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Additive Manufacturing Based Bellows T1.1 DLR Literature Survey Final 10-2015
Additive Manufacturing Based Bellows T1.1 DLR Literature Survey Final 10-2015
-Revised Version-
“Literature Survey of Materials compatible with Propellants”
Additive Manufacturing Based Bellows
Working Package 1: Selection of a suitable Material and Process Combination
October 20th, 2015
Robert.Lechler@dlr.de
Phone: +496298 28 348
Final Report: Literature Survey of Materials compatible with Propellants
1. Introduction
The final report shows the current state of our literature study concerning material-
compatibility with several commonly used storable propellants and some other fluids. The
report is based on the already existing interim report (September 14th, 2015).
During the work, two excel sheets were generated. One sheet contains the
compatibilities of ten alloys available at EOS; the other one contains the compatibilities of
the examined alloys and of many other alloys. In addition, the references are also listed in
the excel sheets.
Table of contents
1. Introduction ....................................................................................................................... 2
8. References ....................................................................................................................... 30
2. Investigated materials
2.1. Aluminum
Aluminum-alloys are probable compatible with Hydrazine and Nitrogen tetroxide [2], [7],
[25].
Aluminum is satisfactory with Helium and Nitrogen [27]. It may be used for Isopropanol
[11]. Aluminum reacts with nitrogen at 1600°C and 100 bar to aluminum nitride (AlN)
[35]. To the best of our knowledge, these reaction conditions will not occur during the
additive manufacturing process simultaneously. Therefore, the building of AlN can be
excluded. Compounds consisting of aluminum and helium are not known to date.
Aluminum carbide (AlC), as reaction product of aluminum and elemental carbon, is
found only at temperatures above 2000°C in the presence of a hydrogen atmosphere
[38].
2.2. Cobalt
Stellite No. 21 is compatible with Hydrazine and Nitrogen tetroxide [1], [11], [13], [17].
Comparability data of MMH is not available.
Stellite is compatible with Hydrazine [3]. Data of MMH and Nitrogen tetroxide is not
available.
Hayeness Stellite 1, Hayeness Stellite 12, Hayeness Stellite 6K, Hayeness Stellite 2 and
Hayeness Stellite 93 are compatible with Nitrogen tetroxide [13]. Data of Hydrazine and
MMH is not available.
Data of the alloy CobaltChrome MP1 is not available.
2.3. Steel
The following stainless steels are compatible with Hydrazine, MMH and Nitrogen
tetroxide:
• 304L (X2CrNi19-11) [1], [3], [6], [8], [13], [14], [22], [23], [24]
The following stainless steels are compatible with Hydrazine and MMH:
• 304 (X5CrNi18-10) [1], [7], [11], [12], [13], [14], [15], [17], [33]
• 321 (X6CrNiTi18-10) [1], [3], [7], [11], [12], [13], [14], [15], [16], [17], [18], [33]
• 17-7 PH [3], [12], [13], [14], [15], [17]
Stainless steels containing more than 0.5% Molybdenum are not compatible with
Hydrazine and MMH because of catalytic decomposition [1]. Molybdenum has been
recognized as a catalytic species in:
• AM-350 [1]
• AM-355 [1]
• A-286 [1]
Hydrazine is also decomposed by the following Metals: Ir > Rh > Ni~Pt~Co~Ru >
Pd~Ag~Cu. Alloys containing these metals are able to decompose Hydrazine [39].
Maraging steels are doubtful compatible with Hydrazine and Nitrogen tetroxide, but
compatible with MMH [2], [7], [15], [25]. Data of the MaragingSteel MS1 (18% Ni
Maraging300) is not available. Personal comment: However, doubts have been
expressed as to whether the use of MaragingSteel MS1, which contains 5 %
Molybdenum (in terms of Hydrazine decomposition).
The stainless steel 17-4 PH (StainlessSteel GP1) should not encounter Hydrazine. It is
compatible with Hydrazine at 140°F (60°C) and it is compatible with MMH [1], [3], [9],
[11], [13], [15], [21]. There are conflicting data for the compatibility with Nitrogen
tetroxide.
The stainless steel 17-7 PH is compatible with Hydrazine at 75°F (24°C) and it is
compatible with MMH [3], [13], [12], [14], [15], [17]. There are conflicting data for the
compatibility with Nitrogen tetroxide (compatible [1], [9], [11], [13], [21]; not compatible
[15]).
Data of the stainless steel 15-5 PH (StainlessSteel PH1) is not available. Precipitation-
harded age-hardenable (PH) steels / precipitation-hardening stainless (PH) steels are
not very compatible with Hydrazine [6].
The stainless steel 316L is compatible with MMH (no tarnish) [19]. Data of Hydrazine and
Nitrogen tetroxide are not available.
Stainless steel is satisfactory with Helium and Nitrogen [27]. Stainless steel (304, 316) is
compatible with Isopropanol [29].
No reactions between elemental iron and nitrogen are known to date. Iron nitride is only
formed by the reaction of Iron with Ammonia or Cyanide/Cyanate-meltings at 500°C [4].
Iron-Helium-compounds are not known to date.
2.4. Nickel
Hastelloy alloys are doubtful compatible with Hydrazine and Nitrogen tetroxide [2], [7],
[25]. Data of MMH is not available.
Hastelloy is not compatible with Hydrazine and Nitrogen tetroxide [1], [11]. Data of MMH
were not available.
Hastelloy C is not compatible with Hydrazine and Nitrogen tetroxide, but compatible with
MMH [1], [13], [15].
Inconel and Inconel-X are compatible with Hydrazine and Nitrogen tetroxide [1], [2], [3],
[11], [13], [16], [17], [18], [25]. Data of MMH is not available.
Inconel X-750 is compatible with MMH [14]. Data of MMH and Nitrogen tetroxide were
not available.
Inconel 625 is compatible with Hydrazine [20]. Data of MMH and Nitrogen tetroxide
were not available.
Data of the alloy Inconel 718 is not available.
2.5. Titanium
Titanium alloys in general are compatible with Hydrazine and Nitrogen tetroxide [2], [7],
[25]. Data of MMH is not available.
Titanium is one of the few elements that burn in pure nitrogen gas, reacting at 800 °C
(1,470 °F) to form Titanium Nitride, which causes embrittlement [26]. Welding is done
under a protective gas (Argon) [4].
There is a minor incompatibility to Isopropanol [28].
Alloys containing Copper and Molybdenum must be avoided for Hydrazine because of
catalytic decomposition [1].
Metals containing Copper, Lead, Zinc or more than 0.5% Molybdenum must be avoided
for MMH because of catalytic decomposition [1].
Copper and Brass are satisfactory with Helium and Nitrogen [27]. There is a slight
corrosion to Isopropanol [28]. Copper will not react with Helium. No compounds
between Cooper and Helium are known to date. There is the binary compound Copper(I)
nitride. This compound can be synthesized by a reaction of Copper(II) fluoride and
Ammonia [37]. A direct formation of Copper(I) nitride of the elements is not known to
date.
The abbreviation “mils/year” describes the abrasion of the metal surface in contact with
the propellant (in thousandths of an inch of material per year) [36].
Class A:
Corrosion Rate mils/year: Less than 1.0
Decomposition: None
Usage Limitations: No Limitations. Typical use involves constant contact with the fuel.
Metals can be considered for long term storage.
Class B:
Corrosion Rate mils/year: 1.0 to 5.0
Decomposition: Slight Degradation over a period of time.
Usage Limitations: Restricted to transient or limited contact. Not recommended for long
term storage.
Class C:
Corrosion Rate mils/year: 5.0 to 50
Decomposition: Limited Decomposition may occur on contact.
Usage Limitations: May only be used in areas where brief contact can occur. Not
recommended for use where contact occurs regularly.
Class D:
Corrosion Rate mils/year: More than 50
Decomposition: Considerable decomposition may occur. May cause ignition or explosion.
Usage Limitations: Metals are totally unsuitable for use under any conditions. Contact
may create a hazardous condition.
Aluminum-alloys:
Class A:
• 6061
• 356
• 2017
• 4043
• 2014-T4
• 5456-H24
• 716
• 25
• 250
• 25H
• 35
• 26H
• 24ST
• 52ST
• 61ST
• 75ST
Class B:
• 40E
• 43
• XA-545
Cobalt-alloys:
Class A:
• Stellite
Class C:
• Stellite, 77°F (25°C)
Steels:
Class A:
• 304L
• 17-4PH (EOS StainlessSteel GP1), 140°F (60°C)
• 17-7 PH (75°F, 24°C)
• 347
Class B:
• 321
• 410
• 430
• 302
Class D:
• 303
• 316
• 317
• 416
• 440C
• 315
• 420 F
• 430 F
• 440 A
• 329
• 17-4PH (EOS StainlessSteel GP1), 160°F (71°C)
Nickel-alloys:
Class B:
• Inconel-X
Miscellaneous metals:
Class A:
• Monel
• Nickel
• Chromel-A
• Nichrome
• Silver
• Tantalum
Class B:
• Brass
• Chromel-A
• Nichrome
• Silver
Class D:
• Cobalt
• Copper
• Iron
• Lead
• Magnesium
• Manganese
• Molybdenum
• Nickel
• Chromel-A
• Silver
• Tin
• Zinc
Class 1:
The Class 1 materials are those which exhibit a corrosion rate of less than 1 mil per year.
The material does not promote decomposition of the propellant or oxidizer and is free
from impact sensitivity.
Rating:
Rate: <1 mils/year
Decomposition of Propellant: No
Shock Sensitivity: No
Class 2:
The materials falling in Class 2 are similar to those in Class 1, except that the corrosion
rate may be as great as 5 mils per year.
Rating: Good
Rate: <5 mils/year
Decomposition of Propellant: No
Shock Sensitivity: No
Class 3:
A material in Class 3 shows only fair corrosion resistances; rates of attack may be of the
order of 5 to 50 mils per year. The material may also cause a moderate breakdown of
the propellant, but it is not shock sensitive under conditions likely to be encountered in
service.
Rating: Fair
Rate: 5 to 50 mils/year
Decomposition of Propellant: Some
Shock Sensitivity: No
Class 4:
Materials in this class are not considered usable for containing the propellant; they have
corrosion rates greater than 50 mils per year, cause extensive decomposition of the
propellant, cause spontaneous ignition, or react on impact.
Rating: poor
Aluminum-alloys:
Class 1:
• 1100, Gas 140°F (71°C); Liquid 140°F (60°C)
• 2020, Liquid 160°F (71°C)
• 2014, Liquid 80°F (26°C)
• 2017, Liquid 160°F (71°C)
• 2024, Liquid 66°F (19°C)
• 3003, Liquid 80°F (26°C)
• 4043, Liquid 160°F (71°C)
• 5052, Liquid 80°F (26°C)
• 5456, Gas 140°F (60°C); Liquid 140°F (60°C)
• 6061, Gas 140°F; (60°C); Liquid 160°F (71°C)
• 6066, Liquid 80°F (26°C)
Class 3:
• 1100, Liquid 140°F (60°C)
• 2020, Liquid 160°F (71°C)
• 2014, Liquid 160°F (71°C)
• 3003, Liquid 140°F (60°C)
• 7075, Liquid 160°F (71°C)
Cobalt-alloys:
Class 1:
• Stellite 21, Liquid 75°F (24°C)
Class 3:
• Stellite, Liquid 77°F (25°C)
Steels:
Class 1:
• 410 Stainless Steel, Liquid 180°F (82°C)
• 440C Stainless Steel, Liquid 80°F (60°C)
• 302 Stainless Steel, Liquid 80°F (60°C)
Class 2:
• 410 Stainless Steel, Liquid 77°F (52°C)
• 302 Stainless Steel, Liquid 140°F (60°C)
• 303 Stainless Steel, Liquid 75°F (24°C)
Class 4:
• Pure Iron ,Liquid 80°F (60°C)
• Mild Steel, Liquid 77°F (25°C)
• 440 Stainless Steel, Liquid 75°F (24°C)
• 321 Stainless Steel, Liquid 60°F (15°C)
• 17-4 PH, Liquid 160°F (71°C)
Nickel-alloys:
Class 1:
• Monel, Liquid 60°F (15°C)
• K-Monel, Liquid 140°F (60°C)
• Inconel, Liquid 200°F (93°C)
• Inconel X, Liquid 80°F (26°C)
• Hastelloy C, Liquid 120°F (49°C)
Class 3:
• Inconel, Liquid 140°F (60°C)
• Inconel X, Liquid 140°F (60°C)
Class 4:
• Nickel, Gas 140°F (60°C); Liquid 140°F (60°C)
• Monel, Liquid 80°F (27°C)
• K-Monel, Gas 200°F (93°C)
• Inconel, Gas 200°F (93°C)
Titanium-alloys:
Class 1:
Titanium 6Al-4V, Liquid 160°F (71°C)
Miscellaneous metals:
Class 1:
• Cadmium Pitting, Liquid room-temperature
• Copper, Liquid, 65°F (18°C)
• Brass, Liquid 80°F (26°C)
• Gold, Liquid, 75°F (24°C)
• Lead, Liquid, 65°F (18°C)
• Magnesium, Liquid 80°F (26°C)
• Molybdenum, Liquid 70°F (21°C
• Nichrome, Liquid 80°F (26°C)
• Chromel A, Liquid 80°F (26°C)
• Silver, Liquid 80°F (26°C)
• Silver Solder, Liquid 75°F (24°C)
• Tantalum, Liquid 80°F (26°C)
• Tin, Liquid 80°F (26°C)
• Zirconium, Liquid 75°F (24°C)
Class 2:
• Brass, Liquid 140°F (60°C)
• Tungsten, Liquid 75°F (24°C)
Class 3:
• Inconel, Liquid 140°F (60°C)
• Silver Solder, Liquid 140°F (60°C)
Class 4:
• Cadmium, Liquid room-temperature
• Copper, Liquid 140°F (60°C)
• Brass, Liquid 140°F (60°C)
• Bronze, Liquid room-temperature
• Gold, Liquid 212°F (100°C)
• Magnesium, Liquid 80°F (26°C)
• Molybdenum, Liquid 80°F (26°C)
• Nickel Liquid, 140°F (60°C)
• Silver, Liquid 75°F (24°C)
• Tantalum, Liquid 212°F (100°C)
• Tin, Liquid 140°F (60°C)
• Zinc, Liquid room-temperature
and
P.E. Uney, D.A. Fester, Material Compatibility with Space storable Propellants Design
Guidebook, March 1972, Martin Marietta Corporation P.O. Box 179, Denver, Colorado
80201, prepared for Jet Propulsion Laboratory California Institute of Technology
Passadena, California 91103, Contract No. HF-556439, Under NAS7-100
Rating 1: compatible
Rating 2: probable compatibility
Rating 3: doubtful compatibility
Rating 4: incompatible
Rating 5: unable to rate
Aluminum-alloys:
Rating 1:
• 3003
• 5052
• Anodized aluminum alloys
Rating 2:
• 1100
• 2014
• 2024
• 2219
• 6061 conflicting data
• 7075
• 356
Rating 3:
• 2021
• 6061 conflicting data
Cobalt-alloys
Rating 3:
• L-605 Cobalt Alloy
Steels:
Rating 2:
• 400 series in general
• 410
• 416
• 430
• 440C conflicting data
• 19-9DL
• Carpenter 20Chb
• HY-140 steel
Rating 3:
• Steels in general
• Stainless steels in general
• 300 series in general
• 301 cryoformed
• 304
• 316
• 321
• 347
• 440C conflicting data
• A-286
• AM350 or AM355
• 17-4PH or 17-7PH
• 1018 or 1020 steels
• Maraging steels
Nickel-alloys:
Rating 2:
• Inconel conflicting data
Rating 3:
• Hastelloy alloys
• Inconel conflicting data
Titanium-alloys:
Rating 1:
• Titanium alloys in general some shock sensitivity reported
• 6Al-4V
• 5Al-2.5Sn
• 75A
• B120VCA
• Pure titanium
• 8Al-1Mo
Rating 2:
• 65A
Miscellaneous metals:
Rating 1:
• Beryllium
• Columbium
• Tantalum
• Tungsten
Rating 2:
• TZM alloy
• L-605 Cobalt Alloy
• Tin
• Gold
• Platinum
Rating 3:
• Inconel conflicting data
• Monel
• Chromium
Rating 4:
• Nickel (pure)
• Magnesium alloys
• Zinc
• Copper
• Brass
• Bronze
• Pure molybdenum
• Kovar metal
• Pure lead
• Silver
• Zirconium
• Pure iron
Class 1:
The Class 1 materials are those which exhibit a corrosion rate of less than 1 mil per year.
The material does not promote decomposition of the propellant or oxidizer and is free
from impact sensitivity.
Rating: Excellent
Rate: <1 mils/year
Decomposition of Propellant: No
Shock Sensitivity: No
Class 2:
The materials falling in Class 2 are similar to those in Class 1, except that the corrosion
rate may be as great as 5 mils per year.
Rating: Good
Rate: <5 mils/year
Decomposition of Propellant: No
Shock Sensitivity: No
Class 3:
A material in Class 3 shows only fair corrosion resistances; rates of attack may be of the
order of 5 to 50 mils per year. The material may also cause a moderate breakdown of
the propellant, but it is not shock sensitive under conditions likely to be encountered in
service.
Rating: Fair
Rate: 5 to 50 mils/year
Decomposition of Propellant: Some
Shock Sensitivity: No
Class 4:
Materials in this class are not considered usable for containing the propellant; they have
corrosion rates greater than 50 mils per year, cause extensive decomposition of the
propellant, cause spontaneous ignition, or react on impact.
Rating: poor
Rate: >50 mils/year
Decomposition of Propellant: Extensive
Shock Sensitivity: Yes
Aluminum-alloys:
Class 1:
• 1100, Liquid 80°F (26°C)
• 1100-C, Liquid 80°F (26°C)
• 2014-T6, Gas 60°F (15°C); Liquid 60°F (15°C)
• 2014-T6, (H2SO4 Anodize) Liquid 60°F (15°C)
2014-T6, (welded) Gas 60°F (15°C); Liquid 60°F (15°C)
• 2024, Gas 60°F (15°C); Liquid 140°F (60°C)
• 2024-C, Gas 150°F (54°C); Liquid 180°F (82°C)
• 2214-T8, Gas 60°F (15°C); Liquid 60°F (15°C)
• 4043, Liquid 80°F (26°C)
• 3032, Liquid 130°F (54°C)
• 5456, Gas 60°F (15°C); Liquid 60°F (15°C)
• 6061, Liquid 130°F (54°C)
Cobalt-alloys:
Class 1:
• Haynes, Stellite 1 Liquid 100°F (37°C)
• Haynes, Stellite 12 Liquid 100°F (37°C)
• Haynes, Stellite 21 Liquid 65°F (18°C)
• Haynes, Stellite 29 Liquid 65°F (18°C)
• Haynes, Stellite 93 Liquid 100°F (37°C)
Steels:
Class 1:
• 410 Stainless Steel, Gas 65°F (18°C); Liquid 150°F (65°C)
• 410 Stainless Steel (welded), Liquid 65°F (18°C)
• 416 Stainless Steel, Gas 65°F (18°C); Liquid 65°F (18°C)
• 440C Stainless Steel, Liquid 100°F (37°C)
• 302 Stainless Steel, Liquid 100°F (37°C)
• 303 Stainless Steel, Liquid 100°F (37°C)
• 304 Stainless Steel, Gas 65°F (18°C); Liquid 140°F (60°C)
• 304L Stainless Steel, Liquid 165°F (74°C)
• 316 Stainless Steel, Gas 65°F (18°C); Liquid 65°F (18°C)
• 321 Stainless Steel, Gas 65°F (18°C); Liquid 65°F (18°C)
• 321 Stainless Steel (welded), Liquid 65°F (18°C)
• 347 Stainless Steel, Gas 65°F (18°C); Liquid 130°F (54°C)
• A-286 (anellated), Liquid 100°F (37°C)
• A-286 (aged), Liquid 60°F (15°C)
• 17-7 PH (Condition A), Liquid 65°F (18°C)
• 17-4 PH (H 1000), Liquid 100°F (37°C)
• 17-7 PH (TH 950), Gas 60°F (15°C); Liquid 100°F (37°C)
• 17-7 PH (RH 950), Liquid 100°F (37°C)
• PH 15-7 Mo (Condition A), Liquid 165°F (74°C)
• 16-25-6, Liquid 80°F (26°C)
Class 4:
• Pure Iron, Gas 286K
• 304 Stainless Steel, Liquid 293K
Nickel-alloys:
Class 1:
• A-Nickel, Gas 60°F (15°C); Liquid 65°F (18°C)
• Nickel, Electroplate Liquid 60°F (15°C)
• Electroless Nickel Plate, Liquid 65°F (18°C)
• Incone,l Gas 65°F (18°C); Liquid 65°F (18°C)
• Monel, Gas 65°F (18°C); Liquid 65°F (18°C)
• Ni-Span-C, Liquid 60°F (15°C)
• Inconel X, Liquid 75°F (24°C)
• Hastelloy Alloys, Liquid 60°F (15°C)
Class 4:
• Monel, Liquid 75°F (24°C)
• K-Monel, Liquid 75°F (24°C)
Titanium-alloys:
Class 1:
• 65A, Liquid 100°F (37°C)
• 75A, Liquid 100°F (37°C)
Miscellaneous metals:
Class 1:
• Gold, Liquid 75°F (24°C)
• Gold Plate, Liquid 65°F (18°C)
• Magnesium 100 A, Gas 40°F (0°C); 65°F (18°C)
• Magnesium AZ31C, Gas 40°F (0°C); Liquid 60°F (15°C)
• Magnesium HM21A-T8, Liquid 60°F (15°C)
• Platinum, Liquid 75°F (24°C)
• Pure Tin solder on 383SS, Liquid 65°F (18°C)
• Tin, Liquid 80°F (26°C)
• Tin Plate, Liquid 60°F (15°C)
Class 2:
• Copper, Gas 80°F (26°C)
• Gold, Liquid 75°F (24°C)
• Gold Plate, Liquid 65°F (18°C); Liquid 65°F (18°C);
• 82 Gold-18 Ni Braze, Liquid 75°F (24°C)
• Lead, Liquid 80°F (26°C)
• Magnesium 100A, Gas 60°F (15°C); Liquid 60°F (15°C)
• Magnesium AZ31C, Gas 65°F (18°C); Liquid 65°F (18°C);
• Platinum, Liquid 75°F (24°C)
Class 3:
• Copper, Gas 80°F (26°C)
• Yellow Brass, Gas 75°F (24°C)
• Red Brass, Gas 75°F (24°C)
• Al Bronze, Gas 75°F (24°C)
• Si Bronze, Gas 75°F (24°C)
• Sn Bronze, Gas 75°F (24°C)
• Lead, Liquid 80°F (26°C)
• Magnesium AZ31C, Liquid 150°F (65°C)
Class 4:
• Cadmium, Liquid 75°F (24°C)
• Cadmium Plate, Liquid 60°F (15°C)
• Copper Plate, Liquid 60°F (15°C)
The following alloys are compatible with Hydrazine and Nitrogen tetroxide:
Miscellaneous metals:
• Tantalum
• Chromium plating
The stainless steel 17-4 PH (StainlessSteel GP1) should not encounter Hydrazine [1]. It is
compatible with Hydrazine at 140°F (60°C) [3], [13] and it is compatible with MMH [15].
There are conflicting data for the compatibility with Nitrogen tetroxide (compatible [1],
[9], [11], [13]; not compatible [15]).
The stainless steel 17-7 PH is compatible with Hydrazine at 75°F (24°C) [3], [13] and it is
compatible with MMH [14], [15]. There are conflicting data for the compatibility with
Nitrogen tetroxide (compatible [1], [9], [11], [13], [21]; not compatible [15]).
The compatibility with Nitrogen tetroxide depends on the moisture [1]. Water
contamination causes formation of Nitric Acid, which is corrosive [11], [13].
The following alloys (available at EOS) were included in this report (details see excel
sheets):
• MaragingSteel MS1 (18% Ni Maraging 300, X3NiCoMoTi 18-9-5, DIN-
number 1.2709)
no data available
8. References