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Manufacture of ODS Alloys Manufacture of ODS Alloys by Mechanical Alloying ...by Mechanical Alloying ...
Processing and ApplicationsProcessing and ApplicationsHuntington AlloysHuntington Alloys
Special Metals CorporationSpecial Metals Corporationa PCC Companya PCC Company
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ODS High Temperature AlloysODS High Temperature Alloys–Superior strength and creep resistance at highly elevated temperatures
–Improved heat resistance over conventional solid solution Ni-Cr alloys–Increase in usage range from 200 to 300°F over conventional solid solution alloys–Fe-Cr-Al alloy offered unique heat resistance, even to sulfidation
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---0.50.54.5Bal.20---MA956
W-4; Mo-21.12.54.5115Bal.MA6000
---0.60.50.3130Bal.MA758
---0.60.50.3120Bal.MA754
OthersY2O3TiAlFeCrNiAlloy
SMC ODS AlloysSMC ODS AlloysChemical CompositionChemical Composition
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INCOLOY MA956 TubingINCOLOY MA956 Tubing
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Production of INCOLOY MA956 TubingProduction of INCOLOY MA956 Tubing• Manufacture powder• Characterize & blend• Fill, evacuate & seal cans• Soak / sinter / homogenize• Extrude• Cut, straighten, deglass & pickle• Cold work - pilger or draw• Anneal, pickle, straighten & cut• Test & certify
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INCOLOY MA956 TubingINCOLOY MA956 TubingSizes Manufactured at SMWL – Hereford, UK
Largest - 114 mm OD X 6 mm AW(4.5” OD X 0.236” AW)
Smallest - 25 mm OD X 2 mm AW(1.0” OD X 0.78” AW)
Smaller tubes made by specialist redrawers
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INCOLOY alloy MA956 INCOLOY alloy MA956 Elongated Grain StructureElongated Grain Structure
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INCOLOY MA956 Flow Formed TubeINCOLOY MA956 Flow Formed TubeLongitudinal Microstructure (50X)Longitudinal Microstructure (50X)
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INCOLOY MA956 TubesINCOLOY MA956 Tubes
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INCOLOY MA956 INCOLOY MA956 Flow Formed TubesFlow Formed Tubes
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INCOLOY MA956 Tube INCOLOY MA956 Tube Explosively Bonded to an Explosively Bonded to an INCOLOY alloy 800H TubeINCOLOY alloy 800H Tube
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INCOLOY alloy MA956 INCOLOY alloy MA956 Tubes Joined by Friction WeldingTubes Joined by Friction Welding
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Weld Clad TubeWeld Clad Tube
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INCOLOY MA956 INCOLOY MA956 Rolled & Riveted TubeRolled & Riveted Tube
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Applications for MA ODS AlloysApplications for MA ODS AlloysAerospace
– Vanes and bands - GE and Honeywell engines. MA754. Primarily military. Texture criticality. Either machined from rolled bar or forged by GE or Doncasters (UK). About 2M lbs. delivered. Replaced by single crystal castings ~2005.
– Blades - Rolls-Royce / Allison Military engines. MA6000 blades forged by Doncasters. Lost out to single crystal casting.
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Applications for MA ODS AlloysApplications for MA ODS AlloysAerospace
– Combustors and nozzles - NASA, GE and Rolls-Royce. MA956 and MA754. Numerous projects over 15-yr period. Proposed Title III project to support F22 engine dropped when engine down-rated for stealth capability. Several classified USAF applications.
– Thermal protection systems - Honeycomb construction using MA956 foil. Classified.
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INCOLOY MA956 INCOLOY MA956 Turbine Nozzle for WR24 7 EngineTurbine Nozzle for WR24 7 Engine
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INCOLOY MA956INCOLOY MA956Transition LinerTransition Liner
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INCONEL MA754 INCONEL MA754 Stator Blade for GE EngineStator Blade for GE Engine
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Applications for MA ODS AlloysApplications for MA ODS AlloysIndustrial Gas Turbines
– Vanes - ABB / Alstom) - MA6000 and MA760. Intense development program in 1980’s. Never commercialized.
– Other Components - GE, Solar, Siemens, Westinghouse, ABB, Mitsubishi, Hitachi, Toshiba. MA956. Never commercialized
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INCONEL MA6000 INCONEL MA6000 LBGT Turbine BladeLBGT Turbine Blade
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Applications for MA ODS AlloysApplications for MA ODS AlloysGlass Production
– Fiberglass Spinners - Owens-Corning, Pilkington, San Gobain. MA758, EX3010. Bowl shaped spinner. Replacing cast cobalt-base alloys. Limited commercial production. Problem was reproducible production of desired microstructure by hot shear spinning.
– Drawn Fiberglass - MA754. Continuing small one-company application.
– Radioactive Waste Vitrification - Various components such as stirrers and gas pipes. MA758. USA DOE and France. Continuing application.
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Applications for MA ODS AlloysApplications for MA ODS AlloysIndustrial Equipment
– Radiant Heaters - MA956– Reactor vessels - MA956– Gas fired heat treatment muffles - MA956– Combustion fans - MA956– Ethylene production reactor tubes - MA956– HIP shields and muffles - MA956– Impellers for floating zone annealing furnaces - MA754– Steel heating furnace skid rails - MA956, MA758– Laboratory testing grips & hardware - MA754, MA6000
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Heat Treating BasketsHeat Treating Baskets
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INCOLOY MA956 Furnace Muffle INCOLOY MA956 Furnace Muffle for Manufacture of Ceramicsfor Manufacture of Ceramics
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INCOLOY MA956 INCOLOY MA956 Radiant Tubes for Radiant Tubes for
Ceramics ManufactureCeramics Manufacture
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INCOLOY MA956 INCOLOY MA956 Vacuum Furnace TrayVacuum Furnace Tray
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MA ODS Alloy MA ODS Alloy Heat Treating Furnace Skid RailsHeat Treating Furnace Skid Rails
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INCONEL MA754 INCONEL MA754 Test Furnace GripsTest Furnace Grips
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Applications for MA ODS AlloysApplications for MA ODS Alloys– Automotive - Glow plugs for Daimler Benz
– MA956
– Nuclear - Fuel cladding - DOE initiated contact in 1980, intense interest in France and Japan. MA957 (Dourmetal had a slightly different formulation). Inadequate hoop strength is limiting factor.
– Nuclear - HTGR heat exchanger - MA956
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Diesel Engine UsingDiesel Engine UsingINCONEL MA758 ValvesINCONEL MA758 Valves
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INCONEL MA758 INCONEL MA758 Fuel Injection ValveFuel Injection Valve
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INCONEL MA758 INCONEL MA758 RadwasteRadwaste VitrificationVitrification
– Molten, aggressive phosphate glass – High chromium alloys required– INCONEL alloys 690, 693, MA758– MA 758 – Strength + Resistance– Glass Stirring Tubes & Components– Agitator Blades
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SummarySummary• ODS materials offer a unique
combination of properties not attainable from conventional alloys.
• Many applications for the products have been identified.
• Unfortunately, material requirements have not been sufficient to justify continued production.
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Questions ???Questions ???
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Thanks !!!Thanks !!!