistance to nitric
and phosphoric acids. Uses include filter parts, heat
exchanger parts, mixer components, pickling hooks and
racks, steam jets and ventilating fans; pumps and valves
represent a major part of CN-7M applications.
CN-7MS (24Ni-19Cr-3Mo-2Cu)
The CN-7MS modification of CN-7M was developed
for improved castability and weldability. Its corrosion
resistance is substantially equivalent to the CN-7M
alloy.
IN-862 (24Ni-21Cr-5Mo)
This alloy was developed as an alternative to CN-7M
for service in sea water. With its increased molybdenum
content, it has better resistance to pitting and crevice
corrosion than CN-7M but its corrosion resistance in
sulfuric acid environments is lower. It has excellent
casting and welding properties, thus giving it advan-
tages in production and repair compared with CN-7M.
PRECIPITATION HARDENABLE ALLOYS
CB-7Cu-1 (16Cr-4Ni-3Cu)
This complex chromium-nickel-copper alloy can be
hardened by a precipitation heat treatment after solution
annealing. It is not intended for use in the solution
annealed condition. The alloy can be used in service
requiring corrosion resistance and high strength at tem-
peratures up to 600 ºF. In the precipitation hardened
condition, its corrosion resistance approaches that of the
CF-8 alloy under certain conditions.
CB-7Cu-2 (15Cr-5Ni-3Cu)
This complex chromium-nickel-copper alloy can be
hardened by a precipitation hardening heat treatment
after solution annealing. It is not intended for use in the
solution annealed condition. It has a superior combina-
tion of strength, toughness and weldability with moder-
ately good corrosion resistance.
NICKEL-BASE ALLOYS
CZ-100 (95Ni min)
Cast nickel is outstanding for maintaining the purity of
a wide range of drugs, foods and chemicals. It is widely
used for the manufacture of caustics and for handling
caustics in processes where low iron and copper content
in the equipment is important.
M-35 (63Ni-30Cu)
This alloy shows good resistance to attack in reducing
environments. It is widely used in handling sulfuric,
hydrochloric and organic acids in the marine, petro-
leum, chemical, power, sanitation, plastics, steel and
food processing industries.
CY-40 (74Ni-15Cr)
This nickel-base alloy has a superior combination of
corrosion resistance under a wide variety of conditions
plus high levels of strength, ductility and weldability. It
protects product purity much as nickel does, but is more
*Trademark of the INCO family of companies
resistant to oxidizing conditions. It is stronger and har-
der than nickel, and as tough. Industries in which it is
used are: dairy, chemical, pharmaceutical, nuclear, pe-
troleum and food processing. Its corrosion resistance to
nitric acid, fatty acids, ammonium hydroxide solutions
and oxidizing conditions in general is superior to nickel.
This alloy is particularly useful in handling corrosive
vapors above 1470 ºF.
Alloy 625 (60Ni-21Cr-9Mo)
This high nickel-chromium-molybdenum alloy, like its
wrought counterpart INCONEL* alloy 625, has excellent
corrosion resistance, especially in sea water, and is
highly resistant to chloride stress-corrosion cracking. It
has superior corrosion resistance in oxidizing atmos-
pheres and to sulfur, and organic and inorganic com-
pounds over a wide temperature range. Cast Alloy 625
has high levels of fatigue and creep strength, above
those of CY-40. Sand-cast Alloy 625 can be air melted
and poured, processed through the cleaning room in the
as-cast condition, and can be welded using SMA
(coated electrode) or GMA (gas metal arc) processes
without preheat or postweld heat treatments.
CW-12M (55Ni-18Cr-18Mo)
This complex nickel-chromium-molybdenum alloy
sometimes contains 5% tungsten and minor amounts of
other elements. It has outstanding resistance to such
highly corrosive media as wet chlorine, strong hypo-
chlorite solutions, ferric chloride and cupric chloride and
is often applied in the handling of such chemicals. It
also has good resistance to boiling concentrated or-
ganic acids such as acetic, formic, lactic and fatty
acids. Maximum corrosion resistance is obtained by quench-
ing the cast alloy from an annealing temperature of
2200-2250 ºF.
N-12M (63Ni-30Mo)
This alloy was developed particularly for resistance
to corrosion by hot concentrated hydrochloric acid solu-
tions and wet hydrogen chloride. It is also resistant to
hot concentrated solutions of pure phosphoric acid and
to hot dilute sulfuric acid. The alloy is most resistant
under reducing conditions and is not considered suitable
for handling oxidizing acids or solutions containing
oxidizing salts. Maximum corrosion resistance is ob-
tained by quenching the cast alloy from an annealing
temperature of 2100-2150 ºF.
Nickel-Silicon Alloy (82Ni-10Si)
This nickel-silicon alloy which sometimes also con-
tains 3% copper has exceptional resistance to all con-
centrations of sulfuric acid up to the boiling point; conse-
quently it is used in the concentration of sulfuric acid. It
is also resistant to many other chemicals including phos-
phoric, formic and acetic acids under reducing condi-
tions but is not resistant to strong oxidizing acids. Be-
cause of its high hardness, this alloy is used extensively
to resist wear, abrasion and galling where corrosion may
33
 TABLE IX
Corrosion Data

CF-3 CF-3M
CD-
Corrosive Medium CA-15 CA-40 CB-30 CC-50 CE-30 CF-8 CF-8M CF-8C CF-16F
4MCu
CF-20
Acetic Acid
5% 4 4 3 3 1 2 2 1 2 2
10% 4 4 4 4 1 2 2 1 2 2
15% 4 4 4 4 1 2 2 1 2 2
20% 5 5 4 4 1 2 2 1 2 3
30% 5 5 5 5 1 2 2 1 2 3
40% 5 5 5 5 1 2 2 1 2 3
50% 5 5 5 5 1 3 3 1 3 3
60% 5 5 5 5 2 3 3 2 3 3
80% 5 5 5 5 2 3 3 2 3 3
99.9% 5 5 5 5 2 3 3 2 3 3
Acetic Anhydride
90% 5 5 5 5 2 3 3 2 3 3
Acetic Acid Vapors
30% 5 5 5 5 2 3 3 2 3 3
100% 5 5 5 5 3 4 4 3 4 4
Aluminum Acetate 4 4 4 4 1 2 2 1 2 2
Aluminum Chloride 5 5 5 5 4 5 5 5 5 5
Aluminum Hydroxide 4* 4* 4* 4* 3 4* 4* 3 4* 4*
Aluminum Sulfate
5% 4 4 4 4 1 2 2 1 2 2
10% 5 5 5 5 1 3 3 1 3 3
Saturated 5 5 5 5 1 5 5 1 5 5
Alum (Aluminum Potassium Sulfate)
10% 5 5 5 5 1 3 3 1 3 3
Saturated 5 5 5 5 2 4 4 2 4 4
Ammonium Bicarbonate 3 3 2 2 1 1 1 1 1 2
Ammonium Carbonate 3 3 2 2 1 1 1 1 1 2
Ammonium Chloride
1% 2* 2* 2* 2* 1* 1* 1* 1 1* 1*
10% 3* 3* 3* 3* 2* 2* 2* 2* 2* 2*
20% 5 5 5 5 2* 4* 4* 3* 4* 4*
50% 5 5 5 5 3* 4* 4* 3* 4* 4*
Ammonium Nitrate 2 2 2 2 1 1 1 1 1 1
Ammonium Sulfate
1% 3 3 3 3 1 1 1 1 1 1
5% 3 3 3 3 1 2 2 1 2 2
10% 4 4 4 4 1 2 2 1 2 2
Saturated 5 5 5 5 2 3 3 2 3 3
Bromine Liquid (Dry) 5 5 5 5 4 5 5 4 5 5
Bromine Liquid (H2O Saturated) 5 5 5 5 5 5 5 5 5 5
Bromine Water (Dilute) 5 5 5 5 4 5 5 4 5 5
Calcium Chloride 5 5 5 5 4 5 5 5 5 5
Calcium Hypochlorite 5 5 5 5 5 5 5 5 5 5
Chlorine Gas (Moist) 5 5 5 5 5 5 5 5 5 5
Copper Sulfate 4 4 3 3 1 2 2 1 2 2
Ethylene Glycol 3 3 3 3 1 2 2 1 2 2
Fatty Acids 300 ºF 300 ºF 300 ºF 300 ºF 600 ºF 400 ºF 400 ºF 600 ºF 400 ºF 400 ºF
Ferric Chloride 5 5 5 5 5 5 5 5 5 5
Ferric Sulfate 4 4 4 4 2 3 3 2 3 3
Ferrous Sulfate 4 4 4 4 1 2 2 1 2 2

LEGEND
1. Good resistance to boiling. 4. Good resistance to 70 ºF.
2. Good resistance to 160 ºF. 5. Not recommended.
3. Good resistance to 120 ºF. *Subject to pitting. **Dilute concentrations.

34
 TABLE IX
Corrosion Data

CF-3 CF-3M
Corrosive Medium CA-15 CA-40 CB-30 CC-50 CD-4MCu CE-30 CF-8 CF-8M CF-8C CF-16F
CF-20
Fluosilicic Acid 5 5 5 5 4 5 5 4 5 5
Formic Acid
5% 4 4 4 4 2 2 2 1 2 2
10% 4 4 4 4 2 2 2 1 2 2
50% 4 4 4 4 3 3 3 1 3 3
100% 5 5 5 5 3 3 3 2 3 3
Hydrochloric Acid 5 5 5 5 5 5 5 5 5 5
Hydrobromic Acid 5 5 5 5 5 5 5 5 5 5
Hydrofluoric Acid 5 5 5 5 5 5 5 5 5 5
Hydrogen Peroxide 3 3 3 3 2 2 2 2 2 2
Lactic Acid
5% 3 3 3 3 1 2 2 1 2 2
10% 5 5 5 5 2 3 3 2 3 3
100% 5 5 5 5 2 3 3 2 3 3
Magnesium Chloride 5 5 5 5 4* 5 5 5 5 5
Magnesium Sulfate 5 5 3 3 2 2 2 1 2 2
Nickel Chloride 5 5 5 5 4* 4* 4* 4* 4* 4*
Nickel Nitrate 3 3 2 2 2 2 2 2 2 2
Nickel Sulfate 5 5 5 5 1 3 3 2 3 3
Nitric Acid
5% 3 3 2 2 1 1 1 1 1 1
20% 3 3 2 2 1 1 1 1 1 1
40% 4 4 3 3 1 1 1 1 1 1
50% 4 4 3 3 1 1 1 1 1 1
65% 4 4 3 3 1 2 2 3 2 2
100% 5 5 4 4 4 4 4 4 4 4
Oxalic Acid
5% 4 4 3 3 1 2 2 1 2 3
10% 5 5 4 4 2 3 3 2 3 3
25% 5 5 4 4 2 3 3 2 3 4
50% 5 5 5 5 2 4 4 3 4 5
Phosphoric Acid (Pure)
5% 3 3 3 3 1 1 1 1 1 1
10% 3 3 3 3 1 1 1 1 1 1
25% 5 5 4 4 1 2 2 1 2 2
50% 5 5 4 4 1 2 2 1 2 2
85% 5 5 4 4 2 3 3 2 3 3
Potassium Sulfate 4 4 3 3 1 3 3 2 3 3
Sodium Carbonate 4 4 3 3 1 2 2 1 2 2
Sodium Chloride 5 5 4* 4* 2* 3* 3* 2* 3* 3*
Sodium Hydroxide
< 20% 4 4 4 4 1 1 1 1 1 1
20-30% 4 4 4 4 2 2 2 2 2 2
30-50% 5 5 5 5 2 2 2 2 2 2
50-70% 5 5 5 5 5 5 5 5 5 5
70-80% 5 5 5 5 5 5 5 5 5 5
Sulfuric Acid
5-10% 5 5 5 5 2 4 4 3 4 4
10-20% 5 5 5 5 2 5 5 3 5 5
20-40% 5 5 5 5 3 5 5 5 5 5
40-60% 5 5 5 5 4 5 5 5 5 5
60-75% 5 5 5 5 4 5 5 5 5 5
75-85% 5 5 5 5 3 5 5 5 5 5
85-90% 5 5 5 5 2 4 4 3 4 4
90-100% 4 4 4 4 2 3 3 2 3 3
Zinc Chloride 5 5 5 5 3* 5 5 3* 5 5
Zinc Sulfate 5 5 5 5 1 4 4 2 4 4
(Continued on pages 36 and 37)

NOTE:
It is not the purpose of this table to make specific recommendations. It should be used simply as a guide to indicate the most suitable candidate
alloys. The effects of contamination, velocity, aeration, etc., will all tend to alter the rating of an alloy exposed to a corrosive environment.

35
 TABLE IX
Corrosion Data

Alloy Ni-Si
Corrosive Medium CH-20 CK-20 CN-7M N-12M CW-12M 625 Alloy CZ-100 M-35 CY-40
Acetic Acid
5% 2 2 1 1 1 1 1 4 3 1
10% 2 2 1 1 1 1 1 3 3 1
15% 2 2 1 1 1 1 1 3 3 2
20% 2 2 1 1 1 1 1 3 3 2
30% 2 2 1 1 1 1 1 3 3 2
40% 2 2 1 1 1 1 1 3 3 2
50% 2 2 1 1 1 1 1 3 3 2
60% 3 3 1 1 1 1 1 3 3 2
80% 3 3 1 1 1 1 1 3 3 2
99.9% 3 3 1 1 1 1 1 3 3 2
Acetic Anhydride
90% 3 3 1 1 1 1 1 3 3 2
Acetic Acid Vapors
30% 3 3 1 1 1 1 1 3 3 2
100% 4 4 1 1 1 1 1 3 3 2
Aluminum Acetate 2 2 1 1 1 1 1 3 3 2
Aluminum Chloride 5 5 4 1 3 4 2 2 2 2
Aluminum Hydroxide 4* 4* 2 1 1 2 1 2 2 2
Aluminum Sulfate
59% 2 2 1 1 1 1 1 3 3 3
10% 3 2 1 1 1 1 1 3 3 3
Saturated 4 4 1 1 1 1 1 5 5 3
Alum (Aluminum Potassium Sulfate)
10% 3 2 1 1 1 1 1 3 3 3
Saturated 3 3 1 1 1 1 3 5 5 4
Ammonium Bicarbonate 1 1 1 1 1 1 1 2 2 2
Ammonium Carbonate 1 1 1 1 1 1 1 2 2 2
Ammonium Chloride
1% 1* 1* 1* 1 1 1* 1 1 1 1
10% 2* 2* 2* 1 1 1* 1 1 1 2*
20% 4* 4* 2* 2 1 1* 2 1 1 2
50% 4* 4* 2* 2 1 2* 2 1 1 2*
Ammonium Nitrate 1 1 1 2 1 1 2 5 5 1
Ammonium Sulfate
1% 1 1 1 1 1 1 1 3 3 3
5% 2 2 1 1 1 1 1 3 3 3
10% 2 2 1 1 1 1 1 3 3 3
Saturated 3 3 1 1 1 1 1 3 3 3
Bromine Liquid (Dry) 5 5 3 3 2 3 3 1 1 1
Bromine Liquid (H2O Saturated) 5 5 4 3 2 3 3 3 3 3
Bromine Water (Dilute) 5 5 3 2 2 3 2 5 5 5
Calcium Chloride 5 5 4 3 1 3 3 2 2 2
Calcium Hypochlorite 5 5 5 5 3 4 5 5 5 5
Chlorine Gas (Moist) 5 5 4 3 1 4 3 5 5 5
Copper Sulfate 1 1 1 4 1 1 4 4 4 2
Ethylene Glycol 2 2 1 1 1 1 1 2 2 1
Fatty Acids 400 ºF 400 ºF 600 ºF+ 600 ºF+ 600 ºF+ 600 ºF 400 ºF 400 ºF 400 ºF 600 ºF
Ferric Chloride 5 5 5 5 2 4 5 5 5 5
Ferric Sulfate 3 3 2 5 2 2 5 5 5 3
Ferrous Sulfate 2 2 1 2 1 1 2 3 3 3

LEGEND
1. Good resistance to boiling. 4. Good resistance to 70 ºF.
2. Good resistance to 160 ºF. 5. Not recommended.
3. Good resistance to 120 ºF. *Subject to pitting. **Dilute concentrations.

36
 TABLE IX
Corrosion Data

Alloy Ni-Si
Corrosive Medium CH-20 CK-20 CN-7M N-12M CW-12M 625 Alloy CZ-100 M-35 CY-40

Fluosilicic Acid 5 5 3 3 2 2 3 4 1 4
Formic Acid
5% 2 2 1 2 1 1 2 2 1 2
10% 2 2 1 2 1 1 2 2 1 2
50% 3 3 1 3 1 1 3 2 1 2
100% 3 3 1 3 1 1 3 2 1 2
Hydrochloric Acid 5 5 5 2 3 4 5 3** 3** 4**
Hydrobromic Acid 5 5 5 2 3 3 5 5** 5 5
Hydrofluoric Acid 5 5 4 4 3 4 4 4 1 4
Hydrogen Peroxide 2 2 2 5 3 3 5 3 4 2
Lactic Acid
5% 2 2 1 3 1 1 3 3 2 2
10% 3 3 1 4 1 1 4 3 2 2
100% 3 3 1 4 2 2 4 3 2 2
Magnesium Chloride 5 5 4* 1 1 1* 1 1 1 2*
Magnesium Sulfate 2 2 1 1 1 1 1 2 2 2
Nickel Chloride 4* 4* 3* 1 2 3* 3 2 2 3*
Nickel Nitrate 2 2 2 4 2 2 5 5 5 3
Nickel Sulfate 3 3 1 2 1 2 2 2* 2* 2
Nitric Acid
5% 1 1 1 5 1 2 5 5 5 3
20% 1 1 1 5 2 3 5 5 5 3
40% 1 1 1 5 3 3 5 5 5 3
50% 1 1 1 5 3 3 5 5 5 3
65% 2 2 2 5 4 4 5 5 5 3
100% 4 4 3 5 5 5 5 5 5 3
Oxalic Acid
5% 2 2 1 1 1 1 1 3 2 3
10% 3 3 1 1 1 1 3 3 2 3
25% 3 3 1 2 1 1 3 3 2 3
50% 4 4 1 3 1 1 4 3 2 3
Phosphoric Acid (Pure)
5% 1 1 1 1 1 1 1 4 1 3
10% 1 1 1 1 1 1 1 4 1 3
25°% 1 1 1 1 1 1 1 4 2 3
50% 2 2 1 1 1 1 1 4 2 3
85% 3 3 2 1 2 2 2 4 3 3
Potassium Sulfate 3 3 1 1 1 1 1 3 1 2
Sodium Carbonate 2 2 1 1 1 1 1 1 1 1
Sodium Chloride 3* 3* 1* 1 1 1 1 2 1 2*
Sodium Hydroxide
<20% 1 1 1 1 1 1 1 1 1 1
20-30% 2 2 1 1 1 1 1 1 1 1
30-50°% 2 2 1 1 1 1 1 1 1 1
50-70% 5 5 270 ºF 4 4 2 1 1 1 1
70-80% 5 5 270 ºF 4 4 2 1 1 1 1
Sulfuric Acid
5-10% 4 4 2 1 1 1 1 4 2 3
10-20% 5 5 2 1 1 2 1 4 2 3
20-40% 5 5 2 1 2 3 1 4 4 3
40-60% 5 5 3 1 2 4 1 5 4 4
60-75% 5 5 3 2 2 4 2 5 5 5
75-85% 5 5 3 2 2 4 2 5 5 5
85-90% 4 4 2 2 2 3 2 5 5 3
90-100% 3 3 225 ºF 250 ºF 2 2 2 4 4 3
Zinc Chloride 5 5 2* 1 2* 2* 1 2 1 2*
Zinc Sulfate 4 4 1 1 1 1 1 2 1 3
NOTE:
It s not the purpose of this table to make specific recommendations. It should be used simply as a guide to indicate the most suitable candidate
alloys The effects of contamination, velocity, aeration, etc., will all tend to alter the rating of an alloy exposed to a corrosive environment.

37
 Industrial Applications
of Corrosion-Resistant Alloy Castings

AERONAUTICAL
Typical Applications
Although the greatest use for high alloys in this industry
is for engine parts required to withstand high temperatures, Fuel jets
Fuel valves
there are applications for the corrosion-resistant grades in
Engine supports
components that must resist both corrosive and erosive
effects to insure dependable operation.

BALL VALVE CONTROL VALVE

Alloy: CF-8 (19Cr-9Ni) Alloy: CB-30 modified
Use: Cryogenic ball valve for service on advanced rocket engine. Use: Aircraft fuel control valve subject to high rate fuel impingement on 2000
mph aircraft.

ARCHITECTURAL
The cast chromium-nickel alloys are used as ornaments
and other components in the architectural treatment of Typical Applications
buildings, bridges, etc. Where these will be exposed to a Ornaments Fire wall fittings
Hand rail fittings Grilles
marine environment, the molybdenum-containing austenitic
grades have the most satisfactory resistance to corrosion.

38
CHEMICAL AND PETROLEUM
Chemical
The corrosion-resistant alloys have their widest application
in the chemical industry. Their function is two-fold: they pro-
vide good equipment life and prevent product contamination.
Many chemical operations would not be economically feasible
if it were not for the corrosion and abrasion-resistant properties
of these alloys.

Typical Applications
Grinders Nozzles
Mixers Vessels
Pumps Piping and fittings
Valves Conveyors

Petroleum
Cast corrosion-resistant alloys of all types are used exten-
sively in the petroleum industry to withstand the corrosive
effects of moist sulfur and carbon dioxide-bearing gases, sour
crudes, sulfuric acid and caustic treating equipment, phos-
phoric acid, salt water and the many forms of organic acids
produced as by-products during the refining operations.

CENTRIFUGAL PUMP CASING AND COVER

Typical Applications
Alloy: CF-8M (19Cr-9Ni-2Mo)
Valves Pipe fittings Weight: 4000 Ib each pump
Pumps Nozzles Use: Pump to circulate 5500 gpm of highly corrosive chemicals with low
Heater tubes specific gravity.

CENTRIFUGALLY-CAST FLANGE
Alloy: CH-20 modified with free ferrite controlled at 5-15% (25Cr-12Ni)
Weight: 150 Ib
Size: 4 in. 2500 Ib welding neck flange @ 14 in. flange O.D. x 3 in. thick x 4½
in. neck O.D. x 7¾ in. O.A.L.
Use: Hydrocracker refinery unit

PRESSURE VESSEL
Alloy: CK-20 (25Cr-20Ni)
Weight: 8,900 Ib
Use: Dissolver vessel in chemical processing plant.

PROCESS PIPING
Alloy: CF-3M (19Cr-10Ni-2Mo)
Weight: 1400 Ib
Size: 16 in. O.D. x ¾ in. wall; flange 26 in. O.D.
Use: Acetic acid processing

39
 BUTTERFLY VALVE-AUTOMATIC, ON-OFF
Alloy: CF-8M (19Cr-9Ni-2Mo)
BUTTERFLY VALVE–AUTOMATIC CONTROL Weight: Body and disc 300 Ib
Alloy: CF-8M (19Cr-9Ni-2Mo) Size: 12 in.
Weight: 600 Ib Use: Chemical service
Size: 24 in.
Use: Chemical service

PUMP COMPONENTS
Alloy: CF-8 (19Cr-9Ni) and CF-8M (19Cr-9Ni-2Mo)
Parts: Housings, gears, impellers
Use: Pumps in a variety of applications primarily in
the Chemical Processing Industry.
All parts are investment castings

PUMP
Alloy: CG-8M (Modified)–wetted parts
Size: 16 in.
Use: Flash cooler service in
phosphoric acid plant.

GATE VALVE
Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: Body casting, 1603 lb;
bonnet casting, 414 Ib
Use: Wedge gate valve for chemical
plant service.

40
PROCESS INDUSTRIES EQUIPMENT
Food Processing Metal Mining and Refining
The corrosion-resistant stainless steels are widely used in The austenitic stainless steels have good resistance
all types of food handling equipment. Their good resistance to to all mine waters which contain sulfur compounds. The
both corrosion and abrasion avoids the hazard of contamina- CF-8M alloy is usually reliable for most of these
tion with metal compounds that might be toxic or might lead to conditions.
food spoilage. In the sulfuric acid leaching of copper ores, the CN-7M alloy
is used in pumps and valves required to handle the 66° Bé
sulfuric acid solution. The copper-containing solution accumu-
Typical Applications
lated after leaching is resisted satisfactorily by the CF-8M
Mixers Nozzles alloy.
Grinders Disintegrators
Valves Screw spindles The CN-7M alloy is also widely used in the sulfuric acid
Pumps Screens treatment of phosphate ore for the production of phosphoric
Agitators acid.

Typical Applications

Valves Pipe fittings

Pumps Filters

Pharmaceutical
The CF alloys (19Cr-9Ni) are widely used in the pharma-
ceutical industry and in the fine chemical industry in corrosive Typical Applications
as well as in relatively non-corrosive environments for main-
taining purity and color of the products. Stainless steels are Pumps Agitators
Valves Nozzles
used in processing Vitamin C, acid solutions containing chlo-
roform, ammonium sulfate, sodium sulfite and to resist organic
acids from protein extraction and biological mediums.

Plating Pulp and Paper

The austenitic stainless steels are used in the electroplating
industry for equipment to handle alkaline cyanide copper plating
baths, sulfuric acid copper plating baths and some chromic acid
plating baths. They are employed in pumps and valves in
equipment used for the storage and handling of 66° Bé sulfuric
acid. The stainless steels are not suitable for handling nickel
chloride and other type plating baths. Tests should be con-
ducted in solutions of this type to determine the suitability of
alloys such as N-12M and CW-12M.
The austenitic stainless steels are used in equipment for
handling the nitric-phosphoric bright-dip solution for alumi-
num.
Typical Applications
The severely corrosive conditions developed in both
the sulfite and the sulfate treating of wood require use of
corrosion-resistant alloys for good service life and to
avoid contamination by corrosion products. In the sulfite
process, alloys having good resistance to acid
environments are required while in the sulfate process
alloys are required that have good resistance to caustic
environments. Frequently, an alloy will be found that has
satisfactory resistance to conditions encountered in both
operations.
Many of the corrosion-resistant alloys have excellent
resistance to erosive effects. This property is exploited
in early grinding steps as well as in subsequent steps
employed in processing the wood pulp.

Valves Filters Typical Applications

Pumps Fittings
Grinders
Digester blow valves
Stock line valves
Stock lines and fittings
White liquor equipment
Green liquor equipment
Black liquor equipment
Causticizing equipment
Bleaching equipment
Sulfuric and sulfurous acid
equipment
Chlorine dioxide
Sulfur dioxide

41
 CENTRIFUGAL PUMP
Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: Upper half 1175 lb; lower half 3000 lb
Size: 57½ in high x 645/8 in. wide x 58½ in. deep
Use: Pump for handling 14,800 gpm of caustic, corrosive paper stock ("white water").

CENTRIFUGE BOWL
Alloy: CG-8M (19Cr-10Ni-3Mo)
Weight: 1679 Ib
Size: 28 in. O.D., 78 in. long
Use: Centrifuges in municipal
sewage treatment plant.

VERTICAL PUMP
Alloy: CF-8M (19Cr-9Ni-2Mo)–wetted parts
Size: 24 in. TURBINE PUMP
Use: Liquid end of pump handling 20,000 gpm acid contaminated water. Alloy: CF-8M (19Cr-9Ni 2Mo)
–wetted parts
Use: Dewatering service in gold
mine.

42
 DIGESTER SCREENS–PIPE FITTINGS
Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: various–screen segments 100 Ib each
Size: 6 in. pipe size at digester fitting
Use: Screens separate pulp from liquor inside digester. Complex fittings
used at bottom of digester between it and blow pit. Liquor is
ammonium sulfite (acid base).

PUMP
Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: 450 Ib
Size: 6 in. x 8 in.–1800 rpm
Use: Sulfuric acid leaching of copper silicate ores at ambient
temperature. Sulfuric acid strength 1-2%.

SINGLE-STAGE CENTRIFUGAL PUMP

Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: 450 Ib
SUCTION ROLL SHELLS Size: 8 in. x 10 in.–1800 rpm
(Suspended Castings) (Casting being bored) Use: Pumping silicate-sulfuric acid liquor in copper leaching
Alloy: CA-15 (12Cr) Alloy: CF-8M (19Cr-10Ni-2Mo) operation.
Weight: 97,200 lb Weight: 64,600 lb
Use: Both used in wet end of paper machine to resist corrosion by white water while
aiding in drying paper.

43
 CENTRIFUGAL PUMP SINGLE STAGE CENTRIFUGAL PUMP
Alloy: CF-8M (Modified) Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: Top casing, 1600 lb; lowercasing, 2380 lb Weight: 600 lb
Use: Handling acidic river water in steel plant–after 22 years, pump Size: 6 in. x 8 in–1800 rpm
showed no sign of corrosion. Use: Stock pump in pulp mill based on ammonium sulfite process–
acid-base sulfite liquor is present.

MARINE
Although CF-type alloy castings have to be used selectively
in the marine field because of their susceptibility to pitting
corrosion, they have applications where, because of velocity
conditions, this form of deterioration cannot develop. The
chromium-nickel type (CF-8) steels have been used successfully
for propellers on tugs and other types of work-boats that are in
relatively constant service.
The CF-3M, CF-8M and CN-7M alloys are frequently used
for components in salt water pumps and valves. These alloys
have also been used successfully in equipment which is
exposed to a marine atmosphere.

Typical Applications

Ship propellers Salt water valves

Salt water pumps Some marine hardware

PROPELLER
Alloy: CF-3 (19Cr-9Ni)
Weight: 22,660 Ib
Size: 15 ft O.D.
Use: Workboat

44
POWER–NUCLEAR AND CONVENTIONAL
Nuclear Energy
In this field, heat and corrosion-resistant alloys are used
in both statically and centrifugally cast forms.
Rigid specifications may require tensile property tests,
hydrostatic tests, radiographic and dye penetrant examina-
tions, depending upon the particular application.

Typical Applications
Valves Control mechanisms
Pump impellers Reactor components CENTRIFUGALLY-CAST PIPE
Alloy: CF-8A (19Cr-9Ni)
Pump casings
Weight: 11,500 Ib (front piece)
Size: 32 in. O.D., 184 in. long (front piece)
Use: Nuclear reactor coolant loop pipe for pressurized water
Power Plants reactor. Meets requirements of ASME Sec. III.

The use of chromium-nickel stainless steels for compo-

nents in power plant equipment has increased the ability of
this industry to meet the ever increasing demand for more
industrial power. These alloys have made it possible for
power plant engineers to design equipment for operation at
increased pressures and temperatures.
In nuclear power plants, the chromium-nickel stainless
steels are used to avoid contamination of the coolants by
metallic corrosion products that would become radioactive.

Typical Applications

Feed water heating equipment

Boiler water deaerator heaters
Valve components (feed water, steam, condensate, fuel oil)
Pump components (feed water, condensate, fuel oil)

CENTRIFUGALLY-CAST TUBE
Alloy: CF-8 (19Cr-9Ni)
Hydraulics Weight: 410 Ib
Size: 8.2 in. O.D. x 5 in. I.D. x 56 in. long
In the hydraulics field, the good resistance to Use: Nuclear control rod drive latch housing.
abrasion and cavitation of the chromium-nickel alloys is
of more significance than their corrosion resistance.
This property makes it possible to design smaller
diameter equipment that will convey large volumes at
higher velocity than it would be possible with other
alloys that do not have this inherent characteristic. CENTRIFUGALLY-CAST FLANGES
Alloy: CF-8M with controlled ferrite (19Cr-10Ni-2Mo)
Weight: 1500 Ib
Typical Applications Size: up to 24 in. pipe size
Use: Nuclear piping flowmeter flanges
Pumps Nozzles
Valves Piping and fittings
Torque tubes

45
 VALVE BODY AND BONNET CASTINGS
Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: Body casting, 1565 lb; bonnet casting, 740 Ib
Use: Castings meet Nuclear Class II, used in valves for nuclear power
plant.

BUTTERFLY VALVE BODIES

Alloy: CF-8M (19Cr-10Ni-2Mo)
Weight: 300 Ib
Size: 16 in.
Use: Nuclear service–must meet ASME Class II requirements.

FRANCIS TYPE RUNNER

Alloy: CF-20 (19Cr-9Ni)
Weight: Range from 460 to 3030 Ib
Size: 325/8 in. dia
Use: For hydraulic turbine installations
in the power industry.

CENTRIFUGALLY-CAST BEARINGS
Alloy: CF-3A (19Cr-9Ni)
Weight: 800-900 Ib
Size: 331/2 in. flange O.D. x 28 in. barrel
O.D. x 25 5 / 8 in. I.D. x 17 in. long
Use: Hydrostatic bearings for nuclear
recirculating pumps.

46
 FLOWMETER NOZZLES
Alloy: CF-8M with controlled ferrite (19Cr-10Ni-2Mo)
Weight: 975 Ib
Size: 243/8 in. flange x 16 in. barrel O.D. x 1¼ in. wall
x 341/8 in. long
Use: Venturi-style flowmeter bodies for use inside main water
recirculating in nuclear power plants.

CONTROL VALVE, AUTOMATIC CONTROL

Alloy: CF-8 (19Cr-9Ni)
Weight: 250 Ib
Size: 6 in. pipe size
Use: Nuclear service, light water reactor,
PWR primary loop, by-pass.
CHECK VALVE
Alloy: CF-8 (19Cr-9Ni)
Weight: 450 Ib
Size: 6 in. pipe size
Use: Nuclear water service handling
demineralized water in the
primary loop of a pressurized
light water reactor.

STEAM TURBINE CASING

Alloy: CK-20 (25Cr-20Ni)
Weight: 9000 Ib
Use: High temperature, high pressure steam
service.

47
 BUTTERFLY VALVE DISC
Alloy: CF-3M (19Cr-9Ni-2Mo)
Weight 160 lb
Size: 20 in. dia BAILEY CONTROL VALVE
Use: Control valve handling raw fresh water from California project to filtering Alloy: CF-3M (19Cr-9Ni-2Mo)
Weight: 5200lb
plant.
Size: 32 in. dia (port size)
Use: Potable water service, Metropolitan Water District of Southern
California.

MULTISTAGE WATERFLOOD PUMP CASING

Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: 4200 lb
Size: 4 in. x 6 in -3600 rpm
Use: Waterflood Huntington Beach, California. Aminol-treated sea water,
de-aerated, inhibited, biocides added.

CENTRIFUGAL PUMP IMPELLER

Alloy: CF-8M (19Cr-9Ni-2Mo)
Height: 36,000 lb
Size: 144 in. dia
Use: Handling freshwater containing silt, on Central Valley California
water project. Replaced bronze which suffered cavitation and
erosion corrosion.

HORIZONTALLY SPLIT, 5 STAGE, HIGH PRESSURE PUMP

Alloy: CF-8M (19Cr-9Ni-2Mo)
Weight: 1050 Ib (part shown)
Size: 4 in. x 6 in. -3600, rpm
Use: Treated sea water–oil field water flood service.

48
 Part III
Fabrication Data
For Heat and Corrosion-Resistant Alloys

Casting is a fabricating step and by its nature is the
quickest method of converting an alloy into a nearly
finished product. The elimination of intermediate steps
between the molten metal stage and the shaped part
provides important economic advantages to the casting
process.
Many castings can be used directly after cleaning and
cutting off the gates and risers but some require machin-
ing to finished dimensions or welding into assemblies.
This section presents information on the machining and
welding practices used on heat and corrosion-resistant
castings.
MACHINING
High-alloy castings are more difficult to machine than
carbon steel because of the characteristics built into
them for heat and corrosion-resistant service. With
proper tools and coolants, however, all necessary ma-
chining can be performed under conditions of compara-
tively slow speeds and moderate feeds.
TABLE X
Machining and Welding of Heat-Resistant Alloy Castings
High speed steel and cemented carbide tools are
used for machining the high alloy castings. Cutting
speeds and feeds for high speed steel tools are shown
in Table X for heat-resistant alloys and in Table XI for
corrosion-resistant alloys. With carbide tools, about two
to three times these speeds should be used. The tool
should not be permitted to dwell in the cut as work
hardening of the material will result. Machines should be
powerful and rigid and tool mountings stiff.
Cutting lubricants are essential for all machining op-
erations on these castings. For best results, a continu-
ous and abundant supply of cutting fluid should be fed to
the tool and thereby act also as a coolant. All lubricants
should be removed completely from the machined parts
that are to be subjected to high temperatures, either
during subsequent fabrication or in service. For high
speed steel tools, sulfurized cutting oils are the pre-
ferred cutting lubricants. A lubricant of soluble oil and
water is used with cemented carbide tools.
Single point tool grind angles for high speed steel are
shown in Figure 6.

HA HC HD HE HF HH HI HK HL HN HP HT HU HW HX
MACHINING
Rough Turn
Speed, sfm 40-50 40-50 40-50 30-40 25-35 25-35 25-35 25-35 30-40 35-45 35-45 40-45 40-45 40-45 40-45
Feed, ipr .010-.030 .025-.035 .025-.035 .020-.025 .015-.020 .015-.020 .015-.020 .020-.025 .020-.025 .020-.025 .020-.025 .025-.035 .025-.035 .025-.035 .025-.035
Finish Turning
Speed, sfm 80-100 80-100 80-100 60-80 50-70 50-70 50-70 50-70 60-80 70-90 70-90 80-90 80-90 80-90 80-90
Feed, ipr .005-.010 .010-.015 .010-.015 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .010-.015 .010-.015 .010-.015
Drilling
Speed, sfm 35-70 40-60 40-60 30-60 20-40 20-40 20-40 20-40 30-60 40-60 40-60 40-60 40-60 40-60 40-60
Feed, ipr 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Tapping
Speed, sfm 10-25 10-25 10-25 10-25 10-20 10-20 10-20 10-20 10-25 5-15 5-15 5-15 5-15 5-15 5-15
Remarks 15 17 15 17 15 17 17 16 17 16 17 16 17 16 17 17 16 17 – 16 17 16 17 16 17 16 17

WELDING E505-18 E446-15 E446-15 E312-15 E308-15 E309-15 E310-15HC E310-15 E310-15HC E330-15 E310-15 E330-15 E330-15 ENiCr-1 or ENiCrFe-1
Electrode Type (also 18Cr- ENiCrFe-
38Ni Bare) 1

Oxy-acetylene Rod Type 410 Bare 446 Bare 327 Bare 312 Bare 308 Bare 309 Bare 309 Bare 310 Bare 310 Bare 330 Bare – 330 Bare 330 Bare Inconel Inconel
Oxy-acetylene Flux None None None None None None None None None None – None None Stainless Stainless
Oxy-acetylene Flame – – – – – S S M M – V V – –
1
Character
Preheat and Interpass 450-550 60-100 Not. Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req.
Temperature, F
Post Heat Treatment, F 2 1550 A. C. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req.
5 3 4 4 4
Annealing Treatment, F 1625 As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast As-Cast

Notes for Table X with Table XI on page 50.

49
 TABLE XI
Machining and Welding of Corrosion-Resistant Alloy Castings

CA- CD-
CA-15 CA-40 6NM CB-30 CC-50 4MCu CE-30 CF-3 CF-8 CF-20 CF-3M CF-8M CF-8C CF-16F CG-8M CH-20 CK-20 CN-7M

MACHINING
Rough Turn
Speed, sfm 40-50 25-35 40-50 40-50 40-50 40-50 30-40 25-35 25-35 25-35 25-35 25-35 30-40 45-55 25-35 25-35 25-35 45-55
Feed, ipr 010-.030 .030-.040 .010-.030 .020-.030 .025-.035 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025 .020-.025
Finish Turning
Speed, sfm 80-100 50-70 80-100 80-100 80-100 80-100 60-80 50-70 50-70 50-70 50-70 50-70 60-80 90-110 50-70 50-70 50-70 90-110
Feed, ipr .003-.010 .015-.020 .005-.010 .010-.015 .010-.015 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010 .005-.010
Drilling
Speed, sfm 35-70 30-60 20-50 30-60 40-60 20-40 30-60 20-40 20-40 20-40 20-50 20-50 30-60 30-80 20-50 20-50 20-40 30-60
Feed, ipr 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Tapping
Speed, sfm 10-25 10-20 10-20 10-25 10-25 10-20 10-25 10-20 10-20 10-20 10-20 10-20 10-25 15-30 10-20 10-20 10-20 10-25
Remarks 12 13 – 14 14 – 15 15 15 15 15 15 15 – 15 15 15 –

WELDING
Electrode Type E410-15 E410-15 – E442-15 E446-15 – E312-15 E308L-15 E308-15 E308-15 E316L-15 E316-15 E347-15 E308-15 E317-15 E309-15 E310-5 E320-15
Oxy-acetylene
410 Bare 420 Bare – – – – – – – – – – – – – – – –
Rod Type
Preheat and
Interpass
Temperature, ºF 400-600 400-600 500-600 600-800 350-400 Not. Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. Not Req. 400-500
Post Heat 1125- 1125- 1100- 1450- 1650 A. C. 2050 1950- Not Req. 1950- 2000- Not Req. 1950- 1950- 2000- 1950- 2000- 2WQ- 1950
Treatment, ºF 1400 A.C. 1400 A.C. 1150 A.C. 1500 A.C. 20507 20507 21007 21007 20507 21007 2050 21007 21507 20507
Annealing 2050 F.C. 9 9 9 9 9 9 – 9 9 9
1450- 1450-
Treatment, ºF 1550- 1550- 1450- to 1750- 1950- 1950-
1500 F.C. 1500 F.C.
1650 F.C. 1650 F.C. 1500 F.C. 1900 2050 2150
8 or A.C.
A.C.
Heat Treatment for
Increasing Strength – – – 11 11 – 11 11 11 11 11 11 11 11 11 11 11 11
Hardening Temp., ºF 1800- 1800- 1900- – – – – – – – – – – – – – – –
1850 1850 1950
Quenching Medium oil oil oil – – – – – – – – – – – – – – –
or air or air or air
Tempering Temp., ºF 600 max 600 max 600 max – – – – – – – – – – – – – – –
10 10 10

Notes for Tables X and XI

1
V – very rich in acetylene; excess acetylene feather should project 1" beyond tip of inner
core.
M – medium rich in acetylene; excess acetylene feather should project ½" beyond tip of
inner core.
S – slightly rich in acetylene; excess acetylene feather should project ¼" beyond tip of
inner core.
2
Heat to original draw temperature, hold sufficiently long to insure uniform heating
throughout section, then air cool.
3
When castings are repeatedly heated and cooled in service, properties may be
improved by heating at 1900 ºF for six hours, then furnace cooling.
4
When castings are repeatedly heated and cooled in service, properties may be
improved by heating at 1900 ºF for twelve hours, then furnace cooling.
5
For improved strength, castings are normalized by heating to 1825 ºF, air cooling to
below 1300 ºF, followed by tempering at 1250 ºF.
6
Drilling feeds:
Drill Diameter Feed, ipr
Under 1/ 8 “ 001-.002
1/ 8 - ¼ 002-.004
¼-½ .004-.007
½-1 .007-.015
Over 1 015-.025
7
This post-weld heat treatment is to restore maximum corrosion resistance.
Quench should be in water, oil or air according to section size, geometry and
cooling rate that will hold as great a portion of the carbides in solution as
possible.
8
Furnace cool to 1000 ºF, then air cool.
9
Same as post-heat treatment.
10
Avoid tempering around 900 ºF. Lower strengths than obtained with 600 ºF
max temper may be achieved by tempering in 1100-1500 ºF range.
11
This alloy normally supplied in the annealed condition.
12
Cuts best when hardened to 225 Brinell.
13
Chips are stringy.
14
Chips are short and brittle.
15
Use chip curler.
16
Use chip curler and breakers.
17
Chips are tough and stringy.

Not Req. –usually not required.

A.C. –air cool
F.C. –furnace cool

50

Figure 6–Tool Bit Angles for High Speed Steel Tools for Machining
Stainless Steel Castings.
WELDING
All of the common welding methods can be used on
high-alloy castings. Information on pre-heat and post-
heat treatments are given for the heat-resistant alloys in
Table X and for corrosion-resistant alloys in Table XI.
The metal-arc process is used in most cases, especially
for the corrosion-resistant alloys, while oxy-acetylene
welding is usually limited to the heat-resistant types.
Oxy-acetylene welding is not normally used for
corrosion-resistant castings because carbon pick-up is
possible if the flame is not correctly adjusted. Carbon
pick-up would decrease the corrosion-resistance of the
chromium-nickel alloys. In the relatively tougher heat-
resistant alloys, this limitation does not exist and oxy-
acetylene welding can be employed. Inert-gas welding
with tungsten or consumable electrodes is common in
the repair welding of investment castings. Submerged
arc welding is confined mainly to fabrication of
corrosion-resistant alloys. Flash welding is utilized in
special applications, such as the joining of tubular
sections.
1. Welding Nickel-Chromium and Chromium-Nickel
Groups of Both Heat and Corrosion-Resistant
Grades.
Alloy castings of the nickel-chromium-iron and
chromium-nickel-iron groups can be welded satisfacto-
rily and the resultant joints will have the same mechani-
cal and physical properties as the base metal. These
alloys have better weldability than the straight chro-
mium alloys. Preheating is seldom required, but post-
weld heat treatments are employed with the corrosion-
resistant types to restore uniform corrosion resistance.
The thermal conductivity of these alloys is about one-
third that of carbon steel and the thermal expansion
coefficient is about 50% greater. This low conductivity
results in the retention of local heat for longer times and
the high coefficient of expansion means that higher
residual stresses and more distortion can be anticipa-
ted.
A. Arc Welding – The electrical resistance of nickel-
chromium and chromium-nickel castings is about six
times that of carbon steel, and the melting point of the
alloys is approximately 100 ºF lower. This combination
of greater resistance and lower melting point permits
these alloys to be arc welded using lower currents than
those required for welding carbon steels. Particular care
must be exercised with the corrosion-resistant types to
have the welding groove well cleaned and free of grease
or dirt, for any contamination of the weld might result in
carbon pick-up. When welding heat-resistant alloys of
the nickel-chromium group, the work must be kept clean
of lubricants and marking crayons that contain sulfur or
lead; otherwise cracking may result. Weaving of the
bead should be avoided because a large puddle pro-
motes weld cracking unless bead width is limited to 3
times the electrode diameter.
Welding Current – Reverse polarity D.C. is most
commonly used for welding the nickel-chromium and
chromium-nickel alloys. Table XII lists suggested elec-
trical settings and electrode sizes for these alloys of
different thicknesses. (In general, these alloys require
about 10% less current than the carbon steels.)
Electrode Selection – The electrode selected to weld a
corrosion-resistant cast alloy should deposit the same
alloy content as the casting. To accomplish this, the
electrode core and coating are adjusted to compensate
for melting losses that occur during welding. Particular
care should be exercised with the corrosion-resistant
cast alloys of low carbon content to assure that the
electrode does not add more carbon.
For the heat-resistant alloys, welding electrodes ca-
pable of depositing high carbon weld metal help prevent
cracking. The varying levels of silicon present in the
several heat-resisting alloy compositions, sometimes
require an adjustment of the carbon introduced into the
weld deposit by the electrode. This is done by the elec-
trode manufacturer to maintain the proper carbon-
silicon ratio in the weld deposit and thus eliminate crack-
ing.
Lime coated electrodes are usually preferred for
welding high-alloy castings. All welding slag must be
removed after welding, for when service temperatures
approach the melting point of the slag, severe metal
attack can occur.
B. Oxy-Acetylene Welding–Oxy-acetylene welding
may be used on the heat-resistant types but this type of
welding should not be used on chromium-nickel cast-
ings intended for corrosion-resistant service. For the
heat-resistant grades, a carburizing flame rich in acety-
lene is suggested, especially if service conditions
include a carburizing atmosphere.
2. Welding the Straight Chromium Alloys
The straight chromium alloys are divided into harden-
able and non-hardenable groups.
51
 The virtue of the hardenable alloys is that their use
permits refinement of the grain size, and also the devel-
opent of a variety of mechanical properties by suitable
heat treating procedures. This hardenability, however,
necessitates extra care when welding, for it can result in
brittle structures in the weld deposits and heat-affected
zone if the weld casting is allowed to cool down to room
temperature in air. Heat treatment is necessary to re-
store ductility and must be done immediately following
welding, and care must be taken that the castings re-
ceive no rough handling between welding and heat
treating. Cracking and distortion can be minimized by
welding the castings only after annealing and not in the
as-cast condition.
The non-hardenable straight chromium alloys contain
18 to 30% Cr, and, although they do not harden when
cooled rapidly, grain growth and brittleness result. Gen-
erally speaking, these grades have limited weldability
and call for extreme care in welding and in composition
control (i.e., nickel content should be kept near the
maximum allowable in the specification).
A. Arc Welding – In arc welding straight chromium
heat and corrosion-resistant castings, the welding cur-
rents used are qenerally lower than those employed for
carbon steel because of their greater electrical resis-
tance and lower melting points.
Welding Current – Reverse polarity direct current is
most commonly used in welding straight chromium
alloys; however, AC can be employed. The type of
welding current used, whether direct or alternating, is a
function of the flux casting present on the electrode.
Table XIII shows suggested electrical settings and elec-
trode sizes for the various section thicknesses.
Electrode Selection – In selecting the proper elec-
trode, it is important that the weld metal have the same
corrosion and heat-resistant properties as the parent
metal. The composition of the casting and commercial
electrodes are not exactly the same, for the electrode is
generally made to an AWS specification as listed it
Tables X and XI.
Lime coated electrodes are generally used for weld-
ing the straight chromium alloys, for they are considered
to give cleaner weld metal and allow for better bead
build-up than the titania or titania lime-coated rod.
B. Oxy-Acetylene Welding – Gas welding does not
find wide application for the straight chromium alloys
and is limited to those with less than 14% chromium.

TABLE XII TABLE XIII

Electrical Settings and Electrode Size for Welding Electrical Settings and Electrode Size for Welding
Chromium-Nickel Alloy Castings Straight Chromium Alloy Castings
Casting Arc Volts, Casting
Thickness Electrode Amperes max Thickness Electrode Amperes Volts
at Weld, Diameter, at Weld. Diameter,
in. In. in in

Under 1/16 1/16 25-40 22 Under 1/16 5/64 25-40 20-22

5/64 35-55 23 1/16-9/64 3/32 or 1/8 50-90 22-24
1/16-7/64 3/32 45-70 24 9/64-3/16 1/8 or 5/32 90-125 22-24
7/64-3/16 1/8 70-105 25 3/16- 1/2 5/64 or 3/16 100-150 23-27
3/16-1/2 5/32 100-140 25 1/2 and above 3/16 125-175 26-29
1/2 and above 3/16 130-180 26

52