HIGH PERFORMANCE ALLOYS

Technical Information
CAST HASTELLOY ALLOYS: CORROSION PROPERTIES AND CHARACTERISTICS
In many industries, nickel-base alloys represent an important segment of structural materials. Critical components made of these alloys are relied upon to function satisfactorily in corrosive services. The demand for safe, reliable and cost-effective performance requires that these nickel-base alloys provide the anticipated corrosion resistance. Corrosion-resistant high alloy castings are often the subject of major concern because failures of cast components have led to significant downtime costs 1 and operating problems. Nickel-base alloy castings are no exception. Premature failures of castings have been encountered in chemical processing, pulp and paper, hazardous waste treatment, metal finishing and flue gas desulfurization services. It is generally accepted that poor quality castings is one main cause of premature failure. To assure quality castings, specifications are an important factor. However, ASTM and ASME specifications that cover castings are not always adequate. 2 Additional specifications must be supplemented in order to avoid lower than expected corrosion resistance.

Premature failure of CW 12 MW (Ni-16Cr-16Mo-4W) Casting

It is recognized that cast components made of the same alloy designation do not always provide similar performance, due to compositional segregation. As such, upto-date technical information on properties and characteristics of specific alloys might be helpful to end-users and component suppliers in their endeavor to procure quality castings.

1. Performance and Reliability of Corrosion-Resistant Alloy Castings, Materials Technology Institute, Manuals No. 5 & 6, 1981. 2. A Reliable Base for High-Nickel Equipment, J.L. Gossett, Chemical Engineering, p. 145, May 1989.

H-2095A

1992, by Haynes International, Inc.

"HASTELLOY" FAMILIES
The first HASTELLOY alloys were introduced more than sixty years ago. Since then, several families of HASTELLOY alloys have been used (cast* and/or wrought) in a wide range of corrosive services.

HASTELLOY Family Alloy Alloy Alloy Alloy Alloy Alloy Alloy A B C D F G X

Nominal Chemical Composition (Wt %) Ni Ni Ni Ni Ni Ni Ni 20 30 16 10 20 20 22 Mo - 20 Fe Mo Cr - 16 Mo - 4 Si - 2 Cu Cr - 6 Mo - 20 Cr - 6 Mo - 20 Cr - 9 Mo - 18

W Fe Fe - 2 Cu Fe

HASTELLOY alloys have been the subject of continuing research and development, aimed at improving their corrosion resistance and mechanical properties. However, like other alloys, the key to successful use of HASTELLOY castings is microstructural quality. Castings of high alloys are often prone to sensitization: i.e., precipitation of both carbides and intermetallics. These precipitates at grain boundaries (and their corresponding depleted zones) represent an easy path for accelerated intergranular corrosive attack. About 50% of premature service failure can be related to intergranular corrosion 1 , which in turn is often caused by compositional effects and inappropriate casting techniques or heat treatments.

Accelerated Intergranular corrosion of high carbon/high silicon alloy C casting (CW 12 MW), improperly heat treated

Cast HASTELLOY alloys are not produced by Haynes International, Inc., which specializes in wrought products. Castings of alloys within some of the HASTELLOY chemistry designations may be produced by various foundries. However, only foundries licensed by Haynes (with approved quality control programs) have the right to produce and market HASTELLOY castings. Contact Haynes for the names of such licensees. 2

C-FAMILY OF HASTELLOY ALLOYS

The C-Family of alloys are the most commonly used HASTELLOY products in corrosive services. Four generations of C-Family alloys have been developed since the introduction of the original HASTELLOY alloy C in 1932. HASTELLOY Development Cast Alloy Date Description C C-276 C-4 C-22 * Maximum 1932 1967 1975 1985 C C C-4C C-22 Grade Designation CW 12 MW CW 12 MW CW 2 M CX 2 MW Composition (Wt%) Mo W C Si 16 16 16 13 4 4 3 .12* .12* .02* .02* 1 .0* 1 .0* .8* .8*

Cr 16 16 16 22

With better understanding of the alloys physical metallurgy, along with advances in melting techniques, the C-Family chemistries have been refined. This has resulted in enhanced thermal stability (reduced sensitization due to precipitation of carbides and intermetallic phases) and improved mechanical properties, weldability and resistance to various forms of corrosion. Lower carbon and silicon levels have been adopted, as well as modifications of chromium and molybdenum/tungsten contents.

Tests conducted on C-family castings allow comparison of their relative resistance to aqueous corrosion. The continuing enhancement in resistance to corrosion is demonstrated by the trend toward lower corrosion rates with the C-4C and C-22 chemistries.

Cast & Annealed

Corrosion Rates (mils per year) ASTM ASTM 10% HCl 10% HNO 3 G-28A G-28B Boiling Boiling 1832 2149 27 860 233 691 808 469 117

C/C-276 (CW 12MW) 1057 C-4C (CW 2M) 195 C-22 (CX 2MW) 71

The improvement is even more evident when evaluating the resistance to localized corrosion. The pitting resistance of the C-Family castings is successfully enhanced, based on the adoption of C-22 chemistry.

Cast and Solution Annealed HASTELLOY C-Family of Alloys (1X) 24-hour exposure; Boiling 10% FeCl 3 C/C-276 (CW 12MW) C-4C (CW 2M) C-22 (CX 2MW)

In addition to improved corrosion resistance, the C-22 alloy is much more ductile than its predecessors, enhancing ease of weld repair, and reducing the chances of mechanical failure in service.

Cast &

Typical Tensile Properties Yield Ultimate Elongation

Annealed

(ksi)

(ksi)
88 80 81

(%)
20 50 60

C-276 (CW 12MW) 47 C-4C (CW 2M) 38 C-22 (CX 2MW) 41

QUALITY ISSUES Like other alloy castings, the aforementioned improvements in HASTELLOY C-family are often unrealized in poor quality castings. When expressed in terms of corrosion rates, quality is highly influenced by metallurgical factors (composition, heating/cooling), casting techniques (melting, pouring, cleanliness) and post cast treatments (hot/cold forming, weld repair, machining). Microstructural quality is a key to attain optimum corrosion resistance. In a compositional sense, silicon and carbon are critical. Silicon, for example, should be held well below the specification maximum, for better resistance to corrosion (despite some adversity to casting characteristics, such as fluidity).

Castings of Ni-22Cr-13Mo-3W-3Fe Corrosion Rates (mils per year) Silicon Wt.% 0.03 0.51 0.67 0.87 10% HCl Boiling 614 1,421 2,292 3,779 ASTM G-28A 41 119 149 211

Casting of Ni-22Cr-13Mo-3W-3Fe (CX 2 MW) 0.03% Si (Good) 0.67% Si (Bad)

For optimum corrosion and mechanical properties, solution annealing should be performed at appropriate temperatures, and water quenching is essential. Long annealing times at lower temperatures may give satisfactory results, but annealing temperatures of less than 2150F (1177C) can be detrimental to some of the HASTELLOY Cfamily castings.

Casting of Ni-22Cr-13Mo-3W-3Fe (CX 2 MW) As-Cast Under Anneal Proper Anneal

If weld repair of castings is necessary, an upper interpass temperature should not be exceeded. If at all possible, castings should receive a post-weld anneal. A variety of wrought welding consumables is available for various HASTELLOY C-family castings. To avoid the presence of non-metallic inclusions, a protective gas cover or slag over the molten metal is necessary. For investment castings of C-22 alloy (CX 2 MW), the pouring temperature is critical, and special de-oxidant additions should be made. Since these alloys have a strong tendency to form oxide films, the flow rate during the filling of the mold should be within specific ranges.

Non-Metallic Inclusions

Care should be taken to avoid the contamination of surfaces prior to solution annealing. Contamination with organic compounds leads to carbon diffusion, and deleterious near-surface precipitation.

Casting of Ni-16Cr-16Mo (CW 2 M) 0.01% C (Bulk) 0.11% C (Surface)

CLOSURE Performance and reliability of HASTELLOY castings are quality dependent. Undesirable performance and unexpected, premature failures can be attributed to microstructural variations due to metallurgical factors, casting techniques and post-cast treatments. Existing specifications on HASTELLOY castings are broad and do not assure an adequate control of microstructural variations. Procurement of quality castings should be made in accordance with well defined specifications along with additional information (e.g., audited practices and corrosion test acceptance) developed by foundries well experienced in HASTELLOY products.

q High quality, AOD refined, remelt bar of HASTELLOY C-Family (CX 2 MW, CW 2 M and CW 12 MW) is available from Cannon-Muskegon Corp., Muskegon, Michigan. Technical information concerning casting procedures is provided by Mr. Theodore Klemp III, (Tel.: 616-755-1681). q Questions relating to the physical metallurgy, properties and performance of HASTELLOY alloys should be directed to either Dr. Paul Crook (Tel.: 317-456-6241) or Mr. Bill Silence (317-456-6201) at Haynes International, Inc., Kokomo, Indiana. 6

STANDARD PRODUCTS
By Brand or Alloy Designation: HASTELLOY

Family of Corrosion-Resistant Alloys

B-2, B-3 , C-4, C-22 , C-276, C-2000 , D-205, G-3, G-30, G-50 and N

HASTELLOY Family of Heat-Resistant Alloys

S, W, and X

HAYNES

Family of Heat-Resistant Alloys

25, R-41, 75, HR-120, 150, HR-160, 188, 214, 230, 230-W, 242, 263, 556, 625, 718, X-750, MULTIMET and WASPALOY

Corrosion-Wear Resistant Alloy

ULTIMET

Wear-Resistant Alloy
6B

HAYNES Titanium Alloy Tubular

Ti-3Al-2.5V

Standard Forms:
Bar, Billet, Plate, Sheet, Strip, Coils, Seamless or Welded Pipe & Tubing, Pipe Fittings, Flanges, Fittings, Welding Wire and Coated Electrodes

Properties Data:
The data and information in this publication are based on work conducted principally by Haynes International, Inc. and occasionally supplemented by information from the open literature, and are believed to be reliable. However, we do not make any warranty or assume any legal liability or responsibility for its accuracy, completeness or usefulness, nor do we represent that its use would not infringe upon private rights. Any suggestions as to uses and applications for specific alloys are opinions only and Haynes International, Inc. makes no warranty of results to be obtained in any particular situation. For specific concentrations of elements present in a particular product and a discussion of the potential health effects thereof, refer to the Material Safety Data Sheet supplied by Haynes International, Inc.

For More Information Contact:

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