Invention of Nickel Alloys

Similar to iron and copper, Nickel has been commonly utilized in the production of alloys since the
beginning of civilization. Although as compare to steel, brass and bronze , the nickel based alloys
have entered into the chemical units recently.
The initial nickel alloy of high commercial significance was Monel alloy 400, produced and
commercialized by International Nickel Co. Ltd in 1905. Another essential alloy was developed in
1930 called as Nickel-Molybdenum alloy and Nickel-Cromium-Molybdenum-tungsten alloy C. Then in
1931, Inconel alloy 600 was developed and later in 1949, Incoloy alloys were produced.
the most common and popular corrosion resistant nickel alloys belong to the family of Monel,
Inconel, Incoloy and Hastelloy alloys.
Heanjia SuperMetals is a leading manufacturer of these excellent corrosion resistant alloys that have
wide interest to the chemical industry. The trade names of these alloys are stated in the following
table:
Alloy
B3
C22
C2000
G30
622
625
688
B4
59

Trade Name
Hastelloy B3
Hastelloy C22
Hastelloy C2000
Hastelloy G30
Inconel 622
Inconel 625 LCF
Inconel 686
Nicrofer 6629
Nicrofer 5923hMo

Choosing Heat and Corrosion resistant Nickel-base alloys

The capability to withstand the grouped attack of heat and corrosion makes nickel based alloys an
outstanding choice for vigorous elevated temperature conditions. The nickel alloys are used in the
variety of applications in chemical units that include vigorous corrosion conditions at the high
temperatures such as above 1000oF.
In several conditions, high strength, chemical resistant nickel alloys are ideally used, if austenitic and
superaustenitic stainless steels are not suitable in the particular conditions. However costlier than
iron alloys, the outstanding functional properties of heat and corrosion resistant alloys usually make
them the highly affordable prolong service provider.
Chemical composition of Nickel alloys
The chemical composition of heat and corrosion resistant nickel alloys that have wide applications
in the chemical industry are stated in the following table:

Alloy

UNS

Nickel

Chromium Molybdenum Iron

Tungsten Copper Other

Inconel
600
Inconel
601
Inconel
617
Inconel
625
Hastelloy
X
Alloy 214
Alloy 230
Alloy 242
Alloy 333
45TM
602 CA

no.
N06600 75

elements
15

N06601 60.5

23

14.4

N06617 52

22

1.5

N06625 61

21.5

2.5

N06002 47

21.8

18.5

N07214 75
N06230 57
65
N06333 46
N06045 46
N06025 63

16
22
8
25.5
27.5
25

2
25
3.30

3
1.5
2
17
23
9.5

1.4 Al

14
2.5
3.3

12.5

1.2 Al

1.5

3.8 (niobium +
tantalum
1.4 Al

4.5 Al
2.5
3.3

1.1 Si
2.8 Si
2.1 Al

The alloys are recognized through their common designations and UNS series. The alloys like 600,
601, 625 belong to Inconel family. Similarly alloy X belongs to Hastelloy family. Several others
recently designed alloys are also stated in the above table. The kinds of alloys inspected are wrought
materials, strengthened basically through solid solution hardeners. The nickel base alloys are
reinforced by precipitation hardening, rather than oxide dispersion reinforced alloys made by
powder metallurgy techniques. The super alloys employed in gas turbine and aerospace applications
are basically used in chemical processing.
Physical and mechanical Characteristics
The physical characteristics of Nickel alloys are identical to those of Stainless steel 300 series. On the
base of individual alloy, thermal conductivity and expansion features may vary considered in
apparatus design.
The mechanical characteristics of nickel based alloys as class are outstanding in terms of strength
and ductile characteristics. Decreased room temperature strength and ductility values are stated in
following table. Excluding for alloy 601, minimum yield strengths are significantly more than 30 ksi
that is the value for the common austenitic stainless steels.
The higher strength of nickel base alloys as compared to ferrous base materials increases
progressively with temperature as shown in the following table:
Alloy
Stainless steel 304
Stainless steel 309
Stainless steel 310
Incoloy 800H
Inconel 600
Inconel 601
Inconel 617

Ambient
42
45
45
29
50
40
45

1000oF
18
26
25
17
40
32
32

1200oF
16
23
21
15
37
28
34

1500oF
10
18
15
13
20
20
35

1800oF

9
9
7
18

Inconel 625
Hastelloy X
214
230
242
333
45TM
602CA

48
49
82
57
113
43
53
50

32
33
72
40
70
25
36
38

35
30
76
39
76
25
34
37

38
26
81
50
24
28
31

18
18
8
21
28
10
13

Note that a 1.500oF, the nickel alloys retain 40% to 75% at their room temperature yield strength as
compare to about 20% to 35% for stainless steels.
The excellence of nickel alloys increases to creeping strength, as shown in the following table:
Alloy

Condition

304SS
309SS
310SS
800H
600
601
617
625
X
214
230
242
333
45TM
602CA

A
A
A
SA
ST
ST
SA
ST
ST
SA
SA
AA
ST
ST
ST

Stress to rupture in 1,000 hours

1,400oF
1.600oF
1,800oF
7.4
3
1.2
7.2
2.7
1
7.4
3
1.2
10
4.9
2
8.1
3.5
1.8
9.8
4.4
2.2
22
8.4
3.6
22
7.5
2.7
16
6.5
2.1
24
7.8
1.7
19
9
2.8
15
14
5.2
2.1
6.1
2.9
1.5
8
4.5
2.4

While stainless steels basically lose any considerable strength at temperatures of 2,000oF and
above, nickel alloys can still function suitably for moderately stressed parts. For a moment, 1000
hours rupture strength at 2,000 of is about 1 ksi for alloys 600, 601, 214 and 333 and 1.4 ksi for alloy
617 and 602CA.
ASME boiler and pressure vessel code comprises permissible stresses for the nickel alloys analyzed
excluding 214, 242 and ASTM.
Metallurgical stability
Another essential feature in alloy chosen for elevated temperature operations is metallurgical
competency that is also called as thermal stability. The term states to the resistance as thermal
stability. The term states to the resistance to produce brittle microstructural phases or precipitates
through aging that is after longer exposure at the high temperatures. That is also known as age
embrittlement manifests basically as decreased ductility and hardness, and may also decrease the
corrosion resistance.

Few alloys like Inconel alloy 600 and Inconel alloy 601, are virtually resistant to age embrittlement,
several undergo different extents of impairment. From these rigorously damaged is Inconel alloy 625
that may go through a marked fall in ductility and impact strength when subjected in the variety of
temperatures from 1200oF to 1400oF. At the elevated temperatures, these characteristics are
somewhat restored because brittle precipitates redissolve. Apparatus failures attributable to
decreased ductility and hardness are infrequent that are ascribed to the very high starting properties
kind of unaged nickel alloys.
Chemical Resistance
The several prevalent form of corrosion in high temperature chemical processing conditions is
gaseous corrosion, mainly oxidation, sulfidation and halogenation such as chloridation and
fluoridation. Other forms of deterioration encountered in hostile high temperature conditions are
carburization, nitridation and hydrogen corrosion. those are not categorized as corrosion in the
traditional sense of the word, because there is no metal loss or surface recession. Instead damage
manifests as metallurgical and mechanical destruction- commonly in the form of embriittlement.
The directional influence of alloying constituents on either resisting or aggravating high temperature
chemical corrosion of nickel base alloys is described in the following table:
Type of
corrosio
n
Oxidati
on

Iron

Chrom
ium

Molybd
enum

Cobalt

Tungst
en

Niobi
um

Silicon

Alumi
num

Titani
um

Enhan
ces
resist
ance
Sulfidati Lower
on
s
resist
ance
Chlorida Enhan
tion
ces
resist
ance

Lower
s
resist
ance
Enhan
ces
resist
ance
Lower
s
resita
nce

Enhan
ces
resista
nce
Enhan
ces
resista
nce
Enhan
ces
resista
nce

Lowers
resistan
ce

Enhan
ces
resista
nce
Enhan
ces
resista
nce
Depen
dent
on
specifi
c
conditi
ons

Lower
s
resista
nce

Lower
s
resist
ance

Lower
s
resist
ance

Enhan
ces
resista
nce
Enhan
ces
resista
nce
Enhan
ces
resista
nce

Lower
s
resist
ance

Depen
dent
on
specifi
c
conditi
ons

Fluorida
tion

Lower
s
resist
ance
Enhan
ces
resist
ance
Lower
s
resist
ance

Lower
s
resista
nce
Enhan
ces
resista
nce
Depen
dent
on
specifi

Enhanc
es
resistan
ce
Enhanc
es
resistan
ce

Enhan
ces
resista
nce
Enhan
ces
resista
nce
Depen
dent
on
specifi
c
conditi
ons
Lower
s
resista
nce
Enhan
ces
resista
nce
Enhan
ces
resista
nce

Carburiz
ation

Nitridati
on

Nickel

Enhan
ces
resist
ance
Enhan
ces
resist
ance
Enhan
ces
resist
ance

Depend
ent on
specific
conditio
ns

Enhan
ces
resista
nce
Enhan
ces
resista
nce

Lower
s
resist
ance

Enhan
ces
resista
nce
Depen
dent
on
specifi

Lower
s
resist
ance
Enhan
ces
resist
ance
Lower
s
resist
ance

c
conditi
ons

c
conditi
ons

The influence of chromium, molybdenum, cobalt, tungsten, silicon and aluminum may either be
favorable or damaging based on the particular exposure conditions, considerably temperature and
reducing nature against oxidizing conditions.
In actual, many material degradation modes may take place at the same time. For instance, several
industrial conditions comprise of oxygen and chlorine, the metals are subjected to oxychlorination,
an extremely vigorous corrosion form. Intensely high corrosion may occur through liquid phases like
molten salts, ash or metals. These vibrant materials are distinctly occurred in the chemical treatment
and hence are not covered in this article.
Corrosion form:
The popular kinds of high temperature chemical corrosions are described as following. The hydrogen
corrosion is skipped as nickel alloys are widely corrosion resistant.
Oxidation: It is a popular corrosion type that takes place at the high temperatures. It is attributed
through the production of metal oxide corrosion extracts. Hence so called scales are often highly
dense and tenacious and hence able to prevent further corrosion. Although, in intensely hostile
conditions oxide layers can be worn out or spall off.
Chromium is very essential element for enhancing oxidation resistance. As in stainless steels,
nominal inclusions of aluminum, silicon and rare earth metals further improve oxide strength and
firmness, particularly in the thermal cycling conditions. The stable oxide scales not just prevent
further oxidation but also become an effective obstruction against other corrosion types.
Sulfidation: In this type of corrosion, metal sulfide layers are produced that provide further security
from corrosion. The reducing sulfidizing conditions are often more vigorous as compare to oxidizing
sulfidizing conditions. The Nickel alloys are more prone to sulfidation rather than stainless steels
significantly due to the creation of low melting point nickel sulfide layer. Since through oxidation,
combination with chromium notably increases corrosion resistance ability.
Chloridation: Elevated temperature conditions to chlorine and its compounds quickly attack the
stainless steels. Since iron chlorides and oxychlorides are highly volatile in nature intense
chloridation may occur without considerable scaling. The nickel alloys are highly resistant to
sulfidation that make them suitable for application in conditions comprising of chlorine.
Carburization: in the conditions containing large carbon magnitude, this element diffuses into the
metal to produce metal carbides. It is a kind of corrosion known as carburization that can result in
intense damage of mechanical properties, ductility and impact strength of metals. The Nickel alloys
attain high carburization resistance due to presence of nickel that is not an active carbide producer.
Nitridation: It is usually known as nitriding that describes the dissolution of nitrogen into the metal
piece to produce metal nitrides. It popularly occurs in the chemical plants in the presence of high
temperature ammonia conditions. Since carburization damages a metal as embrittlement. Nickel

does also not produce nitrides that is considered for providing outstanding resistance by nickel
based alloys to nitridation.
Internal corrosion: Carburization and nitridation are simply elevated temperature corrosion types
featured by internal damage of metal. Almost entire high temperature corrosion are diffusion based
and featured by considerable subsurface corrosion, basically along grain boundaries. It is
implemented to oxidation, sulfidation and particularly to halogenations. In several cases, internal
corrosion enters deeper in the metal surface to result into metal loss. Analysis of high temperature
corrosion hence not depends on thickness or weight loss, but also on metallographic evaluation.
Welding instructions
Nickel alloys are readily welded through common welding mechanisms such as shielded metal arc
welding, gas tungsten arc welding and gas metal arc welding. The Nickel alloy weldments generally
attain outstanding ductility, and their small thermal expansion properties decrease the remaining
stress and damage. Postweld heat processing is normally not necessary for solution strengthened
alloys.
Preferred welding consumables for the nickel alloys are described in the following table:
Alloy
Inconel 600
Inconel 601
Inconel 617
Inconel 625
Hastelloy X
214
230
242
602CA

Welding electrode
ENiCrFe - 3
ENiCrFe - 3
ENiCrCoMo - 1
ENiCrMo 3
ENiCrMo 2
ENiCrMo 2
ENICrWMo - 1
ENiMo 3
EniCrCoMo - 1

Filler metal
ERNiCrFe - 3
ERNiCrFe 3
ERNiCrCoMo-1
ERNiCrMo-3
ERNiCrMo-2
ERNiCrMo-2
ERNiCrWMo-1
ERNiMo-3
ERNiCrCoMo-2

However not added in AWS A5.11 and A5.14 similar filler metals for Inconel alloy 601, alloy 214, 230,
242 and 602CA are present on commercial scale. Matching filler metals are the recommended
option for welds subjected to rigorous high temperature conditions because they offer wider
assurance that the weld metal will attain the identical corrosion resistance as that of base metal. The
Nickel based weld materials are commonly used for unlike metal weld joints among nickel base and
iron base alloys and for accumulating weld overlays on ferrous substrates.
The welding methods followed for nickel based alloys are widely identical to those followed for
stainless steels. Although improvements of joint designs and welding techniques may be stated to
attain complete penetration welds, containing slow flow properties of high nickel weld puddles. The
nickel alloys are more susceptible to weld embrittlement through contaminants. Special care is
needed to protect the weld zone from unwanted particles.
Wrought heat and corrosion resistant nickel alloys are introduced in the broad range of forms such
as plate, sheet and seamless and welded tubing products. ASTM specifications including these are
mentioned in the following table:

Alloy
Inconel
600
Inconel
601
Inconel
617
Inconel
625
Hastelloy
X
230
333
45TM
602CA

Plate/Sheet Seamless
pipe
B168
B167
B168

Welded Pipe
B517

B167

B168

Seamless
tube
B167

Welded tube

B167

B516

B546

B443

B444

B705

B444

B435

B622

B619

B622

B704

B435
B718
B168
B168

B622
B722
B167
B167

B619
B723
B517
B517

B622
B722
B167
B167

B626
B726
B516
B516

Many nickel alloys stated in this article can also be prepared as castings but with nominal
composition changes.
Alloy Properties
Here overview of properties of each alloys is provided that affect their suitability for corrosive
elevated temperature conditions in the chemical units.
1. Inconel 600 has nominal resistance to oxidation, chloridation, carburization and nitridation
but poor resistance to sulfidation. Inconel alloy 600 is broadly utilized in the hot chlorine or
hydrogen chloride and in ammonia conditions.
2. Inconel alloy 601 provides outstanding resistance to carburization and cyclic oxidation. It
offers enhanced strength as well as high thermal stability. Inconel 601 is broadly utilized in
contaminated combustion conditions.
3. Inconel 617 provides excellent high temperature strength, thermal stability and oxidation
resistance and carburization resistance. It is utilized in nitric acid and petrochemical
manufacturing.
4. Inconel 625 has suitable high strength and corrosion resistance to aqueous conditions. It
offers outstanding fatigue resistance but only intermediate thermal stability. Inconel 625 is
utilized in chemical and petrochemical units.
5. Hastelloy X offers excellent pair of strength, fabricability and resistance to oxidation,
carburization, fabricability and resistance to oxidation, carburizing and nitridation. It is a
suitable alloy for stressed parts in rigorous combustion conditions.
6. Alloy 214 has outstanding resistance to oxidation about 2200oF, chloridation, carburization
and nitridation. It has mediocre thermal stability, fabricability and weldability. Alloy 214 is an
alloy for outstanding corrosive conditions. It is controlled availability of product forms and
magnitude.
7. Alloy 230 has the superior balance for strength, thermal stability and fatigue resistance,
oxidation resistance and fabricability among the elevated temperature alloys. It is suitable
for high strength parts against the combustion conditions.

8. Alloy 242 is an excellent nickel alloy for fluorine and fluoride resistance. It offers extremely
high strength and good thermal stability. Alloy 242 is not preferred for applications over
1500oF. It is utilized in manufacturing fluoropolymers.
9. Alloy 333 provides outstanding resistance to oxidation and carburization resistance and
good sulfidation resistance and mechanical characteristics. It is utilized in the variety of
chemical and petrochemical plant applications.
10. Alloy 45TM is the required option for mixed chloridation, oxidation, sulfidation and
carburization resistance. The alloy instigates in incineration and gasification processes.
11. Alloy 602CA provides wide resistance to cyclic oxidation about 2200oF and carburization and
also offers high resistance to oxidizing, sulfidizing gases. It provides high creep strength at
intense temperatures.