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Monelisagroupofnickelalloys,primarilycomposedofnickel
(upto67%)andcopper,withsmallamountsofiron,manganese,
carbon,andsilicon.Strongerthanpurenickel,Monelalloysare
resistanttocorrosionbymanyagents,includingrapidlyflowing
seawater.Theycanbefabricatedreadilybyhotandcold
working,machining,andwelding.[2]
MonelwascreatedbyDavidH.Browne,chiefmetallurgistfor
InternationalNickelCo.Monelalloy400isabinaryalloyofthe
sameproportionsofnickelandcopperasisfoundnaturallyinthe
nickelorefromtheSudbury(Ontario)minesandistherefore
consideredapuritanalloy.Monelwasnamedaftercompany
presidentAmbroseMonell,andpatentedin1906.[3]OneLwas
dropped,becausefamilynameswerenotallowedastrademarks
atthattime.[1]ThenameisnowatrademarkofSpecialMetals
Corporation.
Itisaveryexpensivealloy,withcostrangingfrom5to10times
thecostofcopperandnickel,henceitsuseislimitedtothose
applicationswhereitcannotbereplacedwithcheaper
alternatives.Comparedtocarbonsteel,pipinginmonelismore
than3timesasexpensive.[4]
Contents
1 Properties
2 Uses
2.1 Aerospaceapplications
2.2 Oilproductionandrefining
2.3 Marineapplications
2.4 Musicalinstruments
2.5 DirectionalDrilling
2.6 Other
3 Alloys
3.1 Monel400
3.2 Monel401
TheArtDecogateintheentrance
halloftheGuardianBuildingismade
fromMonelmetal. [1]
3.2 Monel401
3.3 Monel404
3.4 Monel450
3.5 MonelK500
3.6 MonelR405
4 Seealso
5 References
5.1 Bibliography
6 Externallinks
Properties
Monelisasolidsolutionbinaryalloy.Asnickelandcopperaremutuallysolubleinallproportions,itis
asinglephasealloy.Comparedtosteel,Monelisverydifficulttomachineasitworkhardensvery
quickly.Itneedstobeturnedandworkedatslowspeedsandlowfeedrates.Itisresistanttocorrosion
andacids,andsomealloyscanwithstandafireinpureoxygen.Itiscommonlyusedinapplicationswith
highlycorrosiveconditions.Smalladditionsofaluminiumandtitaniumformanalloy(K500)withthe
samecorrosionresistancebutwithmuchgreaterstrengthduetogammaprimeformationonaging.
Monelistypicallymuchmoreexpensivethanstainlesssteel.
Monelalloy400hasaspecificgravityof8.80,[5]ameltingrangeof13001350C,anelectrical
conductivityofapproximately34%IACS,and(intheannealedstate)ahardnessof65RockwellB.[6]
MONELalloy400isnotableforitstoughness,whichismaintainedoveraconsiderablerangeof
temperatures.Monelalloy400hasexcellentmechanicalpropertiesatsubzerotemperatures.Strength
andhardnessincreasewithonlyslightimpairmentofductilityorimpactresistance.Thealloydoesnot
undergoaductiletobrittletransitionevenwhencooledtothetemperatureofliquidhydrogen.Thisisin
markedcontrasttomanyferrousmaterialswhicharebrittleatlowtemperaturesdespitetheirincreased
strength.
Uses
Aerospaceapplications
Inthe1960s,Monelmetalfoundbulkusesinaircraftconstruction,especiallyinmakingtheframesand
skinsofexperimentalrocketplanes,suchastheNorthAmericanX15,toresistthegreatheatgenerated
byaerodynamicfrictionduringextremelyhighspeedflight.Monelmetalretainsitsstrengthatveryhigh
temperatures,allowingittomaintainitsshapeathighatmosphericflightspeeds,atradeoffagainstthe
increasedweightofthepartsduetoMonel'shighdensity.
Monelisusedforsafetywiringintheaircraftmaintenancetoensurethatfastenerscannotcomeundone,
usuallyinhightemperatureareasstainlesswireisusedinotherareasforeconomy.
Oilproductionandrefining
MonelisusedinthesectionofAlkylationunitsindirectcontactwithconcentratedhydrofluoricacid.
Indeed,Moneloffersexceptionalresistancetohydrofluoricacidinallconcentrationsuptotheboiling
point.Itisperhapsthemostresistantofallcommonlyusedengineeringalloys.Thealloyisalsoresistant
tomanyformsofsulfuricandhydrochloricacidsunderreducingconditions.
Marineapplications
Monel'scorrosionresistancemakesitidealinapplicationssuchaspipingsystems,pumpshafts,seawater
valves,trollingwire,andstrainerbaskets.Somealloysarecompletelynonmagneticandareusedfor
anchorcableaboardminesweepers,[7]housingsformagneticfieldmeasurementequipment.In
recreationalboating,Monelwireisusedtoseizeshacklesforanchorrodes,Monelisusedforwaterand
fueltanks,andforunderwaterapplications.Itisalsousedforpropellershaftsandforkeelbolts.
However,becauseoftheproblemofelectrolyticactioninsaltwater(alsoknownasGalvaniccorrosion),
inshipbuildingmonelmustbecarefullyinsulatedfromothermetalssuchassteel.TheNewYorkTimes
ofAugust12,1915publishedanarticleabouta215footyacht,"thefirstshipthathaseverbeenbuilt
withanentirelymonelhull,"that"wenttopieces"injustsixweeksandhadtobescrapped,"onaccount
ofthedisintegrationofherbottombyelectricalaction."Theyacht'ssteelskeletondeteriorateddueto
electrolyticinteractionwiththemonel.[8]
Inseabirdresearch,andbirdbandingorringinginparticular,Monelhasbeenusedtomakebirdbandsor
ringsformanyspeciessuchasalbatrossthatliveinacorrosiveseawaterenvironment.[9]
Musicalinstruments
Monelisusedasthematerialforvalvepistonsinsomehigherqualitymusicalinstrumentssuchas
trumpets,tubasandFrenchhornrotors.RotoSoundintroducedtheuseofMonelforelectricbassstrings
in1962,andthesestringshavebeenusedbynumerousartists,includingSteveHarrisofIronMaiden,
TheWho,Sting,JohnDeacon,andJohnPaulJonesandthelateChrisSquire.Monelwasinuseinthe
early1930sbyothermusicalstringmanufacturers,suchasGibsonGuitarCorporation,whocontinueto
offerthemformandolinastheSamBushsignatureset.Also,C.F.Martin&Co.usesMonelfortheir
MartinRetroacousticguitarstrings.
DirectionalDrilling
Moneldrillcollarsareusedinsurveyingoilwells.Monelcollarsareusedindrillingdirectionalwells
whichrequirethewelltobesteered.Theirusepermitsfasterandmoreaccuratesurveys,reducehazards,
anddecreasesthecostofdrillingdirectionalorcontrolledoilwells.Thereducedcostcomesfromthe
abilityofrealtimesurveysfromaMWDtoolwhichhasmagnetometersbuiltintothem.The
magnetometersifnotsurroundedbynonmagneticmaterial(monel,inconel,CuBe,ornonmagnetic
stainless)willbeunabletoreadtheearthsmagneticfieldwithoutinterferenceandwillgiveanincorrect
reading.
Monelisveryrarelyusedinpresentdaydirectionaldrillingcollars.Theyarestillreferredtoasmonel
collarsbasedontraditionandmisinformation.Monelhasbeensubstitutedwithothernonmagnetic
stainlessmaterialsduetocost.
Other
Thegoodresistanceagainstcorrosionbyacidsandoxygen
makesmonelagoodmaterialforthechemicalindustry.Even
corrosivefluoridescanbehandledwithinmonelapparatusthis
wasdoneinanextensivewayintheenrichmentofuraniumin
theOakRidgeGaseousDiffusionPlant.Heremostofthelarger
diametertubingfortheuraniumhexafluoridewasmadefrom
monel.[10]Regulatorsforreactivecylindergaseslikehydrogen
chlorideformanotherexample,wherePTFEisnotasuitable
optionwhenhighdeliverypressuresarerequired.Thesewill
sometimesincludeaMonelmanifoldandtapspriortothe
regulatorthatallowtheregulatortobeflushedwithadry,inert
gasafterusetofurtherprotecttheequipment.
Identificationtagsmadefrommonel.
Intheearly20thcentury,whensteampowerwaswidelyused,monelwasadvertisedasbeingdesirable
foruseinsuperheatedsteamsystems.[11]Duringtheworldwars,monelwasusedforUSmilitarydog
tags.
Monelisoftenusedforkitchensinksandintheframesof
eyeglasses.Ithasalsobeenusedforfireboxstaysinfiretube
boilers.
PartsoftheClockoftheLongNow,whichisintendedtorunfor
10,000years,aremadefromMonelbecauseofthecorrosion
resistancewithouttheuseofpreciousmetals.[12]
MoneldoorknobsintheBrynAthyn
Cathedral
Monelwasusedformuchoftheexposedmetalusedinthe
interioroftheBrynAthynCathedralinPennsylvania,religious
seatoftheGeneralChurchoftheNewJerusalem.Thisincluded
largedecorativescreens,doorknobs,etc.[1]Monelalsohasbeenusedasroofingmaterialinbuildings
suchastheoriginalPennsylvaniaStationinNewYorkCity.[1]
The19911996Acura(Honda)NSXcamewithakeymadeof
Monel.[13]
OilfieldapplicationsincludeusingMonel(rarelyseedirectional
drillingabove)inbothflexandslickcollars.Instruments
(magnetometersorcompass)whichmeasuretheEarth'smagnetic
fieldtoobtainamagneticdirectionareplacedinthenon
magneticcollarwhichisolatessensorsfromthemagneticpullof
drillingtoolslocatedaboveandbelowthenonmagneticcollars.
Theyareoftenreferredtoas"monelcollars"asthatwasthefirst
materialusedtomakethecollarsandthenamestuck.
ThegreenishroofofPennsylvania
Stationwasmadefrommonel
Monelisalsousedasaprotectivebindingmaterialontheoutsideofwesternstylestirrups.
MonelisusedbyArrowFastenerCo.,Inc.forrustproofT50staples.
MonelhasalsobeenusedinKelvinatorrefrigerators.
MonelwasusedintheBabyAliceThumbGuard,a1930seraantithumbsuckingdevice.[14]
Alloys
ASTM/AISI
TradeName
Alloytype
UNS
%Cu
%Al
%Ti
%Fe
%Mn
%Si
%Ni
Monel400
2.5max 2.0max
63min
Monel401
N04401 2834
2.5max 2.0max
63min
Monel404
N04404 2834
2.5max 2.0max
63min
MonelK500 B865
63min
MonelR405 B164
N04405 2834
Monel400
Monel400showshighstrengthandexcellentcorrosionresistanceinarangeofacidicandalkaline
environmentsandespeciallysuitableforreducingconditions.Italsohasgoodductilityandthermal
conductivity.Monel400typicallyfindsapplicationin:marineengineering,chemicalandhydrocarbon
processings,heatexchangers,valvesandpumps.Itiscoveredbythefollowingstandards:BS3075,
3076NA13,DTD204BandASTMB164.[15]
LargeuseofMonel400ismadeinthealkylationunits,namelyinthereactingsectionincontactwith
concentratedhydrofluoricacid.
Monel401
Thisalloyisdesignedforuseinspecializedelectricandelectronicapplications.Alloy401isreadily
autogenouslywelded,inthethinsectionsinwhichitismostoftenused,bythegastungstenarcprocess.
Resistanceweldingisaverysatisfactorymethodforjoiningthematerial.Italsoexhibitsgoodbrazing
characteristics.Alloy401isnormallyfurnishedaswire.ItiscoveredbystandardUNSN04401.
Monel404
Thisalloyisusedprimarilyinspecializedelectricalandelectronicapplications.Thecompositionof
Monel404iscarefullyadjustedtoprovideaverylowCurietemperature,lowpermeability,andgood
brazingcharacteristics.Monel404canbeweldedusingcommonweldingtechniquesandforgedbut
cannotbehotworked.Coldworkingmaybedoneusingstandardtoolingandsoftdiematerialsforbetter
finish.ItiscoveredbystandardsUNSN04404andASTMF96.Monel404alloyisusedinthefollowing
applications:capsulesfortransistorsandceramictometalsealings.
Monel450
Thisalloyexhibitsgoodfatiguestrengthandhasrelativelyhighthermalconductivity.Itisusedfor
seawatercondensers,condenserplates,distillertubes,evaporatorandheatexchangertubes,and
saltwaterpiping.[16]
MonelK500
MonelK500combinestheexcellentcorrosionresistancecharacteristicofMonelalloy400withthe
addedadvantagesofgreaterstrengthandhardness.Theincreasedpropertiesareobtainedbyadding
aluminumandtitaniumtothenickelcopperbase,andbyheatingundercontrolledconditionssothat
submicroscopicparticlesofNi3(Ti,Al)areprecipitatedthroughoutthematrix.Thecorrosionresistance
ofMonelalloyK500issubstantiallyequivalenttothatofalloy400exceptthat,whenintheage
hardenedcondition,alloyK500hasagreatertendencytowardstresscorrosioncrackinginsome
environments.MonelalloyK500hasbeenfoundtoberesistanttoasourgasenvironment.The
combinationofverylowcorrosionratesinhighvelocityseawaterandhighstrengthmakealloyK500
particularlysuitableforshaftsofcentrifugalpumpsinmarineservice.Instagnantorslowmovingsea
water,foulingmayoccurfollowedbypitting,butthispittingslowsdownafterafairlyrapidinitial
attack.
TypicalapplicationsforalloyK500are:pumpshaftsandimpellers,doctorbladesandscrapers,oilwell
drillcollarsandinstrumentsandelectroniccomponents.[17]
MonelR405
MonelR405isthefreemachiningversionofMonel400.Itisanickelcopperalloywithacontrolled
amountofsulfuraddedtoprovidesulfideinclusionsthatactaschipbreakersduringmachining.Like
Monel400,alloyR405isresistanttoseawaterandsteamathightemperaturesaswellastosaltand
causticsolutions.MonelR405isasolidsolutionalloythatcanonlybehardenedbycoldworking.This
nickelalloyexhibitscharacteristicslikegoodcorrosionresistance,goodweldabilityandhighstrength.A
lowcorrosionrateinrapidlyflowingbrackishorseawatercombinedwithexcellentresistancetostress
corrosioncrackinginmostfreshwaterscombinedtoitsresistancetoavarietyofcorrosiveconditions
justifiesitswideuseinmarineapplicationsandothernonoxidizingchloridesolutions.Thisnickelsteel
alloyisparticularlyresistanttohydrochloricandhydrofluoricacidswhentheyaredeaerated.Aswould
beexpectedfromitshighcoppercontent,alloyR405israpidlyattackedbynitricacidandammonia
systems.
AlloyR405ischieflyusedforautomaticscrewmachinestockanditnotgenerallyrecommendedfor
otherapplications.
Seealso
Cupronickel
Hastelloy
Inconel
References
1. VonMargotGayle,DavidW.Look,JohnG.Waite(1992)."Monel".MetalsinAmerica'shistoricbuildings:
usesandpreservationtreatments.DIANEPublishing.pp.3941.ISBN9780160380730.
2. "MonelontheEncyclopediaBritannica".RetrievedAugust12,2014.
3. AmbroseMonellU.S.Patent811,239(https://www.google.com/patents/US811239)Issuedate:Jan1906
4. PipingMaterialsCostRatios(http://www.engineeringtoolbox.com/pipingmaterialscostratiosd_864.html)
5. PhysicalpropertiesofMonel400(http://www.specialmetals.com/documents/Monel%20alloy%20400.pdf)
6. NickelAlloy400(Monel)(http://www.makeitfrom.com/data/?material=Monel)
7. Teeple,H.O.(1953)."NickelandHighNickelAlloys".Industrial&EngineeringChemistry45(10):2215.
doi:10.1021/ie50526a033.
8. "NewYorkTimes,August12,1915:BigYachtNowJunkAfterSixWeeksUse".TheNewYorkTimes.
August12,1915.RetrievedMay13,2010.
9. Ludwig,JamesP.(1981)."BandWearandBandLossintheGreatLakesCaspianTernPopulationanda
GeneralizedModelofBandLoss".ColonialWaterbirds4:17418.doi:10.2307/1521133.JSTOR1521133.
10. Milford,Robert(1958)."EngineeringDesignofOakRidgeFluorideVolatilityPilotPlant".Industrial&
EngineeringChemistry50(2):187.doi:10.1021/ie50578a032.
11. InternationalNickelCompany,MoneladvertisementinScientificAmerican,1921
12. Beech,Martin(2007)."TheClockoftheLongNowAReflection"(PDF).TheJournaloftheRoyal
AstronomicalSocietyofCanada101(1):45.
13. http://www.nsxprime.com/FAQ/General/nsxkeys.htm
14. http://graphicdesign.tjslabs.com/showpicture?id=1097010675
15. "MonelK400onAzom.com".RetrievedAugust12,2014.
16. "PropertyofMonelalloys".RetrievedApril10,2015.
17. http://www.hpalloy.com/Alloys/descriptions/MONELK_500.html
Bibliography
Shoemaker,LewisE.Smith,GaylordD.(2006)."Acenturyofmonelmetal:19062006".JOM
58(9):22.doi:10.1007/s118370060077x.
Externallinks
MonelCorrosion(http://corrosiondoctors.org/Seawater/monel.htm)
Retrievedfrom"https://en.wikipedia.org/w/index.php?title=Monel&oldid=691979672"
Categories: Nickelalloys Copperalloys Buildingmaterials Namedalloys
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