Incoloy 825 material parts

Industrial application of alloy fittings with high temperature resistance, corrosion resistance and wear resistance and the importance of material weight selection.

I. Typical alloy materials with “three-resistance” characteristics and their applications

(A) Nickel-based alloy-all-around player in high temperature and corrosive environment.

• Core characteristics: high temperature resistance above 1000℃, strong acid and alkali corrosion resistance, abrasive wear resistance (for example, Inconel 718 has a tensile strength of 1220MPa and still maintains high strength at 650℃).
• Industry application:
  • Aerospace:
    • Application: turbine blades and combustion chamber components of aero-engines.
    • Case: The GE9X engine is made of Inconel 738 alloy, which can resist oxidation corrosion in high-temperature gas at 1100℃ and at the same time bear high-speed airflow erosion and wear.
  • Petrochemical industry：

    • Application: catalytic cracking unit, submarine oil pipeline (such as Hastelloy C-276).

    • Characteristics: It is resistant to chloride ion stress corrosion (corrosion rate is less than 0.05mm/year in acidic oilfield environment containing H2S), and its corrosion resistance is better than that of ordinary stainless steel.

  • Energy industry：
    • Application: steam generator and high temperature heat exchanger in nuclear power plant.
    • Case: C-22 nickel-base alloy is used to treat strongly corrosive nitric acid solution in nuclear waste, and at the same time it can withstand high temperature of 300℃.

(B) Cobalt-based alloy-a leader in wear resistance and biocompatibility.

• Core characteristics: high temperature resistance (below 800℃), body fluid corrosion resistance, excellent wear resistance (such as Stellite 6 hardness reaching HRC40-45, sliding wear resistance).
• Industry application:
• • Medical field:
    • Application: artificial hip joint and dental implants.
    • Characteristics: It can resist corrosion in human body fluids, and its wear resistance is better than that of titanium alloy (for example, the wear rate of Co-Cr-Mo alloy is only 1/5 of that of Ti-6Al-4V).
  • Mechanical manufacturing:
    • Application: Engine valve seat ring, high-pressure pump plunger.
    • Case: Stellite 12 is used for diesel engine valve, which maintains surface integrity under high temperature gas scouring (600℃) and high frequency impact.

(C) Titanium alloy-the balance between lightweight and corrosion resistance

• Core characteristics: high temperature resistance of 300-600℃, seawater/chloride corrosion resistance, and wear resistance require surface treatment (for example, the wear resistance is improved by 10 times after TiN coating).
• Industry application:
• • Ocean engineering:
    • Application: Deep-sea detector shell, seawater desalination evaporator.
    • Characteristics: The pitting potential of TA2 titanium alloy in seawater is > 1.2V, which is better than that of 316L stainless steel (0.8V), and its density is only 1/2 of that of steel.
  • Automobile industry:
    • Application: Turbocharging components, exhaust system.
    • Case: Porsche 911 uses titanium alloy exhaust manifold, which can resist the corrosion of high temperature exhaust gas at 800℃ and reduce the weight by 15kg/vehicle.

(D) Special stainless steel-low-cost “three-resistant” scheme

• Core characteristics: high temperature resistance (such as 310S stainless steel at 1200℃), moderate corrosion resistance, and surface hardening to improve wear resistance (such as hardness HRC58-60 of 440C stainless steel after quenching).
• Industry application:
  • Food processing:
    • Application: high temperature sterilization equipment, acid beverage storage tank (such as 316L stainless steel).
    • Characteristics: resistant to citric acid corrosion (corrosion rate < 0.01mm/year in pH<2), and the surface is wear-resistant and easy to clean.
  • Metallurgical industry:
    • Application: blast furnace lining, hot dip galvanizing bath (such as 2205 duplex stainless steel).
    • Characteristics: Resistance to molten zinc corrosion (oxidation resistance in zinc liquid at 450℃) and thermal fatigue wear.

II.the key influencing factors of material weight selection

(A) the contradiction and trade-off between performance and weight

• Aerospace scene:
  • Requirements: Turbine blades should be resistant to high temperature of 1100℃+gas corrosion resistance+wear resistance, and the engine efficiency will be improved by 0.05% for every 1g weight reduction.
  • Solution: Choose low-density nickel-based alloy (such as Inconel 625 with a density of 8.4g/cm³, which is 20% lighter than traditional steel), or use hollow blade structure to reduce weight, and at the same time strengthen wear resistance through directional solidification process.
• Chemical equipment scene:
  • Requirements: The reaction kettle should be resistant to strong acid (such as hydrofluoric acid)+erosion and wear, and the weight will affect the design of equipment support structure.
  • Solution: The density of Hastelloy C-276 is 8.6g/cm³, which is 30% heavier than that of titanium alloy. However, due to the irreplaceable corrosion resistance, it is necessary to balance the weight and strength by optimizing the wall thickness (such as using wound cylinder).

(B) the whole life cycle cost and weight.

• Transportation and installation costs:
  • Case: If a 6-meter-long nickel-based alloy pipeline is used for offshore oil platforms, Hastelloy C-22 weighs 25kg per meter, while titanium alloy TA2 weighs 12kg per meter, which reduces the transportation cost by 50% and requires lower hoisting equipment.
• Energy consumption cost:
  • Law: For every 10% reduction in the weight of rotating equipment (such as pump impeller), the energy consumption of motor will be reduced by 3%-5%. For example, after the cobalt-based alloy impeller (density 8.9g/cm³) was replaced by titanium alloy (density 4.5g/cm³), the energy consumption of chemical pump decreased by 4%, saving about 100,000 kWh annually.

(C) weight priority in special scenes

• Deep-sea engineering:
  • Challenge: For every 1000m descent, the seawater pressure will increase by 10MPa, and the weight of equipment will affect the buoyancy design.
  • Choice: Titanium alloy (low density) is superior to nickel-based alloy. For example, “Endeavor” manned cabin uses TC4 titanium alloy, which bears 110MPa pressure in 11,000m deep sea, and realizes suspension control through weight optimization.
• High-end medical devices:
  • Requirements: The joints of the surgical robot should be wear-resistant and antiseptic, and the weight of the manipulator affects the accuracy.
  • Scheme: Co-based alloy (such as CoCrMo) is selected to make the joint bearing, the density of which is 8.3g/cm³. Although it is heavier than aluminum alloy, the overall weight is reduced through miniaturization design (such as bearing with diameter less than 5mm) to ensure millimeter-level operation accuracy.

III. Decision-making framework for material selection of “three-resistant” alloy

1. Performance prioritization:
   • Aerospace: high temperature resistance > wear resistance > corrosion resistance (oxidation corrosion is the main gas environment);
   • Chemical corrosion protection: corrosion resistance > high temperature resistance > wear resistance (fluid erosion and wear are secondary factors);
   • Mechanical wear resistance: wear resistance > corrosion resistance > high temperature resistance (such as mining machinery working at room temperature).
2. Weight sensitivity coefficient reference:

   industry	Weight sensitivity grade	Typical material selection	Weight optimization means
   Aircraft engine	★★★★★	Nickel-based alloy+hollow structure	3D printing reduces weight (for example, GE’s LEAP engine blades reduce weight by 15%)
   Chemical reactor	★★★☆☆	Hastelloy+thin wall design	Optimization of wall thickness by finite element analysis
   Medical implant	★★★★☆	Cobalt-based alloy+porous structure	Preparation of porous trabecular bone structure by laser sintering

3. Balance formula of cost and weight:
   • When the weight is reduced by 1%, if the material cost is not increased by more than 5%, the scheme is feasible (such as the critical point of cost performance of titanium alloy replacing stainless steel in aviation field).

IV. Summary: Material Philosophy from “Three Endurances” to “Three Effects”

When selecting alloy materials with high temperature resistance, corrosion resistance and wear resistance, weight is not only a physical parameter, but also a core variable in connection performance, cost and design. For example:

• Extreme environment (such as aerospace engine): based on nickel-based alloy, the high temperature resistance is improved by single crystal casting technology, and the wear resistance is strengthened by hollow structure and coating technology (such as ceramic-based composite coating) without increasing weight;
• Civil scene (such as chemical pipeline): Special stainless steel with high cost performance (such as 2507 duplex steel) is preferred, and the weight and “three-resistance” requirements are balanced through thickness optimization and surface hardening (such as nitriding treatment).

In the end, reasonable weight selection can make the alloy material both “strong” and “light” under extreme working conditions, and realize the transformation from material performance to product efficiency.