Inconel 625- Significance in the industrial applications

Inconel 625 has been in use for about a century. Originally it was made for use in
the ultra-critical steam piping, it is regularly being used in the latest applications
and increased demand every year. This post includes the few of industries that
are using Inconel 625 as a chief material and will describe its success. Upgrade
in the material treatment are noticed and featured. These upgrades are
developing better understanding of the specialties of alloy and discovering new
applications.
About Inconel 625
Inconel alloy 625 was made in 1960s, its chemical composition is stated in the
following table:
Ni
61

Cr
21.5

Mo
9

Nb
3.6

Fe
2

C
0.05

Si
0.2

Al
0.2

Ti
0.2

Mn
0.2

S
0.00
1

The traditional applications of alloy 625 are in seawater, aerospace, and

chemical processing plants. In the present time, these industries use a large
volume of alloy annually. This post evaluates the current use of alloy in the
specific applications and its significance in the future applications.
Chemical composition of other alloys
Alloy

Ni

Cr

Mo

Nb

Al

Ti

Si

Fe

SS 316

12

17

2.5

0.08

Rem

SS 321

11

18

0.08

Rem

Incoloy
800
Incoloy
825
Inconel
600
Inconel
617
Inconel
625 LCF
Inconel
690
Hastelloy
C276

32.5

21

0.2

5x
C
-

0.05

Rem

42

22

0.4

0.05

Rem

76

15

0.5

Rem

52

22

1.2

0.08

0.5

61

21.5

3.6

0.2

0.03

0.15

Rem

62

28

0.2

0.01

0.1

Rem

57

16

16

0.01

0.08

Rem

Other
elements
Manganese 1
%
Manganese
2%
Manganese
1.5 %
Manganese 1
%
Nitrogen 0.02
%
Manganese
0.1
Tungsten 4

Inconel 625 has become a first choice material for waterwall overlays and
superheater tubings in the waste to energy steam boilers.

Corrosion resistance of alloy 625

The composition of alloy 625 offers it resistance to an extensive types of
corrosive conditions. In the mild conditions such as ambient media, fresh and
marine water, neutral salts and alkaline media, Inconel 625 is completely attack
resistant. In the aggressive conditions, chromium prevents attack of oxidizing
media. Additionally the presence of nickel and molybdenum makes it to prevent
the attack in the reducing conditions. Due to high content of molybdenum,
Inconel 625 is particularly resistant to pitting and crevice attack. The content of
niobium makes it stabilized against sensitization while welding, hence it avoids
resulting intergranular corrosion. the resistance to chloride ion stress corrosion
cracking is received by the presence of concentrated nickel. This extensive
corrosion resistance makes alloy 625 a common material for use in the variety of
corrosive conditions. To describe the flexibility of this alloy, this posy evaluates
the existing and recent applications of this material such as in refineries, waste
to treatment incinerators and in automotive exhaust units. It is understood that a
wide featuring of the functionality of alloy 625 was shown in 1991.
Petroleum Refinery Applications of Inconel 625: The modern uses of sour crude
feedstocks and emphasis on the high production rates have proven the
conventional materials inefficient and process changing solutions in the standard
refineries. For instance, A refinery in the West Coast recently obtained wide
attack in its tower, overhead condenser and transfer lines because of extensive
throughout of sour crude through their desalter. This throughput results into wide
chloride transfer down-stream that hydrolyzed to hydrogen chloride that caused
the failure of component.
Inconel 625 is a crucial material for refineries for preventing attack of napthenie
acid attack, decreasing polythionic acid based stress corrosion cracking or
chloride induced SCC within specific temperature limits as well as by preventing
attack in oxidizing and reducing media at the elevated temperature.
Attack of Naphthalenic acid and hydrogen chloride in distillation systems- The
refineries in the various areas across US and Middle east suffer from attack by
napthenic acid and sulfur compounds. The acidic attack is most common when
the process stream temperature reaches 220oC to 400oC and at the high steam
speed. This particularly occurs in the transfer line nozzles and return bends. The
issue becomes worst in the vacuum and atmospheric distillation plants and to
some level in the thermal cracking systems. It has been seen that molybdenum
containing alloys are suitable in preventing attack of naphthenic acid and the
resistance improves with increase in the concentration of molybdenum. A
refinery showed considerable service of Inconel 625 welding electrode in nozzles
that supply heated crude to the vacuum tower. Earlier these nozzles got
extensive attack of napthenic acid under high velocity steam. Another refinery
installed alloy 625 clad steel for the renovation of an environmental tower. The
filter metal and electrodes of alloy 625 are commonly used in the production of
distillation tower for their approximately similar coefficient of thermal expansion

with the underlying steel and their potential to handle iron dilution without
corrosion.
Overhead Condensers:
The material choice for the overhead condensers is based on the source of
quenching water, chloride concentration, inhibitors contribution, suitable pH
control and speed of water. Alloy 625 is fit for use. Choosing a material of an
application is based on the ammonia magnitude on the stream side, hydrogen
chloride and hydrogen sulfide.
90/10 cupronickel tubes were used while the renovation of battery condensers
that is attacked by ammonia hydrosulfide and hydrochloride corrosion of the
steel shells. Increase in the chloride content, escaping the crude desalter, as
stated will enhance the service of alloy 625 filler metal overlays in overhead
condensers and transfer lines.
Hydrotreatment and hydrocracking plants:
Hydrotreating involves the use of hydrogen to eliminate sulfur and nitrogen from
engine fuels. It leads to the production of hydrogen sulfide that causes elevated
temperature corrosion and ammonia and its sulfide can cause low temperature
attack and erosion corrosion. moreover, stress corrosion cracking attack occurs
during the off times. Hydrogen cracking pairs desulfurization with cracking to
change the complete feedstocks to significant products. The corrosion issues are
equivalent in hydrotreating and hydrocracking plants. However various alloys
suitably prevent attack of hydrogen sulfide in the general service temperature of
hydrotreating and hydrocracking procedures, but most of them are not fit for
preventing SCC and intergranular attack. The outcomes of the common alloys
employed in the hydrotreaters and hydrocrackers are stated in the following
table
Alloy

SS 321
Alloy 800
Alloy 825
Alloy 625

SCC results
Time required
for initial crack
in hours
No sign of
cracks
5
No sign of
cracks
No sign of
cracks

Time for complete

damage in hours
No damage in 72
hours
30
No damage in 72
hours
No damage in 72
hours

Intergranular attack results

Corrosion rate Corrosion rate
(mm/yr)
(mpy)
3.5

137

42.4
0.3

1668
13

1.4

55

Inconel 625 is selected on the base of its proven corrosion resistance,

mechanical strength and resistance to fatigue.
Welding in refinery

Use of Inconel 625 for welding is not uncommon in the refinery for different
attributes. It has similar coefficient of expansion as of various steels, and it easily
welds with the different metals, additionally alloy 625 has excellent corrosion
resistance properties. following table shows its beneficial factors for using as
welding products.
Use in refineries
Crude transfer lines &
nozzles

Welding product
Inconel 625 filler metal,
welding electrode

Atmospheric towers

Inconel 625 filler metal

Overhead condensers

Inconel 625 filler metal

Hydrotreaters and
hydrocrackers

Inconel 625 filler metal

and welding electrode

Hydro treating air

quenchers

Inconel 625 filler metal

and welding electrode

Advantages
Prevents SCC and chloride
induced SCC, elevated
temperature sulfidation,
Napthenic acid corrosion
Prevents attack of HCl, H2S,
SCC and chloride based SCC
Prevent attack of HCl, H2S,
SCC and chloride based SCC
Small coefficient of
expansion, iron dilution
without failure, resistance to
SCC
Resistance to sulfidation,
ammonium hydrosulfide,
resistance to erosion based
corrosion and SCC.

Waste to energy boiler tube applications

The use of alloy 625 in waste to energy boilers started in 1991. It is discovered
that the solid waste consist of high content of halides. As the nickel based super
alloys offer excellent performance in the halogen media, use of alloy 625 with
other alloys in the lab simulated WTE (waste to energy) conditions was purposed.
The service temperature limit taken was about 593 927oC or 1100oF to 1700oF.
It was a common temperature limit for the flue gas temperature measurements.
Boiler internals and flue stacks were supposed to get thermal exposure at such
temperature limits. The testing media included nitrogen and carbon dioxide
gases, HCl and HBr and sulfur dioxide. There were no residuals occurs in the
tests. The test results are mentioned in the following table.
Mass change data in the above stated conditions after 300 hours at the different
temperatures.
Alloy
SS 316
Incoloy
800
Incoloy
825
Inconel

593oC,
1100oF
-5.48
mg/cm2
-.53 mg/cm2
-1.53
mg/cm2
-0.32

704oC,
1300oF
-152.08
mg/cm2
-245.22
mg/cm2
-127.34
mg/cm2
-0.98 mg/cm2

816oC,
1500oF
-32.75
mg/cm2
-6.63 mg/cm2
-8.52 mg/cm2
-6.03 mg/cm2

927oC,
1700oF
-45.74
mg/cm2
-18.98
mg/cm2
-25.89
mg/cm2
-10.18

600
Inconel
625

mg/cm2
-0.52
mg/cm2

-2.06 mg/cm2

-5.86 mg/cm2

mg/cm2
-5.91
mg/cm2

In the alloys containing high content of iron, peak mass alter seems to be related
with the production of FeCl2 (melting point of 696oC or 1285oF). The corrosion
rates decrease earlier at temperatures higher than melting point of FeCl2
because of volatization of the molten form however the higher temperatures
start rising. The nickel based super alloys attain increased corrosion rates with
rising temperatures. Thereafter, the condition factors are chanced to observe the
temperature and media effects in the waterwall component of a boiler. The
outcomes are described in the following table:
Mass variation for specific alloys in nitrogen-oxygen-HCL-SO2 conditions after
1000 hours at the different temperatures:
Alloy
SS 316
Incoloy
825
Inconel
600
Inconel
625

427oC, 800oF,
micro-m/y
-0.07 mg/cm2
-0.02 mg/cm2

482oC or 900oF,
micro-m/y
-2.54 mg/cm2
-1.27 mg/cm2

593oC or 1100oF,
micro-m/y
-5.08 mg/cm2
-2.54 mg/cm2

-0.04 mg/cm2

-2.03 mg/cm2

-3.05 mg/cm2

-0.02 mg/cm2

-1.78 mg/cm2

-2.79 mg/cm2

The experiment didnt include the use of ash. The data shows an extensive range
of alloys that may be resistant to the boilers flue gas attack in the waterwall.
The outcomes describe a vast increase in the corrosion rates in the nominal or
absence of oxygen media. Following table describes an influence of coating the
samples with a salt mixture and subjecting them to simulated flu gas conditions
of nitrogen, carbon dioxide, oxygen, HCl and SO3 at temperatures 550oC
650oC or 1022oF to 1202oF for 336 hours. The gas flow rate was about 250
cc/min.
Alloy
Incoloy 825

Subjected at 550oC or
1022oF
.228 mm 5.94 mm/y

Inconel 600

.488 mm

Inconel 690

.413 mm

Alloy C276
Inconel 625

.076 mm
.131 mm

12.72
mm/y
10.77
mm/y
1.98 mm/y
3.42 mm/y

Subjected at 650oC or
1202oF
.893 mm
23.28
mm/y
.547 mm
14.26
mm/y
.354 mm
9.23 mm/y
.143 mm
.087 mm

3.73 mm/y
2.27 mm/y

Use of alloy 625 is not only in the WTE plant boilers for the incineration of the
municipal waste.
Power generation applications
Inconel 625 has been fully used as tubes in the solar center receiver of Rockwell
solar power stations. The hot salt use of this alloy included an eutectic mixture of
potassium and sodium nitrate. It is made to heat the salt effectively up to 635oC
or 1175oF to run the electric generator for the full night.
Automotive applications
Service requirements for automotive power units are becoming extremely
challenging. Elevated temperatures and minimum emission factors with the wide
warranties and demands for higher mileage are making conventional engines to
be accepted partially and more deniable because of increased count of engine
platforms. Alloy 625 is used as a key material in the exhaust system for bellows
part of flexible couplings and exhaust gas recirculation (EGR) tubes.
Flexible coupling & EGR tubes
The flexible couplings for automotive engines have challenging applications as
they are prone to corrosion due to a variety of attacking dynamics that occur in
the routine automobile uses. On the base of design and position in the engine,
the failure factors include corrosion fatigue, oxidation, warm salt attack, fatigue,
SCC, pitting and general attack. Generally, EGR tubes may also be sensitive to
fatigue and attack. It is essential to identify the failure cases and choose the
economical materials. The elevated temperatures and leak free units ensure
above ten years warranted service if used super alloys for example Inconel 625.
The produced bellows are the key components of flexible coupling and should
prevent failure to retain prolong and leakage free service. Bellows thin walls
cannot stand the deep corrosion without affecting its life. following table shows
the outstanding resistance offered by Inconel 625 to warm salt stress corrosion
cracking and intergranular corrosion as compared to the typical stainless steel
grades that are traditionally used for flexible coupling bellows.
Warm salt based stress corrosion cracking for U-bend specimens (15 minutes
heating, 5 minute quenching, 7.5% NaCl + 2.5% CaCl2, immersed)
Alloy

SS 316
SS 321
Inconel 625

Cracking depths, mm, mils, mean of duplicates

At 427oC or
At 586oC or
At 621oC or
800oF, 1387
1050oF, 750
1150oF, 1386
cycles
cycles
cycles
.05, 2
.05, 2
.10, 4
.025, 1
.08, 3.2
.25, 1
0
0
0.025, 1

For a better service as bellows in the automotive engines, fatigue resistance is

crucial. The influence of mill processing factors on the tension and tension

fatigue characteristics of Inconel 625 at temperature limit of 593oC is stated

later.
Aircraft applications
As like the bellows for automotive engines, these are also demanded in the
aircraft gas turbines. Inconel 625 is widely employed for tailpipes, hush kits,
vector nozzles and bellows. It is popular for outstanding resistance to fatigue,
sensitization and keeps high strength. Alloy 625 shows stable performance even
after heating from 593oC to 649oC for about 9,000 hours. The impact hardness
for Inconel 625 is evaluated with Inconel 617, a superalloy popular for its
consistent performance, is shown in the following table:
Temperature

Test time,
Test time,
2200 hours
4400 hours
Room temperature impact results in J/cm2 for Inconel 625
593 oC
1100 of
314
234
649 oC
1200 of
86
49
Room temperature impact outcomes in J/cm2 for Inconel 617
593 oC
1100 of
223
181
649 oC
1200 of
35
35

Test time,
8800 hours
168
31
98
40

So, Inconel 625 is a significant material for the variety of industrial applications.
Heanjia Super-Metals produce alloy 625 in the several standard forms such as
wire, rod, sheet, pipe, tubing, mesh and others. Contact us to receive a quick
quote today.