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