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Stainless Steel and Nickel Base

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Stainless Steel and Nickel Base TABLE OF CONTENTS Introduction................................................................................................... 1 Stainless Steels .............................................................................................. 2 Nickel-Base Alloys......................................................................................... 2 Role of Alloying Elements ............................................................................ 3 Chromium .........................................................................................3 Nickel ................................................................................................. 3 Molybdenum ...................................................................................4 Minor Elements ................................................................................. 4 Designations for Cast Stainless Steel and Nickel-Base Alloys................. 5 Corrosion-Resistant Castings ...................................................................... 6 Stainless Steels................................................................................... 60 Martensitic..........................................................................................13 Austenitic............................................................................................16 Duplex.................................................................................................33 Nickel-Base Alloy Castings...............................................................36 Heat-Resistant Castings ...............................................................................46 Stainless Steels ...................................................................................46 Nickel-Base Alloys.............................................................................59 Cr-Ni Alloy and High-Performance Nickel-Base Alloy Castings for Heat-Resisting and Elevated-Temperature Corrosion Applications ...................................................................................... 72 Fabrication .................................................................................................... 74 Casting Methods.............................................................................. 74 Machining ......................................................................................... 78 Welding.............................................................................................. 79 Purchasing Considerations ......................................................................... 80 Works Cited ................................................................................................... 81 Trademarks ................................................................................................... 82 Suggested Additional Reading ................................................................. 82 Appendix A ................................................................................................... 83 Appendix B ................................................................................................... 87 Appendix C................................................................................................... 88 STAINLESS STEELS Stainless steels are distinguished from other steels by a minimum chromium content of 10.5%, which makes them more resistant to corrosive aqueous environments and to oxidation. Although there are exceptions, stainless steel castings are classified as “corrosion-resistant” when used in aqueous environments and vapors below 1200°F (650°C) and "heat-resistant" when used above this temperature. The usual distinction between the heat and corrosion-resistant casting grades is carbon content. For a stainless steel casting to perform well in a corrosive environment, the carbon content must be low. Heat-resistant grades have higher carbon contents to improve elevated temperature strength. NICKEL-BASE The chemical composition and microstructure differences between the wrought and cast ALLOYS versions of stainless steels can affect Except for some of the high silicon and performance. (See Role of Alloying Elements.) proprietary grades, cast nickel-base alloys Some stainless steel casting grades can be generally have wrought approximate precipitation-hardened by heat treatment, but equivalents. Although the cast and wrought the mechanical properties of most rely on their versions of nickel-base alloys are commonly chemical composition. The yield and tensile used in combination because they provide strengths of castings are comparable to their similar performance, there are some chemistry wrought equivalents. differences, primarily to improve castability and Cast stainless steels generally have equivalent soundness. corrosion resistance to their wrought equivalents, Like stainless steels, nickel-base castings are but they can become less corrosion-resistant due categorized as corrosion-resistant if they are to localized contamination, microsegregation, or used in aqueous environments and vapors lack of homogeneity. For example, mold quality below 1200°F (650°C) and heat-resistant if may cause superficial compositional changes they are capable of continuous or intermittent that influence performance, and carbon pick-up use for sustained times above this from mold release agents can affect corrosion temperature. Carbon content is usually a resistance. Heat treatment and weld repair distinguishing factor between the heat and procedures can influence the performance of corrosion-resistant alloys, but this dividing line some cast grades and should be taken into can be vague, particularly for alloys used in the consideration during grade selection. 900-1200°F (480 to 650°C) range. Additional information about the characteristics, Additional information about the properties and applications of specific cast characteristics, properties and applications of stainless steel grades can be found in the specific cast nickel-base alloys can be found in following corrosion and heat-resistant sections. the following corrosion and heat-resistant 2 • Castings ROLE OF ALLOYING ELEMENTS Chromium, nickel, and molybdenum are At elevated temperatures, chromium provides the primary alloying elements that resistance to oxidation and sulfur-containing determine the structure, mechanical properties, and corrosion resistance of and other corrosive atmospheres; contributes stainless steel and nickel-base alloy to high temperature creep and rupture strength; castings. and, in some alloys, increases resistance to carburization. Nickel and chromium have the greatest influence on heat-resistant castings. Intentional additions of less than 1% NICKEL carbon, nitrogen, niobium, tantalum, titanium, sulfur, and slightly larger Nickel in stainless steels promotes the stability additions of copper, manganese, silicon, of austenite. Austenite is stronger and more and aluminum are used to modify stable at higher temperatures then ferrite. Less properties. Some minor elements can nickel is needed to retain an austenitic have a positive or negative effect on structure as the nitrogen or carbon levels properties depending on the application. increase. When sufficient nickel is added to a chromium stainless steel, the structure CHROMIUM changes from ferritic to austenitic. Adding nickel improves toughness, ductility, and A stainless steel contains a minimum of weldability. 10.5% chromium because this level of Nickel increases resistance to oxidation, chromium causes the spontaneous carburization, nitriding, thermal fatigue, and formation of a stable, transparent, strong acids, particularly reducing acids. It is passive, protective film. Increasing the an important alloying element in stainless level of chromium enhances corrosion steel and nickel-base alloys used for resistance. corrosive and high temperature applications. Wollaston Alloys, Inc., Braintree, Massachusetts This 1,500 pound (675 kg) main feed booster pump and a 625 pound (281 kg) adaptor are used on aircraft Castings • 3 Atlas Foundry & Machine Company, Tacoma, Washington Stainless steel pump casings are produced in a variety of sizes and shapes for pipeline, refining, and boiler feed applications. MOLYBDENUM eliminate susceptibility to intergranular corrosion. Molybdenum additions improve resistance to pitting and crevice corrosion in chloride- Nitrogen additions to austenitic and duplex containing environments and corrosion by stainless steels improve pitting resistance and sulfuric, phosphoric, and hydrochloric acids. retard the kinetics of sigma phase formation. The elevated temperature mechanical Additions of sulfur, selenium, and lead in properties of austenitic stainless steels and stainless steel improve machinability. the strength and tempering resistance of Columbium additions can improve high- martensitic stainless steels are improved by temperature creep strength. Copper additions molybdenum. improve resistance to sulfuric acid. A combination of manganese and nitrogen may MINOR ELEMENTS be used as a partial substitute for nickel in some stainless steels. The presence of small amounts of carbon and nitrogen cannot be avoided during melting. In Silicon is added to cast stainless steel grades to some grades, these elements are added increase casting fluidity and improve castability. deliberately. Increasing the carbon content in As carbon plus silicon content is increased, high temperature alloys improves high partial eutectic solidification improves castability temperature strength
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