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This group of alloys are used for their outstanding corrosion and high temperature resistance. Many are metallurgically related to the austenitic stainless steels but are much more highly alloyed, particularly with nickel, chromium and molybdenum in order to enhance their corrosion resistance. These alloys are used resist extremely corrosive conditions in the energy, power, chemical and petrochemical industries.
The term “superalloy” is applied to alloys which have outstanding high temperature strength and oxidation resistance. The nickel-based superalloys contain carefully balanced alloying additions of chromium, cobalt, aluminium, titanium and other elements. Often components are produced by carefully controlled solidification in order to get an optimum directionally solidified or even single crystal structure. These components can have strengths at 1000°C which exceed that of ordinary steels at room temperature. They are essential in the hottest parts of gas turbines both for power generation and aircraft.
Applications and Characteristics of Nickel Alloys
Nickel and nickel alloys are used for a wide variety of applications, the majority of which involve corrosion resistance and/or heat resistance. Some of these include:
- Aircraft gas turbines
- Steam turbine power plants
- Medical applications
- Nuclear power systems
- Chemical and petrochemical industries
A number of other applications for nickel alloys involve the unique physical properties of special-purpose nickel-base or high-nickel alloys. These include:
- Low-expansion alloys
- Electrical resistance alloys
- Soft magnetic alloys
- Shape memory alloys
Heat-Resistant Applications.
Nickel-base alloys are used in many applications where they are subjected to harsh environments at high temperatures. Nickel-chromium alloys or alloys that contain more than about 15% Cr are used to provide both oxidation and carburization resistance at temperatures exceeding 760°C.
Corrosion Resistance.
Nickel-base alloys offer excellent corrosion resistance to a wide range of corrosive media. However, as with all types of corrosion, many factors influence the rate of attack. The corrosive media itself is the most important factor governing corrosion of a particular metal.
Low-Expansion Alloys
Nickel was found to have a profound effect on the thermal expansion of iron. Alloys can be designed to have a very low thermal expansion or display uniform and predictable expansion over certain temperature ranges.Iron-36% Ni alloy (Invar) has the lowest expansion of the Fe-Ni alloys and maintains nearly constant dimensions during normal variations in atmospheric temperature.The addition of cobalt to the nickel-iron matrix produces alloys with a low coefficient of expansion, a constant modulus of elasticity, and high strength.
Electrical Resistance Alloys
Several alloy systems based on nickel or containing high nickel contents are used in instruments and control equipment to measure and regulate electrical characteristics (resistance alloys) or are used in furnaces and appliances to generate heat (heating alloys).
Types of resistance alloys containing nickel include:
- Cu-Ni alloys containing 2 to 45% Ni
- Ni-Cr-Al alloys containing 35 to 95% Ni
- Ni-Cr-Fe alloys containing 35 to 60% Ni
- Ni-Cr-Si alloys containing 70 to 80% Ni
Types of resistance heating alloys con-taining nickel include:
- Ni-Cr alloys containing 65 to 80% Ni with 1.5% Si
- Ni-Cr-Fe alloys containing 35 to 70% Ni with 1.5% Si + l% Nb
Soft Magnetic Alloys
Two broad classes of magnetically soft materials have been developed in the Fe-Ni system. The high-nickel alloys (about 79% Ni with 4 to 5% Mo; bal Fe) have high initial permeability and low saturation induction.
Shape Memory Alloys
Metallic materials that demonstrate the ability to return to their previously defined shape when subjected to the appropriate heating schedule are referred to as shape memory alloys. Nickel-titanium alloys (50Ni-50Ti) are one of the few commercially important shape memory alloys.
Some high-temperature variants include:
- Alloy 601. Lower nickel (61%) content with aluminum and silicon additions for improved oxidation and nitriding resistance
- Alloy X750. Aluminum and titanium additions for age hardening
- Alloy 718. Titanium and niobium additions to overcome strainage cracking problems during welding and weld repair
- Alloy X (48Ni-22Cr-18Fe-9Mo + W). High-temperature flat-rolled product for aerospace applications
- Waspaloy (60Ni-19Cr-4Mo-3Ti-1.3Al). Proprietary alloy for jet engine applications
Some corrosion-resistant variants in the Ni-Cr-Fe system include:
- Alloy 625. The addition of 9% Mo plus 3% Nb offers both high-temperature and wet corrosion resistance; resists pitting and crevice corrosion
- Alloy G3/G30 (Ni-22Cr-19Fe-7Mo-2Cu). The increased molybdenum content in these alloys offers improved pitting and crevice corrosion resistance
- Alloy C-22 (Ni-22Cr-6Fe-14Mo-4W). Superior corrosion resistance in oxidizing acid chlorides, wet chlorine, and other severe corrosive environments
- Alloy C-276 (17% Mo plus 3.7W). Good seawater corrosion resistance and excellent pitting and crevice corrosion resistance
- Alloy 690 (27% Cr addition). Excellent oxidation and nitric acid resistance; specified for nuclear waste disposal by the vitreous encapsulation method
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