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THE PAPER OF MODERN METAL ALLOYS

“INCONEL”

Submitted in partial fulfillment for the course of Metal Physics and Alloys
Lecturer: Arif Tjahjono S.T., M.Si.

Compiled by:
Niken Aprilia Eka Putri
(11160970000062)

PHYSICS DEPARTEMENT
FACULTY OF SCIENCE AND TECHNOLOGY
STATE ISLAMIC UNIVERSITY SYARIF HIDAYATULLAH
JAKARTA
2019
PREFACE

With all the praise and thanks to Allah SWT, who has given His love and mercy so
that a paper entitled MODERN METAL ALLOYS “INCONEL” can we finish well. The
paper is structured to meet one of the tasks of the courses Metal Physis and Alloys. On this
occasion, we would like to thank profusely to all those who have helped us in completing
the writing of this paper, to Arif Tjahjono S.T., M.Si. as lecturer in Metal Physics and
Alloys for the support and motivation.
We are fully aware that the many flaws in the writing of this paper, in terms of
material, technical and presentation. Therefore, we expect criticism and constructive
suggestions to further refine the writing of this paper. Finally, we hope that the writing of
this paper can be useful for readers.

Ciputat, 14th December 2019

The writer

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TABLE OF CONTENTS

PREFACE ...................................................................................................................... ii
TABLE OF CONTENTS .............................................................................................. iii
CHAPTER I INTRODUCTION .................................................................................. 1
1.1 Background ................................................................................................... 1
1.2 Formulate of The Problem ............................................................................ 1
1.3 Aims of Paper ............................................................................................... 2
CHAPTER II DISCUSSION ........................................................................................ 3
2.1 Inconel .......................................................................................................... 3
2.2 Chemical Composition of Inconel ................................................................ 4
2.3 Physical and Mechanical Properties ............................................................. 4
2.4 Characteristics of Inconel ............................................................................. 6
2.5 Types of Inconel ........................................................................................... 6
2.6 Machining Proccess of Inconel ..................................................................... 8
2.7 Applications of Inconel ................................................................................ 9
CHAPTER III CLOSING ............................................................................................ 12
3.1 Conclusion .................................................................................................... 12
BIBLIOGRAPHY ......................................................................................................... 13

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CHAPTER I

INTRODUCTION

1.1 Background

No other materials have contributed more to the development of mankind over


the millennia than metals and alloys. Throughout centuries, studies of metals belonged
to one of the oldest branches of Applied Materials Science–Metallurgy. This changed in
the late 19th and early 20th centuries, when applications of metallic materials spread
into other areas of science and technology including electronics, energy, aeronautics
and space travel, to name a few. Currently, it’s impossible to imagine a world in which
we could successfully function without metals and alloys.

Traditionally, metals are portrayed as shiny solids, most of which are good
conductors of heat and electricity. They are ductile and most will melt at high
temperatures. Metal and alloy shapes can easily be changed by mechanical processing, a
technique that can be used for the preparation, modification and chemical conversion of
metal alloys and composites. Presently, there are 87 known metals, and one of them is
Inconel This paper deals with the basic but essential knowledge and information on
Inconel that would be helpful for researchers, scientists, engineers and professionals
dealing with nickel-chromium based super alloys.

1.2 Formulate of The Problem

1. What is an Inconel?
2. What is the chemical composition of Inconel?
3. How are the physical and mechanical properties of Inconel?
4. How are the characteristic of Inconel?
5. What are the types of Inconel?
6. How is machining process of Inconel?
7. What applications of Inconel?

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1.3 Aims of Paper

1. To know what Inconel is


2. To know what the chemical composition of Inconel
3. To find out the physical and mechanical properties of Inconel
4. To find out the characteristic of Inconel
5. To know the types of Inconel
6. To find out machining process of Incoonel
7. To know applications of Inconel

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CHAPTER II

DISCUSSION

2.1 Inconel

Inconels are a class of nickel-chrome-based super alloys characterized by high


corrosion resistance, oxidation resistance, strength at high temperatures, and creep
resistance. Inconel is able to withstand elevated temperatures and extremely corrosive
environments due to two factors. One reason is because of the formation of the
intermetallic compound Ni3Nb in the gamma double prime (ɣ’’) phase. This
intermetallic phase acts as a ‘glue’ on the grain boundaries. This ‘glue’ prevents the
grains from increasing in size when heated to high temperatures (for the most part,
smaller grains means a high strength and larger grains lends itself to a higher ductility).
Second, Inconel has a high corrosion resistance due to the passivation layer that forms
when heated. Both of these factors make Inconel ideal alloys for applications from hot
section gas turbines to deep sea well drilling.

Picture 2.1 Inconel


Inconel is a family of austenitic nickel-chromium-based superalloys. Inconel
alloys are oxidation-corrosion-resistant materials well suited for service in extreme
environments subjected to pressure and heat. When heated, Inconel forms a thick,
stable, passivating oxide layer protecting the surface from further attack. Inconel retains
strength over a wide temperature range, attractive for high temperature applications
where aluminum and steel would succumb to creep as a result of thermally induced
crystal vacancies. Inconel's high temperature strength is developed by solid solution

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strengthening or precipitation hardening, depending on the alloy.

The Inconel family of alloys was first developed in the 1940s by research teams
at Wiggin Alloys (Hereford, England), which has since been acquired by Special Metals
Corporation, in support of the development of the Whittle jet engine. In June 2018,
SpaceX CEO Elon Musk announced completion of work on a new Inconel superalloy
called SX 300 developed for high-temperature, high-pressure, highly oxidative
environments in a rocket engine.

2.2 Chemical Composition of Inconel

Inconel alloys vary widely in their compositions, but all are predominantly nickel,
with chromium as the second element. Chemical composition of Inconel shown in the
table below:

Element, proportion by mass (%)

Inconel Nb &
Ni Cr Fe Mo Co Mn Cu Al Ti Si C S P B
Ta

14.0–
600 ≥72.0 6.0–10.0 N/A ≤1.0 ≤0.5 ≤0.5 ≤0.15 ≤0.015
17.0

44.2– 20.0– 8.0– 10.0– 0.8– 0.05–


617 ≤3.0 ≤0.5 ≤0.5 ≤0.6 ≤0.5 ≤0.015 ≤0.015 ≤0.006
61.0 24.0 10.0 15.0 1.5 0.15

20.0– 8.0– 3.15–


625 ≥58.0 ≤5.0 ≤1.0 ≤0.5 ≤0.4 ≤0.4 ≤0.5 ≤0.1 ≤0.015 ≤0.015
23.0 10.0 4.15

690 ≥58 27–31 7–11 ≤0.50 ≤0.50 ≤0.50 ≤0.05 ≤0.015

Nuclear
grade ≥58 28–31 7–11 ≤0.10 ≤0.50 ≤0.50 ≤0.50 ≤0.04 ≤0.015
690

50.0– 17.0– 2.8– 4.75– 0.2– 0.65–


718 Remainder ≤1.0 ≤0.35 ≤0.3 ≤0.35 ≤0.08 ≤0.015 ≤0.015 ≤0.006
55.0 21.0 3.3 5.5 0.8 1.15

14.0– 0.7– 0.4– 2.25–


X-750 ≥70.0 5.0–9.0 ≤1.0 ≤1.0 ≤0.5 ≤0.5 ≤0.08 ≤0.01
17.0 1.2 1.0 2.75

Table 2.1 Chemical Composition of Different Types of Inconel

2.3 Physical and Mechanical Properties


Inconel alloys are oxidation-and corrosion-resistant materials well suited for
service in extreme environments subjected to high pressure and kinetic energy. When
heated, Inconel forms a thick and stable passivating oxide layer protecting the surface

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from further attack. Inconel retains strength over a wide temperature range, attractive
for high-temperature applications where aluminium and steel would succumb
to creep as a result of thermally induced crystal vacancies. Inconel's high temperature
strength is developed by solid solution strengthening or precipitation strengthening,
depending on the alloy. In age-hardening or precipitation-strengthening varieties, small
amounts of niobium combine with nickel to form the intermetallic compound Ni3Nb
or gamma double prime (γ″). Gamma prime forms small cubic crystals that inhibit slip
and creep effectively at elevated temperatures. The formation of gamma-prime crystals
increases over time, especially after three hours of a heat exposure of 850 °C, and
continues to grow after 72 hours of exposure. Physical and Mechanical Properties are
shown in the table below:

Physical
Types
Properties

Inconel Inconel Inconel Inconel Inconel Inconel Inconel Inconel


600 601 622 625 718 725 825 925

Density 8.14 e-
8.47 8.11e-9 8.61 8.44 8.192 8.3 8.08
(g/cm3) 9

Melting 1354- 1360- 1351- 1287- 1370- 1271- 1370- 1311-


Point (°C) 1413 1411 1387 1348 1430 1343 1400 1366

Thermal
Conductivity 14.8 11.1 13.2 9.8 6.5 11.2 11.1 12
(W/m·K)

Mechanical
Properties

65-85 86 145- 43 135-


Hardness 86 RB 331 HB 76 RB
HRB HRB 240 HB HRC 165 RB

Yield
205-
Strength 310 570 413 1240 427 338 810
640
(MPa)

Elongation
Break At 2 42 42 54 30 12 57 45 24
Inches (%)

Table 2.2 Physical Properties and Mechanical Properties of Inconel

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2.4 Characteristics of Inconel
Inconel is considered a super alloy and special metals with specific applications. It
has several characteristics that make is a desirable metal:
 Good resistance to acids, such as sulfuric, phosphoric, nitric, and hydrochloric
 Almost completely free from chloride induced stress corrosion cracking
 Excellent mechanical properties at both extremely low and extremely high
temperatures
 Outstanding resistance to pitting, crevice corrosion and intercrystalline corrosion
 High resistance to oxidation at elevated temperatures

2.5 Types of Inconel


There are many different varieties of Inconel’s, each has a different composition,
but all are generally nickel, with chromium as the second element.
Inconel alloys are corrosion and oxidation resistant and therefore are well suited
for usage in extreme environments. When heat is applied to Inconel it forms a protective
oxide layer through passivation. Inconel retains strength over a wide temperature range,
an advantage for high temperature applications. Depending on the alloy, Inconel's high
temperature strength is established either by solid solution strengthening or precipitation
strengthening.
Inconel alloys are generally known for their resistance to oxidation and their
ability to maintain their structural integrity in high temperature atmospheres. While each
variation of Inconel has unique traits that make it effective in different circumstances,
the majority of the alloys are used frequently in the industry. There are the types of
Inconel that is frequently used:
 Inconel 601

Picture 2.2 Inconel 601


Like Inconel 600, Inconel 601 offers resistance to various forms of high-

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temperature corrosion and oxidization. Inconel 601 is a nickel-chromium alloy that
has additions of aluminum. These additions increase its resistance to oxidation and
various forms of corrosion. This has made Inconel 601 a common material in heat
treating equipment, furnaces, and gas-turbine components. Inconel 601's ability to
stave off the strain that would result in many alloys when exposed to high
temperatures has led to its use in furnaces and heat treating equipment like retorts
and baskets.
 Inconel 625
Inconel 625 differs from many of the other Inconel alloys because its
composition includes substantial amounts of nickel, chromium, and molybdenum. It
also has an addition of niobium. The result is an alloy that possesses high levels of
strength without ever having to go through a strengthening heat treatment. Inconel
625 is especially effective at resisting crevice corrosion, making it a chosen
material in the aerospace and marine engineering industries.
 Inconel 690
Inconel 690 contains high-chromium and nickel alloy. The high-chromium
element of the alloy gives it a particularly strong resistance to corrosion that occurs
from salts, oxidizing acids, other elements commonly found in aqueous
atmospheres and can endure the sulfidation that takes place at high temperatures.
Due to anticorrosive properties 690 enjoys strong metallurgical stability which
allows it to retain structural integrity in various applications.
 Inconel 718

Picture 2.3 Inconel 718


Inconel 718 has high levels of iron, molybdenum, and niobium as well as
traces of titanium and aluminium. Inconel 718 is designed to provide a high level of
strength and flexibility, this allows it to be particularly resistant to post-weld

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cracking. Well suited to both high-temperature and aqueous environments. Inconel
718 is age-hardenable with no significant detrimental effects. It responds slowly to
being treated in this way, meaning that it can be annealed and welded without any
spontaneous hardening during either heating or cooling.
One of the outstanding features of Inconel alloy 718 is that it is extremely
versatile and easy to work with. It shows excellent welding characteristics,
especially with regards to its resistance to post-weld cracking. In comparison to
other nickel-based superalloys, particularly those hardened by aluminium or
titanium, it is vastly superior. Because it can be fabricated so readily and into
increasingly complex parts.
 Inconel 722
Inconel 722 is a nickel-chromium alloy that shares many of the same
properties as other Inconel alloys. Inconel 722 can withstand the stress caused by
several types of acids, which has made it popular in the chemical industry.

2.6 Machining Proccess of Inconel


Inconel is a difficult metal to shape and to machine using traditional cold
forming techniques due to rapid work hardening. After the first machining pass, work
hardening tends to plastically deform either the workpiece or the tool on subsequent
passes. For this reason, age-hardened Inconels such as 718 are machined using an
aggressive but slow cut with a hard tool, minimizing the number of passes required.
Alternatively, the majority of the machining can be performed with the workpiece in
a “solutionized” form, with only the final steps being performed after age hardening.
External threads are machined using a lathe to “single-point” the threads or by
rolling the threads in the solution treated condition (for hardenable alloys) using a screw
machine. Inconel 718 can also be roll-threaded after full aging by using induction
heat to 1,300 °F (700 °C) without increasing the grain size. Holes with internal threads
are made by threadmilling. Internal threads can also be formed using a sinker electrical
discharge machining (EDM).
Cutting of a plate is often done with a waterjet cutter. New whisker-reinforced
ceramic cutters are also used to machine nickel alloys. They remove material at a rate
typically eight times faster than cemented carbide cutters. Apart from these methods,
Inconel parts can also be manufactured by selective laser melting.
More often than machining, water-jet or laser, grinding is a preferred and
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economical method for forming nickel alloy components to shape and finish. Due to the
hardness of the abrasives used, the grinding wheels are not as affected by the material
work hardening and remain sharp and durable.
Welding of some Inconel alloys (especially the gamma prime precipitation
hardened family; e.g., Waspalloy and X-750) can be difficult due to cracking and
microstructural segregation of alloying elements in the heat-affected zone. However,
several alloys such as 625 and 718 have been designed to overcome these problems.
The most common welding methods are gas tungsten arc welding and electron-beam
welding.

2.7 Applications of Inconel


Based on nickel and chromium, these superalloys offer exceptional high-
temperature and corrosion resistance, which makes them particularly appealing. Due to
all of these characteristics, Inconel alloys can be used for a wide variety of applications.
Applications of Inconel alloys used for:
 Chemical and petrochemical processing
 Components where exposure to high mechanical stress and sea water are required
 Flare stacks on offshore oil platforms
 Gas turbines, rocket motors/engines, and space craft
 Pollution control equipment
 Nuclear reactors
Here look at five industrial applications that use Inconel alloys.
 Aerospace and Jet Engines
Nickel alloys are a natural choice within the aerospace industry. Engine
parts, in particular, are exposed to high temperatures and high pressure. Materials
need to be able to withstand this environment and retain their strength and
integrity. Nickel alloys exhibit low expansion at these high temperatures, offer
creep resistance under high-stress conditions, and are corrosion resistant.
Inconel 600, for example, is used for jet engine and airframe components,
such as lockwire, exhaust liners and turbine seals. While Inconel 601 has such high
mechanical strength and is so easy to work with, making it useful across a broad
range of aerospace applications.

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 Oil And Gas Extraction
One of the key industrial applications for Inconel alloys is in oil and gas
extraction. There are many factors to consider in this sector for design engineers
when it comes to material selection. Temperatures can be very high and the raw
substances being processed or stored are volatile and corrosive.
Superalloys such as Inconel 625 are utilised for the separation of extracted
fluids in the processing systems for liquefied natural gas production. This material
offers outstanding fatigue and thermal-fatigue strength, as well as good oxidation
resistance, high tensile, creep and rupture strength, and excellent weldability. It’s
often employed to line steel transfer piping in sour gas and gas extraction
equipment.
 Pollution Control And Waste Processing
Pollution control and waste processing are difficult environments where
materials need to work hard. There are naturally hazardous and corrosive
substances that need to be stored, moved and processed. The alloys used in waste-
processing systems must therefore have excellent resistance to both oxidising and
reducing acid solutions, as well as resistance to the high temperatures involved in
operations without losing structural integrity or strength.
One useful alloy in this area is Inconel C-276, which has excellent corrosion
resistance in these kinds of environments. It has a high amount of molybdenum
present (15-17%), which gives this alloy particular resistance to pitting and crevice
corrosion. It also maintains a low carbon content, which minimises carbide
precipitation during welding to ensure it keeps its corrosion resistance in as-welded
structures.
 Automotive
Car engines are delicate beasts. They generate a lot of heat, but need to be
reliable and lightweight. As the car industry evolves, engineers are continually
sourcing materials that can keep up with the technological advancements and drive
to deliver the ‘next big thing’ in cars. As well as more power and greater thrust, car
engines also need to be fuel-efficient and control pollution levels – it’s no mean
feat to balance all these requirements.
The right materials, therefore, are essential. This is another area where
Inconel 625 comes in useful, such a versatile material that it is. High-performance
cars and supercars often use this nickel alloy for exhaust couplings, for example.

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Inconel alloys are also used in the ignition systems, sensors, safety devices and
electrical switch gear.
 Marine Industry
There are a number of seawater applications of Inconel alloys. On offshore
platforms, for example, or in the power and processing plants that use seawater as a
coolant. Seawater systems are highly corrosive environments and yet it is essential
to use materials that will not degrade under these conditions.
Inconel alloys perform well in such extreme situations. For example, the old
favourite Inconel 625 is used in wire rope, propeller blades, propulsion motors and
sheathing for undersea communication cables. Other uses for the Inconel alloy
range include down-hole equipment, platform risers, hangers and high-strength
fasteners.

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CHAPTER III

CLOSING

3.1 Conclusion
Inconels are a class of nickel-chrome-based super alloys characterized by high
corrosion resistance, oxidation resistance, strength at high temperatures, and creep
resistance. There are many different varieties of Inconel’s, each has a different
composition. While each variation of Inconel has unique traits that make it effective in
different circumstances, the majority of the alloys are used frequently in the industry.
There are the types of Inconel that is frequently used, including Inconel 601, Inconel
625, Inconel 690, Inconel 718, Inconel 722, and many more. Inconel alloys can be used
for a wide variety of industrial applications:
 Aerospace and Jet Engines
 Oil And Gas Extraction
 Pollution Control And Waste Processing
 Automotive
 Marine Industry, etc.

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BIBLIOGRAPY

Material Matters Vol 2 No.4 Advanced Metals and Alloys. Sigma-Aldrich Corporation: USA
https://en.m.wikipedia.org/wiki/Inconel
https://markforged.com/blog/inconel-vs-stainless-steel/
https://www.marlinwire.com/blog/inconel-use-case-examples
https://www.corrotherm.co.uk/blog/5-applications-of-inconel-alloys
https://www.chemistrylearner.com/inconel.html

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