History of , 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- and one for history of many nickel — and co- the -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 . 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 “”. This December, 1912 by name came from the Latin word in Kokomo, . 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 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- alloys for 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 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 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 , 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 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. Following this trans- Hastelloy alloy used by the Man- which powered the first Boeing 727 alloys. Hastelloy C-276 is now an action, alloy development work hattan Project and the Chemical aircraft. Fifty years later, Hastelloy industry standard alloy for use in the continued vigorously and took ad- Warfare Service. X remains the largest volume nickel- chemical and petrochemical pro- vantage of the advanced capabili- Production during the war years based sheet alloy for gas turbine hot cessing. Haynes 188 remains the al- ties of the new melting and rolling was at an all time high, with em- section components. loy of choice for jet engine after- technologies. New low carbon ployment reaching over 2,000 dur- 1957 saw the installation of 6 burner components in engines like double melted alloys were being ing the second world war and 3,000 new vacuum furnaces in Kokomo. the Pratt and Whitney F-100. The introduced into both aerospace and by the end of the Korean war. This melting technology allowed invention of Haynes 188 allowed jet chemical industry applications. A major milestone occurred in the company to manufacture more engine designers to increase the tem- New markets, such as Flue Gas the late 1940s with the establish- sophisticated alloys, particularly perature in the engine by 300 de- Desulfurization, were beginning to ment of the wrought alloy plant in alloys with additions of aluminum grees F, resulting in substantially use superalloys such as Hastelloy Kokomo. Prior to this, wrought and . greater thrust and performance. C-276 in many critical applications. 8 Winter 2005 Hastelloy B-2, the second genera- 214®, Haynes 242®, Haynes HR- include a new nickel-chromium- an idea to a viable alloy product. tion of Hastelloy B alloy, was in- 120®, Haynes HR-160®, and molybdenum alloy, Hastelloy G- Even though the nickel and cobalt troduced. Hastelloy C-4, designed Haynes 230®. All of these superal- 35®, designed for phosphoric acid metallurgy field has been thor- for the European chemical indus- loys are still in production and have service. Also just being introduced oughly researched over the last 100 try was also brought out. become standard engineering mate- is a new high temperature alloy, years, there are still innovations to Changes in the commercial or- rials in many applications. Haynes 282™ which is an age- be found. R&D remains an impor- ganization were occurring as well. The 4-High allowed the com- hardenable superalloy designed for tant part of Haynes’ business and More and more applications in the pany to produce large continuous hot section components in military new alloys will continue to be in- Chemical Process Industries and hotbands to feed the cold strip and commercial gas turbines. This vented in Kokomo. the Aerospace market were open- mill. Prior to the 4-High, hot bands alloy appears to be a significant im- As the company approaches its ing up in . The company were built up by welding long, provement over existing hot section 100th anniversary, Haynes Interna- opened a service center in Corby, narrow 0.250” plates together end- alloys and will likely develop into tional is a company that lives up to England in 1974 and one in Lille, to-end to form a coil. This method a high volume aerospace alloy. its slogan “A History of Innovation France in 1978. Nickel Contor, a of building up a hotband is still Often research and development Spanning a Century”. service center in Zurich, Switzer- used for some small volume hard- can take several years to go from land, was purchased in 1977. to-make alloys where their metal- The Arcadia tubular manufac- lurgical properties prevent 4-High This article was written with the help of many people. Many of the turing facility in Arcadia, Louisi- hotband rolling. facts cited and many of the quotations come directly from the book ana was started in 1977. Uses for superalloys continued STELLITE — A History of the Haynes Stellite Company 1912-1972, by By 1980 it was clear that the to expand in the 1980s. Millions of Ralph D. Gray. Dr. F. Galen Hodge, associate director of the Materials company had to improve its sheet pounds were specified for flue gas Technology Institute, greatly assisted in the editing of the article and in and coil manufacturing. New appli- desulfurization units at coal-fired the chronology of events. Numerous others also helped with the years cations required better quality con- power plants. Removing sulfur after 1972, when Ralph Gray’s book ends. Many thanks to all who helped. trol and lower costs, and higher ca- compounds from the exhaust gases Some of the trademarks used in the article, along with their owners, pacities were needed for growth. It of coal burning boilers can be very follows: Haynes, Hastelloy, Multimet, C-22, C-2000, G-30, 214, 230, G- was for these reasons that the com- corrosive and nickel-based super- 35, 242, HR-120, HR-160, and 282 are trademarks of Haynes Interna- pany embarked on its most ambi- alloys are used in the “scrubbers”, tional, Inc. Stellite is a trademark of Deloro Stellite, Inc. tious capital expansion project. breeching ducts, and even chimney liners of power plants. Hastelloy C- Installation of the 276, C-22® and C-2000® alloys “4-High” are standard engineering materials In 1980 work began on the in- in these systems. Another interest- stallation of a new 4-High combi- ing application involved the nation plate/hot band Stekel mill. Abrams M-1 Main Battle Tank. This facility would have the ability This tank has a 1500 horsepower to hot roll superalloy plate product gas turbine engine and uses an air- up to 2 inches thick and 72 inches to-air heat exchanger, often referred wide and produce continuous to as the recuperator, to heat intake 10,000 pound hot bands at widths air with the exhaust gases from the up to 48 inches with a thickness of turbine. The recuperator is a plate 0.250” or less. When installation type unit and uses several hundred was finished in 1982, Haynes had pounds of superalloy for each en- a state-of-the-art hot mill that is still gine. Haynes supplied millions of the largest, most powerful 4-High pounds for this application. Stekel mill in the world devoted to the rolling of nickel- and cobalt- Today based superalloys. This mill was Today Haynes International is a designed and installed by George thriving developer and manufac- Tippins of Pittsburgh, PA and fea- turer of superalloys with 8 com- tures a 12 million pound separat- pany-owned service centers around The & Steel Technology ing force. The two mill housings the world. The combination of pri- Conference and Exposition weigh 300,000 pounds each and mary manufacturing facilities with May 1–4, 2006 were cast in Germany. multiple service center locations is Cleveland Convention Center Alloy development was also unique in the superalloy industry. Cleveland, Ohio, USA moving at a fast pace. The early The research and development For More Information or to Reserve Your Booth 1980s saw the introduction of sev- commitment is also quite unique in Visit www.aist.org or contact Geraldine Kane (ext. 639 or [email protected]) eral major alloys including Hastelloy today’s highly competitive environ- or Jeffrey Campbell (ext. 640 or [email protected]) at (724) 776-6040 C-22®, Hastelloy G-30®, Haynes ment. The most recent inventions Pittsburgh ENGINEER 9