Nickel Alloy Pipes
Nickel Alloy Pipes
Definition
Nickel Alloy PipesThe defining characteristic of nickel alloy pipes is their exceptional resistance to corrosion, high temperatures, and oxidative attack. They hold up where conventional stainless steel or carbon steel would fail: in concentrated acids, chloride-rich brines, or furnace atmospheres above 1000 °F.
Key Properties Of Nickel-alloy Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Nickel alloys withstand attack from acidic, alkaline, and chloride-containing media. This performance drives their use in chemical processing, petrochemical plants, and seawater service. |
| High-Temperature Performance | Many nickel alloys retain strength, ductility, and oxidation resistance at temperatures that would compromise most other metals. Aerospace, power generation, and heat treatment operations depend on this. |
| Durability | Nickel alloy pipes deliver long service life even under severe operating conditions. Reduced replacement and maintenance frequency translates to lower life-cycle costs. |
| Versatility | The broad range of available nickel alloy compositions allows engineers to match the material precisely to the service environment, from cryogenic to high-temperature, from mildly corrosive to aggressively acidic. |
Major Applications
Nickel alloy pipes see consistent use across industries where corrosion, temperature, or both exceed the limits of stainless and carbon steel.
| Industry | Application |
|---|---|
| Chemical Processing | Handling aggressive chemicals, acids, and solvents at elevated temperatures and pressures |
| Oil and Gas Industry | Downhole tubing, processing equipment, and offshore production, particularly where resistance to sour gas (H₂S) is required |
| Power Generation | Superheaters, re-heaters, and other high-temperature boiler components, including nuclear reactor internals |
| Aerospace | Components exposed to high temperatures and corrosive fuels or oxidizing atmospheres |
| Desalination and Water Treatment | Piping systems that resist chloride-induced corrosion in seawater desalination plants |
Main Types of Nickel Alloys
| Alloy Type/Name | Characteristics | Applications |
|---|---|---|
| Nickel-Copper (Monel®) | Excellent corrosion resistance in seawater; resistant to a range of acids and alkalis; strong and ductile. | Marine engineering, chemical processing equipment, oil & gas valves, and pumps. |
| Nickel-Chromium (Inconel®) | High-temperature strength; excellent resistance to oxidation and corrosion. | Aerospace, nuclear reactors, exhaust systems, high-temperature applications. |
| Nickel-Chromium-Iron (Incoloy®) | Good strength; excellent resistance to oxidation and carburization at high temperatures. | Furnace components, chemical processing, petroleum refining. |
| Nickel-Molybdenum (Hastelloy® B) | Exceptional resistance to reducing acids; highly resistant to stress-corrosion cracking. | Chemical processing industries, especially with corrosive acids. |
| Nickel-Chromium-Molybdenum (Hastelloy® C) | Superior resistance to oxidizing media; excellent performance in mixed acid/chloride environments. | Pollution control, chemical processing, waste treatment. |
| Nickel-Iron-Chromium (Alloy 800/Incoloy® 800 series) | Resistant to oxidation and carburization; moderate sulfur resistance at high temperatures. | High-temperature industrial applications, power generation. |
| Precipitation Hardened Nickel Alloys | Heat treatable for higher strength without compromising toughness. | Aerospace components, oil & gas industry for high-strength, corrosion-resistant parts. |
| Nickel-titanium (Nitinol) | Unique shape memory and superelastic properties; excellent corrosion resistance; biocompatibility. | Medical devices, actuators, and orthodontic equipment. |
| Nickel-Silicon (Ni-Si Alloys) | High strength and electrical resistivity; good corrosion resistance. | Electrical heating elements, resistance wire, control resistors. |
| Nickel-Iron (Alloy 42, Kovar®) | Controlled thermal expansion properties; matches glass and ceramic expansion for sealing. | Glass-to-metal seals, electronic tube components, aerospace and semiconductor applications. |
| Nickel-Chromium-Cobalt (Waspaloy, Haynes®) | Excellent strength at high temperatures; resistance to oxidation and corrosion. | Gas turbine engines, aerospace components, and high-temperature fasteners. |
ASTM Specifications for Nickel Alloy Pipes
| Nickel Alloy Grade | ASTM Specification | Description |
|---|---|---|
| Nickel 200 | ASTM B160, B161, B162 | Pure nickel with excellent corrosion resistance and good mechanical properties. |
| Monel® 400 | ASTM B164, B165, B127 | Nickel-copper alloy with excellent corrosion resistance across a broad spectrum of media. |
| Inconel® 600 | ASTM B166, B167, B168 | Nickel-chromium alloy with strong oxidation resistance at high temperatures. |
| Inconel® 625 | ASTM B443, B444, B446 | Nickel-chromium-molybdenum alloy with outstanding strength and toughness from cryogenic to high temperatures. |
| Hastelloy® C-276 | ASTM B574, B575, B622 | Nickel-molybdenum-chromium alloy with excellent corrosion resistance in severe environments. |
| Alloy 20 | ASTM B473, B464, B468 | Nickel-chromium-molybdenum alloy developed specifically to resist corrosion in sulfuric acid environments. |
| Incoloy® 800 | ASTM B408, B409, B564 | Nickel-iron-chromium alloy with good strength and resistance to oxidation and carburization. |
| Alloy 400 (Monel®) | ASTM B564, B127, B164 | Nickel-copper alloy with high strength and excellent corrosion resistance in acidic and alkaline environments. |
| Nitinol | ASTM F2063 | Nickel-titanium alloy known for its unique shape memory and superelastic properties. |
| Waspaloy | ASTM B637 | Nickel-chromium-cobalt alloy used for its strength and stability at high temperatures. |
| Hastelloy® B-2 | ASTM B333, B335 | Nickel-molybdenum alloy with exceptional resistance to reducing environments. |
| Hastelloy® X | ASTM B435, B572 | High-temperature nickel-chromium-iron-molybdenum alloy with good oxidation resistance. |
Leading Manufacturers
The market for nickel-alloy pipes is far more concentrated than markets for carbon or standard stainless steel grades. Below is a list of well-known manufacturers and suppliers in the industry:
| Manufacturer | Specialty | Website |
|---|---|---|
| Special Metals Corporation | Extensive range of nickel alloys including Inconel, Incoloy, Monel, and Nimonic alloys in a wide variety of forms | specialmetals.com |
| Haynes International | Corrosion-resistant and high-temperature alloys; produces Hastelloy and other nickel-based alloys | haynesintl.it |
| Sandvik Materials Technology | Advanced stainless steels and special alloys (Sanicro) for corrosion-resistant applications; wide range of nickel alloy pipes and tubes | home.sandvik |
| VDM Metals | Broad portfolio of nickel alloys and high-performance materials; innovative alloy solutions for demanding applications | vdm-metals.com |
| ATI (Allegheny Technologies) | Diverse range of specialty metals including nickel-based alloys for high temperatures and corrosive environments (aerospace, oil & gas, chemical processing) | atimaterials.com |
| Outokumpu | Primarily stainless steel; also offers high-performance nickel alloys emphasizing quality and sustainability | outokumpu.com |
| Aperam | Global player in stainless steel and specialty alloys including nickel alloys, focusing on sustainability and innovation | aperam.com |
| Jindal Stainless | One of the largest stainless steel conglomerates in India; also produces nickel alloy products for diverse industrial applications | jindalstainless.com |
Features By Nickel-alloy Grade
Chemical Composition Of Major Nickel-alloy Grades
| Alloy Name | Nickel (Ni) | Chromium (Cr) | Molybdenum (Mo) | Iron (Fe) | Copper (Cu) | Aluminum (Al) | Titanium (Ti) | Carbon (C) | Other Elements |
|---|---|---|---|---|---|---|---|---|---|
| Inconel 600 | 72 | 14-17 | - | 6-10 | - | - | - | 0.15 | - |
| Inconel 625 | 58-63 | 20-23 | 8-10 | 5 max | - | 0.4 | 0.4 | 0.10 | Nb 3.15-4.15 |
| Inconel 718 | 50-55 | 17-21 | 2.8-3.3 | Balance | - | 0.2-0.8 | 0.65-1.15 | 0.08 | Nb+Ta 4.75-5.5 |
| Hastelloy C-276 | 57 | 14.5-16.5 | 15-17 | 4-7 | - | - | - | 0.01 | W 3-4.5, V 0.35 max |
| Monel 400 | 63 min | - | - | 2.5 max | 28-34 | - | - | 0.3 | - |
| Alloy 20 | 32-38 | 19-21 | 2-3 | 31-44 | 3-4 | - | - | 0.07 | Nb 0.1-0.3 |
| Hastelloy B-2 | Balance | 1 max | 26-30 | 2 max | - | - | - | 0.02 | - |
| Incoloy 800 | 30-35 | 19-23 | - | 39.5 min | - | 0.15-0.60 | 0.15-0.60 | 0.1 | - |
| Incoloy 825 | 38-46 | 19.5-23.5 | 2.5-3.5 | 22 min | 1.5-3 | 0.2 max | 0.6-1.2 | 0.05 | Ti 0.6-1.2 |
| Nitinol | 55 | - | - | - | - | - | 45 | - | - |
Please note:
- The percentages are approximate and can vary based on the specific alloy formulation and manufacturer.
- “Balance” indicates that the remaining composition is primarily nickel, after accounting for the specified elements.
- Some alloys may contain additional elements in trace amounts not listed in this table, which can affect their properties and applications.
- “Nb” stands for Niobium, “Ta” for Tantalum, “W” for Tungsten, and “V” for Vanadium, which are elements that can significantly influence the alloy’s characteristics.
This table captures the diverse compositions of major nickel alloys and reflects the complexity of these advanced materials, each tuned for a specific service environment.
Nickel 200/201
Nickel 200 pipes are made from commercially pure nickel that delivers high thermal and electrical conductivity, magnetic properties, and strong resistance to many corrosive media.
With a nickel content of approximately 99.6%, Nickel 200 (UNS N02200) stands out for its resistance to caustic alkalis and corrosive media across a wide temperature range.
Nickel 201 (UNS N02201) is a low-carbon version of Nickel 200, preferred where low gas content and low vapor pressure matter.
Key Properties of Nickel 200 Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Excellent resistance to corrosion by distilled and natural waters, and by many organic substances. Also resists caustic alkalis and acidic media, except oxidizing acids. |
| High Thermal Conductivity | Efficient heat transfer allows use in heat exchangers and similar equipment requiring thermal conductivity. |
| Electrical Conductivity | High electrical conductivity supports electronic and electrical applications. |
| Magnetism | Nickel 200 is magnetic at room temperature, which can be advantageous in certain applications. |
| Fabrication and Weldability | Nickel 200 can be easily fabricated and welded, offering flexibility in manufacturing processes. |
Applications of Nickel 200 Pipes
Nickel 200 pipes serve wherever corrosion resistance and high thermal or electrical conductivity are required simultaneously.
| Industry | Application |
|---|---|
| Chemical Processing | Manufacture and handling of sodium hydroxide, particularly at temperatures above 300 °C where steel would fail by stress-corrosion cracking |
| Food Processing | Food processing equipment and handling of foods, synthetic fibers, and alkalis |
| Electrical and Electronic | Production of electrical components, including leads, battery components, and heat exchangers |
| Aerospace | Components requiring high-temperature resistance combined with thermal conductivity |
| Marine | Marine engineering and desalination plants, leveraging resistance to seawater corrosion |
Considerations and Limitations
Nickel 200 pipes are not recommended where sulfur compounds may induce stress-corrosion cracking. They should also be carefully evaluated for oxidizing acid environments, where higher-alloyed materials may perform better.
For industries that need corrosion resistance together with high thermal and electrical conductivity across a wide temperature range, Nickel 200 remains a strong contender. It serves the chemical processing, food processing, electrical, aerospace, and marine sectors reliably.
Selecting Nickel 200 requires matching its capabilities to the service environment; within those boundaries, it delivers efficient and durable performance.
Monel® 400/500 Pipes
Monel pipes are fabricated from a family of nickel-copper alloys recognized for their strength, corrosion resistance, and durability in aggressive environments. The primary composition (nickel and copper, with small amounts of iron, manganese, carbon, and silicon) yields a combination of properties that few other alloys can match. Monel 400 is the most widely specified grade; Monel K-500 offers enhanced hardness and strength through precipitation hardening.
Key Properties of Monel Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Excellent resistance to seawater, hydrofluoric acid, sulfuric acid, and alkalis. Particularly valued in marine and chemical processing service. |
| Strength | Higher strength than many other nickel alloys, especially at elevated temperatures. Handles high-pressure service well. |
| Toughness | Good toughness over a wide temperature range, including sub-zero conditions where other materials turn brittle. |
| Thermal Conductivity | Good thermal conductivity, beneficial in heat exchange and dissipation applications. |
Common Applications of Monel Pipes
| Industry | Application |
|---|---|
| Marine Engineering | Shipbuilding, seawater intakes, and marine fixtures (excellent resistance to seawater corrosion) |
| Chemical Processing | Transporting corrosive chemicals, manufacturing chemical equipment, and handling organic compounds |
| Oil and Gas | Oil refinery piping, sour gas service, and offshore rig applications |
| Power Generation | Feedwater heaters, steam generators, and other components exposed to corrosive substances at high temperatures |
Grades of Monel and Their Specific Uses
| Grade | Description |
|---|---|
| Monel 400 | The most widely used Monel alloy, offering excellent general corrosion resistance, good weldability, and moderate to high strength. The standard material for marine and chemical processing service. |
| Monel K-500 | Enhanced strength and hardness from aluminum and titanium additions. Used for chains, cables, springs, valve trim, fasteners in marine service, and oil well drilling collars. |
Installation and Fabrication
Monel pipes can be welded, machined, and formed using standard methods, though the material’s work-hardening behavior demands experience. Welding typically calls for Monel filler metal to maintain the same corrosion resistance and strength as the base metal across the joint.
Monel pipes deliver a rare combination of corrosion resistance, strength, and durability under aggressive conditions. Their higher cost compared to standard stainless steel is typically justified by extended service life and reduced maintenance in marine, chemical processing, and offshore environments.
Cupronickel Pipes (90/10 & 70/30 Types)
Cupronickel pipes are made from an alloy of copper, nickel, and strengthening elements such as iron and manganese. The result is a material with superior corrosion resistance in marine environments, along with excellent thermal stability and durability. The two standard compositions are 90/10 (90% copper, 10% nickel) and 70/30 (70% copper, 30% nickel).
Key Properties of Cupronickel Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Excellent resistance to seawater corrosion, including resistance to biofouling, well proven in marine service |
| Thermal Stability | Maintain mechanical properties over a wide temperature range; withstand thermal cycling without degradation |
| Good Fabricability | Easily welded, fabricated, and formed into complex shapes and configurations |
| Antimicrobial Properties | Copper content reduces biofouling and helps maintain cleanliness in potable water systems |
Applications of Cupronickel Pipes
Cupronickel pipes see extensive use across marine and coastal industries:
| Industry | Application |
|---|---|
| Marine Engineering | Shipbuilding piping systems, heat exchangers, and condensers (seawater corrosion resistance) |
| Desalination Plants | Heat exchanger tubing in multi-stage flash distillation (resists corrosion and biofouling) |
| Offshore Oil and Gas | Fire water systems, hydraulic lines, and cooling water circuits on offshore platforms |
| Power Generation | Cooling systems and condensers, especially at coastal sites using seawater as coolant |
| Coinage and Musical Instruments | Production of coins and certain musical instruments (corrosion resistance and aesthetic appeal) |
Fabrication and Machining
Cupronickel pipes respond well to standard metalworking techniques: welding, soldering, and bending. The material work-hardens, so machining requires attention to prevent excessive tool wear. When cupronickel contacts dissimilar metals, use insulating materials or coatings to prevent galvanic corrosion.
Considerations for Use
The choice between 90/10 and 70/30 depends on service conditions and mechanical requirements. The 70/30 alloy generally provides higher corrosion resistance and strength at the expense of slightly lower thermal conductivity and higher material cost.
Cupronickel alloys have earned their reputation in marine and coastal environments through decades of reliable performance. Their combination of corrosion resistance, durability, and thermal stability keeps them in demand from shipbuilding to desalination.
Inconel® 600 Pipes
INCONEL® 600 (UNS N06600) is a nickel-chromium alloy with excellent resistance to oxidation at high temperatures and to corrosion from sulfur compounds and chloride ions.
INCONEL® 600 pipes handle demanding service where both heat and corrosion resistance are needed simultaneously.
Key Properties of INCONEL® 600 Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Outstanding resistance to chloride-ion stress-corrosion cracking, corrosion by high-purity water, and caustic corrosion. Versatile resistance to many organic and inorganic compounds. |
| High-Temperature Resistance | High chromium content provides excellent resistance to oxidation, maintaining strength and resistance to scaling at temperatures up to 2000 °F (1093 °C). |
| Strength | Solid solution strengthening from chromium and nickel delivers high strength and good workability across a broad temperature range. |
| Fabricability | Can be formed and welded readily, accommodating a variety of fabrication processes. |
Applications of INCONEL® 600 Pipes
INCONEL® 600’s combination of high-temperature strength and corrosion resistance puts it to work across multiple sectors:
| Industry | Application |
|---|---|
| Chemical Processing | Reactors and vessels handling corrosive chemicals at high temperatures |
| Heat Treatment | Retorts, muffles, and furnace components (resistance to oxidation and scaling at elevated temperatures) |
| Aerospace | Exhaust liners, turbine seals, and components requiring high-temperature resistance |
| Nuclear | Reactor cores and control rod components (resistance to corrosion by high-purity water) |
| Power Generation | Superheater tube supports and steam generator tubing |
Considerations for Use
Evaluate the specific service environment before specifying INCONEL® 600. The alloy may embrittle when exposed to sulfur compounds at high temperatures. Understanding the operating conditions (temperature, atmosphere, and potential contaminants) is critical for selecting the right alloy for the job.
INCONEL® 600 pipes perform well where high-temperature strength, corrosion resistance, and durability intersect. With correct material selection and maintenance, they deliver reliable service in chemical processing, aerospace, nuclear, and power generation environments.
Inconel® 625 Pipes
INCONEL® 625 (UNS N06625) is a nickel-chromium-molybdenum alloy with a niobium addition that stiffens the matrix, providing high strength without a strengthening heat treatment. The alloy resists severely corrosive environments, high-temperature oxidation and carburization, and maintains high strength and toughness from cryogenic temperatures up to 1800 °F (982 °C).
Key Properties of INCONEL® 625 Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Outstanding resistance to chloride-ion stress-corrosion cracking, reducing environments, and oxidizing conditions. Resists seawater, pitting, and crevice corrosion. |
| High-Temperature Performance | Maintains strength over a wide temperature range with strong resistance to oxidation and carburization at elevated temperatures. |
| Strength and Toughness | High tensile, creep, and rupture strength from cryogenic to elevated temperatures. |
| Fabricability | Can be welded and formed with relative ease, supporting complex designs and installations. |
Applications of INCONEL® 625 Pipes
The corrosion resistance, high-temperature capability, and strength of INCONEL® 625 pipes put them to work across demanding sectors:
| Industry | Application |
|---|---|
| Oil and Gas | Offshore rigs for brine heaters, seawater piping, and underwater equipment (excellent seawater corrosion resistance) |
| Aerospace | Exhaust systems, engine thrust-reverser systems, and special seawater applications |
| Chemical Processing | Reactor cores and control systems where resistance to corrosive substances is required |
| Nuclear Industry | Reactor core and control rod components in nuclear water reactors |
| Power Generation | Superheater tubing and heat exchangers requiring corrosion resistance and strength at high temperatures |
Considerations for Use
Despite INCONEL® 625’s broad capability, each application needs careful evaluation of the specific corrosive agents and the operating temperature range. Select based on a thorough understanding of the environment to fully use the alloy’s properties for long-term reliability.
INCONEL® 625 pipes serve well in oil and gas, aerospace, chemical processing, nuclear, and power generation, wherever corrosion resistance, elevated-temperature capability, and strength all matter. Proper selection and maintenance deliver durable, long-term performance.
Difference between Inconel 600® and Inconel 625® Pipes
Inconel 600® and Inconel 625® are both high-performance nickel-chromium alloys with excellent corrosion and high-temperature resistance. Despite these similarities, they differ significantly in composition, properties, and target applications. Here is a direct comparison:
Composition
| Parameter | Inconel 600 | Inconel 625 |
|---|---|---|
| Nickel | Approx. 72% | Approx. 58-62% |
| Chromium | Approx. 14-17% | Approx. 20-23% |
| Iron | 6-10% | 5% max |
| Molybdenum | - | Approx. 8-10% |
| Niobium | - | Approx. 3.15-4.15% |
| Design Focus | High strength and good corrosion resistance, particularly to alkaline solutions and sulfur compounds | Matrix stiffening via niobium and molybdenum, providing high strength without heat treatment |
Properties
| Property | Inconel 600 | Inconel 625 |
|---|---|---|
| Corrosion Resistance | Excellent overall | Superior; resists a wider range of environments including seawater and chloride ion stress-corrosion cracking (higher Mo and Nb content) |
| High-Temperature Performance | Good | Enhanced resistance to oxidation and carburization in extreme environments |
| Strength and Toughness | Good | Higher tensile, creep, and rupture strength across a broader temperature range, including cryogenic temperatures |
Applications
| Alloy | Typical Applications |
|---|---|
| Inconel 600 Pipes | Furnace components, chemical processing, food processing equipment, and nuclear engineering. Valued for high-temperature service where resistance to sulfur compounds and alkaline solutions matters. |
| Inconel 625 Pipes | More demanding environments requiring exceptional strength and corrosion resistance: oil and gas extraction, marine engineering, aerospace components, and chemical processing equipment, especially under high chloride levels, acidic conditions, or extreme temperatures. |
Hastelloy® C-276 Pipes
HASTELLOY® C-276 is a nickel-molybdenum-chromium superalloy with a tungsten addition. It delivers exceptional resistance to pitting, crevice corrosion, and stress corrosion cracking across a wide spectrum of chemical environments. UNS N10276 is one of the most broadly capable corrosion-resistant alloys available, and pipes manufactured from this material are specified wherever aggressive chemicals are present.
Key Properties of HASTELLOY® C-276 Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Exceptional resistance to strong oxidizers (ferric and cupric chlorides), hot contaminated media (organic and inorganic), chlorine, formic and acetic acids, acetic anhydride, and seawater/brine solutions. |
| High-Temperature Performance | Maintains excellent corrosion resistance at elevated temperatures, though not primarily a high-temperature strength alloy compared to Inconel or Waspaloy. |
| Versatility | Handles reducing through oxidizing chemical environments, outperforming conventional stainless steels and many nickel alloys. |
| Weldability | Can be welded by common nickel-alloy methods, retaining corrosion resistance and strength near welds. Accommodates complex fabrications. |
Applications of HASTELLOY® C-276 Pipes
HASTELLOY® C-276 pipes are specified where other alloys cannot survive the chemical environment:
| Industry | Application |
|---|---|
| Chemical Processing | Reactors, heat exchangers, and columns involving corrosive chemicals |
| Pollution Control | Scrubbers and ducting systems for controlling industrial emissions |
| Pulp and Paper Production | Bleaching processes and other corrosive stages of paper manufacturing |
| Waste Treatment | Systems for processing hazardous and toxic wastes |
| Pharmaceutical Industry | Reactors and equipment that must resist attack from aggressive chemicals |
| Power Generation | Flue gas desulfurization systems for coal-fired power plants |
Considerations for Use
The specific conditions of each application (temperature, pressure, and chemical composition) must be evaluated to confirm that C-276 is the right choice. Its cost exceeds that of many stainless steels and lower-tier nickel alloys, so engineers should confirm that C-276’s advanced corrosion resistance is actually needed before specifying it.
HASTELLOY® C-276 pipes are the go-to solution when the chemical environment is too aggressive for lesser alloys. Their broad corrosion resistance, combined with good weldability and durability, maintains process integrity in chemical processing, pollution control, and waste management, where a pipe failure can shut down an entire operation.
Alloy 20 Pipes (“Carpenter”)
Alloy 20, also known as Carpenter 20 or UNS N08020, is a nickel-iron-chromium austenitic alloy with copper and molybdenum additions. It was developed specifically for sulfuric acid service and performs well in other acidic environments. This focus on acid resistance drives its specification in chemical and petrochemical plants.
Key Properties of Alloy 20 Pipes
| Property | Description |
|---|---|
| Corrosion Resistance | Developed primarily for sulfuric acid; also resists phosphoric acid, nitric acid, and chlorides. The chromium, molybdenum, and copper content together provide resistance to both general corrosion and pitting. |
| Ease of Fabrication | Fabricated like other austenitic stainless steels: welded, machined, and formed using standard methods. |
| Mechanical Properties | Good mechanical properties at both ambient and elevated temperatures, including high strength and toughness. |
Applications of Alloy 20 Pipes
Alloy 20 pipes go where sulfuric acid or similar corrosive media would destroy standard stainless steel:
| Industry | Application |
|---|---|
| Chemical and Petrochemical Processing | Equipment for the manufacture and handling of sulfuric acid and other corrosive chemicals |
| Pharmaceuticals | Processing pharmaceutical products where purity and contamination prevention are paramount |
| Food and Dye Production | Food processing equipment and dye manufacturing (excellent performance in acidic environments) |
| Power Generation | Flue-gas desulfurization systems in power plants where sulfuric acid is a by-product |
| Synthetic Rubber and Plastics | Reactors, mixers, and other equipment handling corrosive materials in production processes |
Considerations for Use
Alloy 20 excels in sulfuric acid service, but for highly oxidizing conditions, alloys with higher chromium and molybdenum contents may be needed. Evaluate the specific temperature, acid concentration, and the presence of other corrosive species before finalizing the material selection.
Alloy 20 pipes fill a specific niche: acid-resistant service, particularly sulfuric acid. Their composition balances corrosion resistance, fabricability, and mechanical properties. Whether handling harsh chemicals in petrochemical plants, maintaining purity in pharmaceutical manufacturing, or resisting acid attack in food processing, Alloy 20 delivers reliable service within its design envelope.
Incoloy® 800 Pipes
INCOLOY® 800 (UNS N08800) is a nickel-iron-chromium alloy engineered for stability, strength, and resistance to oxidation and carburization at high temperatures. These properties make INCOLOY® 800 pipes a standard choice for high-temperature industrial service.
Key Properties of INCOLOY® 800 Pipes
| Property | Description |
|---|---|
| High-Temperature Strength | Maintains structural integrity in high-temperature environments, resisting creep and rupture. Effective up to about 1100 °F (593 °C). |
| Corrosion Resistance | High chromium content enhances resistance to oxidation and carburization, two common forms of high-temperature corrosion. |
| Chloride SCC Resistance | Moderate resistance to chloride stress-corrosion cracking (not as resistant as some other nickel alloys). |
| Thermal Expansion | Relatively low coefficient of thermal expansion compared to austenitic stainless steels; beneficial for dimensional stability under temperature fluctuations. |
Applications of INCOLOY® 800 Pipes
INCOLOY® 800 pipes serve in high-temperature applications where resistance to oxidation and carburization is the primary requirement:
| Industry | Application |
|---|---|
| Petrochemical and Chemical Processing | Heat exchangers, cracking furnaces, and piping systems requiring resistance to harsh chemicals and high temperatures |
| Power Generation | Coal gasification units and superheater tubing in power plants |
| Thermal Processing Equipment | Furnace components (muffles, retorts, conveyor systems) that must withstand high temperatures without degrading |
| Nuclear Power | Steam generator tubing in pressurized water reactors (high-temperature stability and resistance to aggressive media) |
Variants of INCOLOY® 800
Modified versions include INCOLOY® 800H (UNS N08810) and INCOLOY® 800HT (UNS N08811), which feature controlled carbon levels and aluminum/titanium additions for enhanced high-temperature properties. These variants deliver improved creep resistance for the most demanding thermal service.
Considerations for Use
Evaluate the specific environmental conditions and stresses the material will face, including exposure to corrosive substances and cyclic temperature variation. Selecting the right variant (800, 800H, or 800HT) depends on the expected operating temperature and required creep life.
INCOLOY® 800 pipes offer a balanced combination of strength, corrosion resistance, and dimensional stability under thermal cycling. They serve reliably in chemical processing, power generation, and furnace applications where high-temperature performance and oxidation resistance are required.
Nitinol Pipes
Nitinol, a portmanteau of Nickel (Ni), Titanium (Ti), and the Naval Ordnance Laboratory (NOL) where it was discovered, is a shape memory alloy that returns to a predetermined shape when heated above its transformation temperature. This property, combined with superelasticity at certain temperatures, drives its use in specialized applications far removed from conventional piping.
Key Properties of Nitinol Pipes
| Property | Description |
|---|---|
| Shape Memory Effect | Can undergo deformation at one temperature and recover its original shape upon heating above the transformation temperature. Exploited in actuators and self-deploying mechanisms. |
| Superelasticity | Also called pseudoelasticity; withstands significant deformation without permanent set above the transformation point. This makes Nitinol pipes highly resilient to mechanical stresses. |
| Biocompatibility | Compatible with the human body, supporting use in medical devices. Its corrosion resistance supports longevity inside biological environments. |
| Corrosion Resistance | Comparable to titanium; strong corrosion resistance broadens its applicability, especially in aggressive environments. |
Applications of Nitinol Pipes
Nitinol’s unique properties have carved out a role in medical and smart-material applications:
| Industry | Application |
|---|---|
| Medical Devices | Stents (peripheral, vascular, coronary), catheters, guidewires, and orthopedic implants (shape memory effect expands stent at body temperature) |
| Actuators and Sensors | Aerospace and automotive components using shape memory and superelastic properties for precision control |
| Couplings and Connectors | Phase transformation provides a secure, temperature-responsive fit |
Fabrication and Processing
Working with Nitinol requires specialized processing due to its phase transformation behavior. Laser cutting, electropolishing, and shape-setting heat treatments are used to achieve target geometries and surface finishes without degrading the material’s properties.
Considerations for Use
The transformation temperature range must align with the operational environment to exploit shape memory or superelastic behavior. Nitinol processing is more complex and costly than conventional alloys; evaluate cost-effectiveness carefully against the application requirements.
Waspaloy Pipes
WASPALOY is a high-strength, nickel-based, age-hardenable superalloy with excellent strength retention up to about 1600 °F (870 °C) and good oxidation resistance. Its composition (primarily nickel, chromium, and cobalt, with smaller amounts of molybdenum, titanium, and aluminum) balances high-temperature strength with corrosion resistance for aerospace and industrial gas turbine duty.
Key Properties of WASPALOY Pipes
| Property | Description |
|---|---|
| High-Temperature Strength | Maintains strength and hardness at elevated temperatures where lesser alloys soften or degrade. |
| Oxidation and Corrosion Resistance | Good resistance to oxidation and corrosion in the harsh environments of jet engines and gas turbines. |
| Age Hardenable | Strengthened through precipitation hardening heat treatment; critical for applications demanding durability under sustained stress. |
| Creep Resistance | Excellent resistance to creep (slow deformation under mechanical stress) at high temperatures. |
Applications of WASPALOY Pipes
WASPALOY is specified primarily in aerospace and power generation where high-temperature strength and corrosion resistance are essential:
| Industry | Application |
|---|---|
| Aerospace Industry | Turbine disks, shafts, and blades in jet engines; other engine components requiring high strength at elevated temperatures |
| Gas Turbines | Combustors and afterburner parts requiring resistance to high-temperature corrosion and oxidation |
| Industrial Furnace Parts | Components requiring high strength and resistance to thermal cycling |
| Fasteners and Springs | High-strength fasteners and springs that must perform reliably at high temperatures |
Fabrication and Machining
WASPALOY is difficult to machine and form due to its high strength and work-hardening characteristics. Advanced machining techniques and proper tooling materials are necessary. The age-hardening process requires precise heat treatment control to achieve target mechanical properties.
Considerations for Use
Evaluate WASPALOY’s high-temperature capabilities alongside its mechanical properties and corrosion resistance. The alloy’s cost, driven by its complex composition and processing, should be weighed against the performance demands of the application.
WASPALOY pipes address the narrow but critical space where extreme temperatures and corrosive atmospheres converge, particularly in aerospace and power generation. Their high-temperature strength, oxidation resistance, and precipitation-hardened durability make them a standard material for gas turbine and jet engine components. Selection and fabrication require attention to the alloy’s unique processing requirements and cost.
Hastelloy® B-2 Pipes
HASTELLOY® B-2 (UNS N10665) is a nickel-molybdenum alloy with excellent resistance to reducing acids and chemical process environments. It improves on the original HASTELLOY® B (UNS N10001) with enhanced resistance to hydrogen chloride gas and sulfuric, acetic, and phosphoric acids. The high molybdenum content gives HASTELLOY® B-2 strong resistance to pitting and stress-corrosion cracking in harsh chemical processing conditions.
Key Properties of HASTELLOY® B-2 Pipes
| Property | Description |
|---|---|
| Exceptional Chemical Resistance | Outstanding corrosion resistance to strong reducing acids (hydrochloric acid, sulfuric acid) and other aggressive chemicals. |
| Stress-Corrosion Cracking Resistance | Alloy composition minimizes carbide precipitation during welding, maintaining corrosion resistance in heat-affected zones of welded joints. |
| Fabricability | Can be fabricated using standard industrial processes (welding, machining, forming); accommodates complex component geometries. |
Applications of HASTELLOY® B-2 Pipes
HASTELLOY® B-2 pipes serve in harsh chemical processing environments where reducing acids dominate:
| Industry | Application |
|---|---|
| Chemical Processing | Reactors, heat exchangers, and columns in chemical production where reducing conditions are present |
| Pharmaceutical Industry | Reactors and equipment for synthesizing and processing acidic pharmaceutical products |
| Pulp and Paper Production | Bleaching processes and other stages involving corrosive chemicals |
| Waste Treatment | Handling waste streams containing aggressive chemical agents |
Fabrication and Welding
HASTELLOY® B-2 pipes can be fabricated using standard commercial methods. Care must be taken during welding to avoid hot cracking. Use matching filler metals so the weld zone maintains the same corrosion resistance as the base metal. Pre-heating and post-weld heat treatments are not required, but clean all contaminants from the joint area before welding.
Considerations for Use
| Factor | Detail |
|---|---|
| Temperature Limitations | Performs well in reducing environments but is not recommended for oxidizing media or in the presence of ferric or cupric salts, which can rapidly corrode the alloy. |
| Cost and Availability | Specialized nature may influence cost and availability. Specify where the unique reducing-acid resistance is needed for the application. |
HASTELLOY® B-2 pipes deliver unmatched resistance to reducing acids and aggressive chemicals. They maintain integrity under harsh conditions without compromising performance, serving the chemical processing and pharmaceutical sectors where reducing-acid corrosion is the primary threat.
With proper fabrication and welding practice, HASTELLOY® B-2 provides reliable, long-lasting systems in the most chemically demanding applications.
Hastelloy® X Pipes
HASTELLOY® X (UNS N06002) is a nickel-chromium-iron-molybdenum alloy developed for exceptional oxidation resistance, fabricability, and high-temperature strength. It performs in environments up to 2200 °F (1204 °C), handling conditions that push beyond the limits of most other alloys.
Key Properties of HASTELLOY® X Pipes
| Property | Description |
|---|---|
| Oxidation Resistance | Superior oxidation resistance at elevated temperatures; withstands prolonged high-temperature exposure without significant degradation. |
| High-Temperature Strength | Maintains strength and structural integrity at high temperatures, resisting deformation and failure under stress. |
| Corrosion Resistance | Good resistance to stress-corrosion cracking and a variety of corrosive media, complementing its high-temperature capabilities. |
| Fabricability | Can be welded, formed, and machined using standard methods; accommodates complex component manufacture. |
Applications of HASTELLOY® X Pipes
HASTELLOY® X pipes serve in the most thermally demanding environments:
| Industry | Application |
|---|---|
| Aerospace Industry | Gas turbine engine components: combustion zones, afterburners, turbine blades, and vanes |
| Industrial Furnaces | Retorts, muffles, and conveyor belts requiring resistance to high temperatures and oxidizing atmospheres |
| Petrochemical Processing | Pyrolysis tubes, furnace baffles, and burner nozzles (stable under heat and corrosive environments) |
| Power Generation | Superheater tubing and other high-temperature components requiring long service life |
Considerations for Use
| Factor | Detail |
|---|---|
| Operating Environment | While built for high temperatures, specific conditions (including potential exposure to corrosive substances) must be evaluated to confirm compatibility. |
| Fabrication Techniques | Fabrication requires attention to preserving mechanical properties and corrosion resistance, particularly in welded areas. |
| Cost-Effectiveness | The advanced properties carry a price premium; justify selection by the operational demands of the application. |
HASTELLOY® X pipes balance high-temperature strength, oxidation resistance, and fabricability. Their proven service in aerospace, industrial furnaces, petrochemical processing, and power generation demonstrates the alloy’s capability in extreme thermal environments.
Titanium Pipes
Titanium pipes are manufactured from titanium, a transition metal valued for its high strength-to-weight ratio, superior corrosion resistance, and solid mechanical properties. These characteristics drive titanium’s specification across aerospace, chemical processing, power generation, and marine industries.
Key Properties of Titanium Pipes
| Property | Description |
|---|---|
| High Strength-to-Weight Ratio | Delivers the strength of steel at roughly half the weight, a critical advantage where both strength and weight matter. |
| Exceptional Corrosion Resistance | Exceptionally resistant to seawater, chlorine, acids, alkalis, and other chemicals. The resistance comes from a stable, protective oxide layer that reforms instantly if damaged. |
| Biocompatibility | Non-toxic and not rejected by the body; the standard material for medical implants (joint replacements, dental implants). |
| High-Temperature Performance | Maintains strength and resists creep at elevated temperatures; used in power generation and aerospace. |
| Low Thermal Expansion | Lower thermal expansion rate than many metals, providing dimensional stability across varying temperatures. |
Applications of Titanium Pipes
Titanium pipes serve where weight savings, corrosion resistance, or both justify the material cost:
| Industry | Application |
|---|---|
| Chemical Processing | Piping systems transporting corrosive chemicals (long service life and reliability) |
| Aerospace | Aircraft hydraulic systems and structural components (strength, light weight, high-temperature resistance) |
| Marine Applications | Desalination plants, shipbuilding, and offshore oil and gas platforms (seawater corrosion resistance) |
| Power Generation | Cooling systems and condensers, especially where seawater serves as coolant |
| Medical Devices | Prosthetics and orthopedic implants (biocompatibility and strength) |
Fabrication and Machining
Titanium’s reactivity at high temperatures requires inert gas shielding during welding to prevent contamination. Machining demands attention to cutting speeds, tooling materials, and cooling. Titanium work-hardens rapidly, which accelerates tool wear if parameters are not controlled.
Considerations for Use
Titanium costs more than most common metals due to its processing and machining requirements. However, its durability, corrosion resistance, and performance in aggressive service often justify the investment over the full life cycle.
Titanium pipes deliver strength, light weight, and outstanding corrosion resistance. Their use across aerospace, chemical processing, marine, power generation, and medical sectors reflects the material’s ability to perform where other metals cannot. With proper welding and machining practice, titanium pipes provide long-lasting, reliable service.
Zirconium Pipes
Zirconium pipes are manufactured from zirconium, a transition metal with remarkable corrosion resistance, a high melting point (approximately 1855 °C / 3371 °F), and excellent heat resistance. These properties make zirconium the material of choice where corrosive agents would destroy most other metals, particularly in chemical processing and nuclear reactor applications.
Key Properties of Zirconium Pipes
| Property | Description |
|---|---|
| Outstanding Corrosion Resistance | Exceptional resistance to acids (hydrochloric, sulfuric) even at high concentrations and temperatures. A stable, protective oxide layer provides the corrosion barrier. |
| High Melting Point | Around 1855 °C (3371 °F), contributing to excellent high-temperature stability under extreme conditions. |
| Low Thermal Neutron Absorption | Low neutron absorption cross-section, the key property that makes zirconium the standard cladding material for nuclear fuel rods. |
| Good Heat Resistance | Resists heat-induced degradation efficiently, maintaining integrity in high-temperature service. |
Applications of Zirconium Pipes
Zirconium’s unique property set places it in specialized, high-value applications:
| Industry | Application |
|---|---|
| Chemical Processing | Production and handling of acetic and hydrochloric acids, alkalis, and other corrosive chemicals (longevity and reduced maintenance costs) |
| Nuclear Reactors | Cladding for fuel rods (low neutron absorption allows efficient fuel use while preventing corrosion) |
| Desalination Plants | Heat exchangers and other components (resistance to seawater corrosion for efficient operation) |
| Aerospace | Systems handling aggressive chemicals (high-temperature stability and resistance to corrosive fluids) |
Fabrication and Machining
Zirconium is malleable and can be formed and welded into complex components. However, its reactivity at high temperatures can lead to embrittlement if exposed to certain elements. Inert atmosphere processing and careful handling are required to maintain component integrity.
Considerations for Use
Zirconium’s cost limits its use to applications where its unique properties (particularly acid resistance and low neutron absorption) are genuinely required. Proper design and material selection are key to capturing zirconium’s benefits cost-effectively.
Zirconium pipes serve demanding applications that require exceptional corrosion resistance, high-temperature performance, and durability. Their role in chemical processing and nuclear industries reflects zirconium’s unique advantages in aggressive environments. With appropriate fabrication and handling, zirconium delivers long-term, reliable service.
Other Non-ferrous Grades
Non-ferrous pipes are manufactured from materials that do not contain significant amounts of iron. They offer advantages over ferrous materials: corrosion resistance, non-magnetic behavior, and in some cases, superior strength-to-weight ratios. The following are common non-ferrous pipe grades and their key characteristics:
Copper and Copper Alloys
| Grade | Composition | Key Properties | Applications |
|---|---|---|---|
| Copper (C11000) | Pure copper | Excellent electrical and thermal conductivity, formability, corrosion resistance | Plumbing, HVAC, electrical |
| Brass (C26000, C27000) | Copper-zinc alloy | Good strength, corrosion resistance, machinability | Decorative applications, water lines, musical instruments |
| Bronze (C90500, C95500) | Copper-tin alloy (sometimes aluminum) | Strength, wear resistance, corrosion resistance | Marine applications, bearings, bushings |
| Cupronickel (C70600, C71500) | 90/10 and 70/30 copper-nickel | See above for an in-depth discussion | Marine, desalination, offshore |
Aluminum and Aluminum Alloys
| Grade | Composition | Key Properties | Applications |
|---|---|---|---|
| Aluminum (6061, 6063) | Aluminum alloy | Lightweight, corrosion resistance, good strength-to-weight ratio | Structural applications, automotive parts, aerospace |
| Aluminum Bronze (C95400) | Aluminum-copper alloy | High strength, excellent corrosion and wear resistance | High-load bearings, bushings, marine hardware |
Sizes of Nickel Alloy Pipes
Applicable ASME Dimensional Standard
ASME B36.19M covers the dimensions and weights of stainless steel pipes, and is also widely applied to nickel alloy pipes. This standard specifies requirements for diameter, wall thickness, and weight, which provides compatibility and interchangeability across piping systems.
The standard covers welded and seamless wrought stainless steel pipe dimensions.
While the title says “stainless steel,” ASME B36.19M is widely referenced for nickel alloys as well, because many nickel alloys share similar sizing and are used alongside or instead of stainless steels in corrosive service. Pipes are categorized by nominal pipe size (NPS) and schedule number (SCH), which define the outer diameter and wall thickness, respectively.
Typical Size Range For Nickel-alloy Pipes
The typical production range for these high-end pipes covers the following:
| Parameter | Range |
|---|---|
| Nominal Pipe Size (NPS) | 1/8 inch to 12 inches. Above NPS 12, actual dimensions correspond to the pipe’s outer diameter in inches. |
| Schedule Number (SCH) | SCH 5S, 10S, 40S, and 80S are the common schedules. The “S” suffix denotes stainless steel sizing but applies equally to nickel alloys. Higher schedule numbers mean thicker walls and higher pressure ratings. |
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I really enjoyed reading the blog about ASTM nickel alloy pipes. It provides a clear explanation of the different types of nickel alloys, such as Inconel and Incoloy, and their uses in high-temperature and corrosive environments. The insights into their material properties and applications in industries like aerospace, chemical processing, and energy were exactly what I needed. This is a valuable resource for anyone working with nickel alloy pipes.