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History of Haynes International, Inc

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History of Haynes International, Inc History of Haynes International, Inc. By Charlie Sponaugle Haynes International, Inc. The story of Haynes Interna- much additional experimentation tional spans almost a century. In- he was successful, and was awarded tertwined with the 94 years of two patents in 1907, one for the Haynes’ continuous operation is the nickel-chromium alloy and one for history of many nickel — and co- the cobalt-chromium alloy. Subse- balt-based superalloys. Tracing the quent work produced other cobalt- evolution of these unique materi- based alloys with additions of mo- als, we will follow their applica- lybdenum and tungsten. Patents on tions in aerospace, rockets to Mars, these new alloys were granted in world wars, the chemical industry, late 1912 and Haynes began to set and medical prosthetics. up a manufacturing site. Haynes The company was formed in called these alloys “Stellite”. This December, 1912 by Elwood Haynes name came from the Latin word in Kokomo, Indiana. Elwood “stella” for star because of their Haynes was an inventor, teacher, star-like luster. (Stellite is a regis- experimenter, businessman, and tered trademark of Deloro Stellite, philanthropist. He was born in Port- Inc., Belleville, ON, Canada.) land, Indiana in 1857 and received While Haynes was targeting us- his education at Wooster Polytech- age in cutlery, dental instruments, nic Institute and John Hopkins and edged tools, their real value was University. His post graduate work found in lathe tools. Cutting tools at John Hopkins provided the ba- made from “Stellite” would outlast sis for his successful metallurgical other products, and most impor- work that followed. tantly would allow cutting speeds After a short early career as a three times as fast as the best avail- The business was sold to Union In the early 1920s research was teacher, Haynes entered the oil and able high speed steel tools. Carbide in April, 1920 and this also being conducted on nickel- gas industry. It was during this time The first name of the company marked the start of the second chap- molybdenum alloys for corrosion that Haynes ideas for a “horseless was Haynes Stellite Works. In the ter of the company’s history. resistance. This research was car- carriage” were developed. Haynes early years of the company, Haynes The first few years of Union ried out at Union Carbide’s R&D moved to Kokomo in December of continued experimentation with Carbide & Carbon (UCC) owner- facilities at Niagara Falls and 1892 and found time to work on his cobalt-based alloys. He was granted ship were difficult for all parties. marked the beginning of the nickel- “horseless carriage”. His first au- a patent for a cobalt-chromium- Being owned by a “group of east- based superalloy industry. A patent tomobile, the “Pioneer”, was suc- molybdenum-tungsten-carbon al- ern capitalists” was a challenge in was obtained on a nickel-molybde- cessfully tested July 4, 1894. While loy in 1913, now known as small-town Kokomo. num alloy composition range in there is some dispute as to who the Haynes® alloy 6B, that has been 1921. From this came Hastelloy® honor of the first automobile in the in continuous production since its The Union Carbide Era A alloy and two years later, United States goes to, (J. Frank discovery. Patents were granted for Union Carbide’s interest in Hastelloy B alloy. The unique com- Duryea tested a horseless carriage other cobalt alloys as well. Haynes was a result of Haynes be- position of Hastelloy B is still be- in September, 1893), the success of The business was incorporated ing a customer of various ing manufactured today. About the “Pioneer” led Haynes to form in October, 1915 as Haynes Stellite ferroalloys provided by UCC. Af- 1926 work was beginning on an automobile company producing Company. Over the course of the ter the First World War ended sales nickel-molybdenum-chromium al- high-end automobiles through the next year revenues for “Stellite” had fallen and profitability was re- loys for improved corrosion resis- mid 1920s. alloy exceeded $1,000,000. The stored by 1925. Research continued tance in oxidizing environments. It was during 1887 that Haynes company began to expand rapidly on the cobalt alloys, expanding into From this research Hastelloy C was began experimenting with metals in and had 20-25 employees in 1916. hard-facing products. New alloys born. Today the fifth generation of search of a material that would re- By 1918 sales were about included trade names such as J- this alloy (Hastelloy C-2000®) is sist tarnishing and be suitable for $3,600,000. The reason for the Metal, Star-J, and Haynes Stellite being supplied to the chemical pro- cutlery. After a number of years of growth was the First World War and 98M2. There was considerable cess industry by Haynes Interna- unsuccessful experiments, he began the demand for lathe cutting tools. competition in the hard-facing mar- tional. Hastelloy D, a nickel-sili- working with nickel-chromium and By 1920 employment was up to ket with the Stoody Company dur- con-copper alloy was also invented cobalt-chromium alloys. After about 125 people. ing this time. during the 1920s. Pittsburgh ENGINEER 7 The History of Haynes International, Inc. continued The company weathered the de- products were finished by outside pression years selling its hard-fac- rolling mills. The new wrought al- ing alloys in industrial and agricul- loy plant was situated on about 100 tural applications and the new acres of land south of the main plant Hastelloy alloys in the growing location. This new facility included chemical process industry. During rolling equipment for the produc- this time new melting technology tion of plate and sheet products. was moved to Kokomo from Union New high temperature wrought Carbide’s facility in Niagara Falls, alloys were also being added. NY. It was about 1940 that the first MULTIMET® (a nickel-cobalt- wrought versions of the Hastelloy chromium-molybdenum-tungsten alloys were being developed and alloy) appeared in 1949 and in 1950 rolled at Ingersoll Steel and Disc the cobalt alloy L-605 (now called Company in New Castle, Indiana. Haynes alloy 25) was first manufac- The 1940s were the beginning tured. These alloys found increas- of a new era for the company. The ing usage in aircraft superchargers second world war would alter the and in the newly invented jet engine. company’s future much as the first The invention of a new nickel- world war had done. One of the based alloy, Hastelloy X, in 1953 growing applications for Stellite marks the beginning of the next was investment cast turbine blades chapter in the company’s history. The 1960s were characterized Along with advances in melting (or buckets). These blades were by advances in superalloy metal- technology and the subsequent re- used in the superchargers for mili- The Expansion Era lurgy, particularly the introduction finement in superalloy capabilities, tary piston engines on a number of In many respects the 1950s of Argon Oxygen Decarburization the 1960s brought a new cold strip planes. Over 25 million buckets marks the beginning of significant (AOD) and Electro Slag Remelting mill to the company. This mill gave were produced for the war effort. change for the company. New al- (ESR). AOD processing allows for the company greatly expanded ca- Haynes Stellite alloys 21 and 31, loys, led by Hastelloy X, were be- the manufacturing of alloys with pabilities and capacity in the produc- both cobalt-based, were used in this ing invented, and new applications very low levels of carbon. This pro- tion of sheet, coil, and strip prod- application about 1941. Haynes were being found. In the case of cess is similar to decarburizing steel ucts. The growing aerospace market Stellite was the premier investment Hastelloy X, it was the right alloy with an oxygen lance. The ESR pro- was a big user of sheet material and casting house in the US at this time the new strip mill was the right capi- and supplied about 70% of the tur- tal expansion at the right time. As in Even though the nickel and cobalt bine buckets used. “ past wars, the Vietnam conflict used Another application using both metallurgy field has been thoroughly substantial amounts of products pro- the Stellite alloys and the new duced in Kokomo, Indiana. Ironi- researched over the last 100 years, Hastelloy alloys was search light cally, one of the major applications reflectors for the US Navy. These there are still innovations to be found. was for helicopter rotor shields made metallic reflectors were shatter- ” from Haynes alloy 6B, which was proof and maintained a high luster at the right time. Just as the alloy cess is a second melting operation invented by Elwood Haynes before even in saltwater environments. was being introduced, Pratt & that refines the cast structure and re- the first world war. These reflectors were made from Whitney was looking for a replace- moves impurities. These improve- plate rolled by outside conversion ment material for a failed combus- ments allowed the development of The Modern Era sources using billet melted in tor can in their new JT-3 jet engine. a new class of superalloys for both In January, 1970 Union Carbide Kokomo. Another factor in the Hastelloy X was tested and per- high temperature and corrosive ap- sold the company to Cabot corpo- growth of the company during the formed very well. It was chosen for plications. The most notable were ration, ending fifty years of owner- 1940s was the large amount of the JT-3 and the later JT-8D engines, Hastelloy C-276 and Haynes® 188 ship by UCC.
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