1. 2 their evolution beyond the first prototypes depended on materials becoming available with...
TRANSCRIPT
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Their evolution beyond the first
prototypes depended on materials
becoming available with hitherto
unknown resistance to
temperature, stress and corrosion
by combustion products.
In the early 1940s, Special Metals
worked with the UK government to
create the first of the superalloys
to meet those demands.
History The aircraft
engines were the first!
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Within a very few years the NIMONIC and INCONEL superalloys had become the cornerstones of jet engine metallurgy; the first, annealed products supplemented by new series of higher strength, age-hardenable alloys.
Gas turbine propulsion is now universal for all but the lowest powered aircraft.
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New standards of materials performance are being set
all the time for aircraft to fly higher, faster, further, more
economically, even more quietly.
And, for over fifty years, the technology has been
spreading into other areas where land-based engines
are used for power generation and for such specialist
applications as trans-continental pipelines, and for
marine applications where gas turbine power acts as an
on-demand supplement to more conventional systems.
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Special Metals was critically involved at the beginning of gas turbine technology. It remains a world leader in the development and production of the superalloys that support the engines of today and the design demands for the years to come.
The following slides offer an introduction to the current level of investment in new and established alloy products, and in melting, remelting and manufacturing facilities.
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Alloy ASTM / ISO
35N LT® F562 , ISO 5832-6
MP35N® F562, ISO 5832-6
L605 F90, ISO 5832-5
FWN1058® F1058, ISO 5832-7
ELGILOY® F1058, ISO 5832-7
CCM® F1537, ISO 5832-12
DFT® (Composite)
Alloy 41
Alloy 625 B446
Alloy X-750 B574
HASTELLOY Alloy C-276 B619
HASTELLOY Alloy C-22
Alloy 31 Alloy 600 INCONEL® Alloy 601 INCONEL Alloy 617 Alloy 718 Alloy 901 Alloy 902 HASTELLOY® Alloy B HASTELLOY Alloy B-2 HASTELLOY Alloy C-4 HAYNES® Alloy C-263 HASTELLOY® Alloy S HASTELLOY® Alloy X Chromel HAYNES 188 HAYNES 214™ HAYNES 230™ HAYNES 242™ Hiperco 50B Ni200 NIMONIC® 90 ULTIMET® WASPALOY®
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For compressor blades and vanesINCONEL® alloy 718NIMONIC® alloys 90 & 901INCOLOY® alloy 909For turbine blades and vanesINCONEL® alloy MA754NIMONIC® alloys 80A, 90, 101, 105 & 115For discs and shaftsINCONEL® alloys 706, 718 & X-750NIMONIC® alloys 90, 105, & 901WaspaloyINCOLOY® alloys 903 & 909Rene 88, 95IN 100UDIMET® alloys 700 & 720UDIMAR® alloys 250 & 300
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For casings, rings, and seals
INCONEL® alloys 600, 617, 625, 718, X-750, 783 & HXNIMONIC® alloys 75, 80A, 90, 105, 263, 901, PE11, PE16 & PK33WaspaloyINCOLOY® alloy 909
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For sheet fabrications (combustors, ducting, exhaust systems, thrust reversers, hush kits, afterburners, etc.)
INCONEL® alloys 600, 601, 617, 625, 625LCF®, 718, 718SPF,
™ X-750 & HXNIMONIC® alloys 75, 86, 263, PE11, PE16
& PK 33INCOLOY® alloy MA956 UDIMET® alloys 188 and L-605
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For fasteners and general engine hardware
INCONEL® alloys 600, 625, 718 & X-750
NIMONIC® alloys 80A, 90, 105, 263 & 901
INCOLOY® alloy A-286
Waspaloy
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35N LT
• Melt Practice This superalloy is typically double melted
to remove impurities. However this melt practice is an
enhancement of the standard melt practice for ASTM F-562 material yielding much lower inclusion counts.
This results in improved fatigue life of as-drawn wire by as much as 800%.
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Typical Chemistry
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Mechanical Properties
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Thermal Treatment
• A reducing atmosphere is preferred for thermal treatment but inert gas can be used.
• 35N LT will fully anneal at 1010-1177°C in just a few minutes. For optimum mechanical properties, cold worked 35N LT should be aged at 583-593°C for four hours.
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Applications
• Typically used in the coldworked condition, tensile strengths are typically comparable to 304.
• End uses in the medical field are: pacing leads, stylets, catheters and orthopaedic cables.
•35N LT is an excellent
combination of strength and
corrosion resistance.
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MP35N • Melt Practice
• This superalloy is initially melted using Vacuum Induction Melting (VIM) techniques.
• This is followed by an Electro Slag Remelt (ESR) to remove some impurities. This practice may be followed by Vacuum Arc Remelting (VAR). The triple-melt practice is thought to give best overall performance for this alloy.
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• MP35N alloy is a nonmagnetic, nickel-cobalt-chromium-molybdenum alloy possessing a unique combination of ultrahigh tensile strength (up to 300 ksi [2068 MPa]), good ductility and toughness, and excellent corrosion resistance.
• In addition, this alloy displays exceptional resistance to sulfidation, high temperature oxidation, and hydrogen embrittlement.
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• The unique properties of MP35N alloy are
developed through work hardening, phase
transformation and aging. If the alloy is
used in the fully work hardened condition,
service temperatures up to 399°C are
suggested.
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Typical Chemistry
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•Physical Properties
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Thermal Treatment
• A reducing atmosphere is preferred for
thermal treatment but inert gas can be
used. MP35N will fully anneal at 1010-
1177.25°C in just a few minutes.
• For optimum mechanical properties, cold
worked MP35N should be aged at 583-
593.25°C for four hours.
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•Mechanical Properties
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Mechanical Properties
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Applications
• MP35N is an excellent combination of
strength and corrosion resistance.
Typically used in the cold-worked
condition, tensile strengths are typically
comparable to 304. End uses in the
medical field are: pacing leads, stylets,
catheters and orthopaedic cables.
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Surface Conditions
Cobalt based alloys develop a highly polished
appearance as they are drawn to fine diameters. Surface
roughness can be less than 5 RMS when processed
using SCND* dies and measured with a profilometer.
Diameters over .040" will not have as smooth a finish
because of polycrystaline dies. Diameters over .100"
have an even rougher surface because they are drawn
with carbide dies.
Additional finish treatments can enhance the surface of the wire.
* SCND means single crystal natural diamond.
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FWM 1058 Alloy General
• FWM 1058® Alloy, Conichrome®, Phynox® and Elgiloy® are all trademark names for the cobalt-chromium-nickel-molybdenum-iron alloy specified by ASTM F 1058 and ISO 5832-7.
• Batelle Laboratories originally developed the alloy for making watch springs, and it was patented in 1950.
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• As demonstrated in the table below,
the current FWM 1058 Alloy melt
specification, specifically designed by
Fort Wayne Metals, is equivalent to
Conichrome, Phynox and Elgiloy.
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Typical Chemistry (%)
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• The alloy is first melted using Vacuum
Induction Melting (VIM) techniques. A
secondary melt operation, Electro
Slag Remelt (ESR), is then employed
to further remove impurities and
improve overall homogeneity.
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• FWM 1058 Alloy derives its maximum
properties from a combination of cold work
and thermal processing, and is not a true
precipitation-hardening alloy since the
response to heat treatment is a function of
the degree of cold work.
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Physical Properties
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Thermal Treatment
• After cold working, the mechanical strength of this cobalt based super alloy can be increased by heat treating. In wire form, cold worked FWM 1058 Alloy will gain tensile strength at temperatures from 480-540°C when exposed for approximately 2-5 hours. Reducing or inert atmospheres are typically used for protection during thermal treatment. After annealing with a rapid quench, the alloy has a face-centered cubic structure.
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• Reducing or inert atmospheres are
typically used for protection during thermal
treatment.
• After annealing with a rapid quench, the
alloy has a face-centered cubic structure.
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Magnetic Resonance Imaging (MRI)
Surgical implants
constructed of FWM 1058
Alloy wire can be safely
imaged using magnetic
resonance without risk of
migration and with
minimal image
degradation because of
the nonmagnetic
characteristics of
the material.
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Biocompatibility• Although there is no universally accepted
definition for biocompatibility of biomaterials, a medical device should be safe for its intended use. ASTM F 1058 alloy has been employed successfully in human implant applications in contact with soft tissue and bone for over a decade.
• Long-term clinical experience of the use of this material has shown that an acceptable level of biological response can be expected if the alloy is used in appropriate applications.
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Surface Conditions
• Cobalt based alloys develop a highly
polished appearance as they are drawn to
fine diameters. Surface roughness can be
less than 5 RMS when processed using
single crystal natural diamond (SCND)
dies and measured with a profilometer.
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• Diameters over 0.040" will not have as
smooth a finish because they are drawn
through polycrystalline dies. Wire
measuring over 0.100" will have an even
rougher surface because it is drawn
through carbide dies. However, the
surface of the wire can be enhanced with
additional finish treatments.
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Mechanical Properties
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Applications
• Because of its excellent corrosion
resistance, mechanical strength and
fatigue resistance combined with high
elastic modulus, FWM 1058 Alloy wire and
rod is an attractive candidate for surgical
implants.
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• It is one of the preferred materials for the
fabrication of various stents, pacemaker
lead conductors, surgical clips, vena cava
filters, orthopaedic cables, and orthodontic
appliances. The alloy is also commonly
used in the watchmaking industry as a
precision spring material.
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Ti 6Al-4V ELI One of the most commonly used titanium
alloys is an alpha-beta alloy containing 6%
Al and 4% V. This alloy, usually referred to
as Ti 6Al-4V, exhibits an excellent
combination
of corrosion resistance,
strength and toughness.
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• Typical uses include medical devices or
implants, aerospace applications and
pressure vessels. In the case of medical
applications, stringent user specifications
require controlled microstructures and
freedom from melt imperfections.
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• The interstitial elements of iron and
oxygen are carefully controlled to improve
ductility and fracture toughness. Controlled
interstitial element levels are designated
ELI (extra low interstitials). Hence the
designation Ti 6Al-4V ELI.
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Typical Chemistry
Titanium alloy powder
preparation for selective
laser sintering
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Surface Conditions
• Ti 6Al-4V ELI has a tendency to stick, fret or cold
weld with drawing dies during processing. Common
industry practice to avoid this condition usually
employs heavy etching or pickling at finish size
resulting in a course or very textured surface.
• Fort Wayne Metals has developed processing
techniques with enhanced surface treatments which
require minimal etching at finish size to remove
residual oxide, yielding a cleaner and smoother
surface finish.
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Diameter Tolerances
Enhanced surface treatments and processing techniques allow Fort Wayne Metals to offer tighter and more controlled
tolerances. The chart in the right column details standard diameter tolerances for Ti 6Al-4V ELI in wire and coil forms.
Most diameters can be produced to tighter tolerances.
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Applications
Fort Wayne Metals manufactures Ti 6Al-4V ELI in
straightened and cut bar, coil, strands and cables, flat wire
and wire form to support a variety of critical medical and
industrial based applications. End uses include: Orthopaedic pins and screws · Springs Orthopaedic cables · Surgical staples Orthodontic appliances · Ligature clips
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Values are typical and may not represent all diameters.
Test method will affect results.Ti 6Al-4V ELI in centerless ground bar, coil, and wire can be offered in annealed or cold worked conditions.
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Other Titanium & Titanium Alloys Available
CPTi Gr.1 · Ti 6Al-4V ELI CPTi Gr.2 · Ti 6Al-7Nb CPTi Gr.3 · Ti 3Al-2.5V CPTi Gr.4 · Ti 3Al-8V-6Cr-4Mo 4Zr (Ti Beta C)
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