5.

Ni-Cr steel, Ni-Mo steel and Ni-Cr-Mo steel

-By Group 11 (MSE 671A)
Rajat Pandey(13542)
Lavanya Bathwal(13374)
Ranjeet Kumar(13554)
Neeraj Singh Thakur(13428)
1. Ni-Cr-Mo Steel:
Demand for higher strength and toughness requires increasing alloy content for improved
hardenability.
Alloying elements such as chromium, molybdenum, etc. are added to carbon steel to improve
properties such as hardness, strength and toughness. Ni-Cr-Mo low alloy steel is generally used as a
high hardenability, high tensile strength steel in most industrial sectors where high strength and
moderate impact properties are essential in fairly large components.

Application:
The rotor shafts of large electric generators are made of steel. Rotor shaft is a single piece solid
forming manufactured form a vacuum casting. It is forged from a vacuum cast steel ingot.
Other applications: axles, rolls, die holders, rams, collets, spindles, gears, bolts and couplings, etc.

Properties:
For its use in generator rotor shafts it must withstand fast rotation, and yet remain operational for a
period measured in decades.Therefore, it is important that they have:
high strength(tensile strength not lower than 700 MPa)
high toughness
very good fatigue resistance.
It is also well known that high strength tends to cause low toughness, and vice versa which is a
problem. Further because of the use of the material they should have:
suitable magnetic properties
Contributions of various elements:
Nickel - It is an essential component in increasing the hardenability and toughness of the central
section of the shaft material but also deteriorates the magnetic properties. Conventionally, as a
rotor shaft material for a comparatively large size generator driven by a gas turbine or a steam
turbine a steel containing not less than 3.0%(may be present upto 4%) nickel has been used.
Chromium - It is an indispensable for the hardenability, strength, and toughness of the central
section. In general, chromium content is less than 2%.
Molybdenum - Important for hardenability, toughness and to alleviate temper embrittlement.
Therefore content should not be less than 0.2 but above 0.5% deteriorates the magnetic
properties.So prefarably, should be kept between 0.3-0.4%.
Carbon - Needed to improve hardenability and strength, so that the low alloy steel needs it in an
amount of not less than 0.15%. However, if the carbon amount exceeds 0.35%, toughness of the
generator rotor shaft material is deteriorated. Therefore, the carbon amount is set to be 0.15 to
0.35%, preferably 0.20 to 0.30%

Processing:
Forging

Forging temperature for material should be 850-1200C. Soak times should be kept minimum to
avoid heavy scaling but sufficient time should be given to allow centre to achieve furnace
temperature. After forging, the pieces should be allowed to cool in still air.
Heat Treatment
Heat treatment after forging is carried out to render the steel suitable for machining, and to meet
the mechanical property limits specified for the steels particular applications.
o Annealing- Heat to 790-840C for a time commensurate with ruling section and furnace cool.
o Hardening- Heat to 820-850C for a time commensurate with ruling section and quench in
oil, water or polymer.
o Tempering- Should be done whilst the material is still hand warm. Re-heat to 450-660oC as
required, dependent on final required properties. Hold for time commensurate with the ruling
section and cool in still air.
# Tempering below 450 could lead to temper embrittlement.
Machining- The material has good machinability in the quenched and tempered condition and
various operations like sawing, turning and milling can be achieved indeed satisfactorily.
Welding- Should be done in the annealed condition and the work piece should be stress relieved
(640-660oC) after cooling to hand warm. Pre-heat temperature should be atleast 370oC.

Alternative:
Low alloy steel contains a reduced amount of nickel, an increased amount of chromium, and additive
copper. Specifically the low alloy steel contains, by mass percent, a primary component of Fe, 1.3 to
2.0% Ni, 2.1 to 3.0% Cr, and 0.15 to 0.35% Cu.

2. Ni-Mo Steel:
Application:
They are used for case hardened gears, bearings and cases.

Properties:
AISI 48XX steels include three standard grades : 4815, 4817, 4820 and three respective H grades with
the same numeric characters.
Percentage of elements Mo= 0.20 - 0.30 %
Ni(AISI4820)= 3.25 - 3.75 %
Ni(AISI4820H)= 3.20- 3.80%
These grades are carburised steels with high hardenability in both the case and core. The average
machinability rating of these grades is 50% at brinell hardness range of 187-229 HB.
Heat Treatment Processes and Microstructural changes:

Hardness of steels depends on heat treatments 197 HB when annealed.

212-235 HB when normalised
235-401 HB when carburised, quenched in oil and tempered. Lower tempering temperature and a
smaller work piece diameter result in higher hardness.
401-415 HB when quenched in oil, tempered and carburised
Surface hardness of around workpiece quenched in oil decreases when the diameter of the workpiece
increases :
0.5 in = 421 HB
1.0 in = 401 HB
2.0 in = 336 HB
4.0 in = 265 HB
= 502 HB - 2994

3. Ni-Cr :
Application:
These nickel chromium base alloys are used extensively in applications where heat resistance and/or
corrosion resistance is required. In some members of the group, where conditions are less demanding,
some nickel is replaced by iron to decrease the overall cost.
Where corrosion resistance is significant, molybdenum is used as an alloying addition in nickel
chromium based alloys.

Use: Inconel
Inconel is a family of austenite nickel-chromium-based superalloys.
Inconel alloys are oxidation and corrosion resistant materials well suited for service in extreme
environments subjected to pressure and heat. When heated, Inconel forms a thick, stable, passivating
oxide layer protecting the surface from further attack. Inconel retains strength over a wide temperature
range, attractive for high temperature applications where aluminum and steel would succumb to creep
as a result of thermally induced crystal vacancies. Inconels high temperature strength is developed by
solid solution strengthening or precipitation hardening, depending on the alloy.
Tesla Motors is now using Inconel, in place of steel, to upgrade the main battery pack contactor in its
Model S so that it remains springy under the heat of heavy current. Ford Motor Company is using
Inconel to make the turbine wheel in the supercharger of its EcoBlue diesel engines introduced in
2016. Rolled Inconel was frequently used as the recording medium by engraving in black box
recorders on aircraft.

Heat Treatment:
Table 1. Age-hardening practices for nickel-chromium alloy- Inconel

Alloy
Inconel
718

Solution treated
Temperature Cooling
method
980 C

Inconel X-1150 C
750
980 C

AC
AC
AC

Age hardening
Heat to 720C, hold 8h; furnace cool to 620C, hold until
furnace time for entire age-hardening cycle equals 18h; air
cool
Heat to 845C, hold 24h; air cool; reheat to 705C, hold 20h;
air cool
Heat to 730C, hold 8h; furnace cool to 620C, hold until
furnace time for entire age-hardening cycle equals 18h; air
cool

Alternative:
Alternatives to the use of Inconel in chemical applications such as scrubbers, columns, reactors, and
pipes are Hastelloy, perfluoroalkoxy (PFA) lined carbon steel or fiber reinforced plastic.
Hastelloy
The primary function of the Hastelloy superalloys is that of effective survival under high-temperature,
high-stress service in a moderately to severely corrosive, and/or erosion-prone environment where
iron-based alloys would fail, including the pressure vessels of some nuclear reactors, chemical
reactors, distillation equipment, and pipes and valves in chemical industry. Although a super alloy,
Hastelloy experiences degradation due to fabricating and handling. Electropolishing or passivation of
Hastelloy can improve corrosion resistance.

Heat Treatment: Age hardening

Table 2. Age-hardening practices for nickel-chromium alloy -Hastelloy
Alloy
Solution treated
Temperature Cooling method Age hardening
Hastelloy X 1175 C
AC
Heat to 760C, hold 3h; air cool; reheat to 595C,
hold 3h; air cool
Inconel is better than Hastelloy because its high iron content makes it a more cost effective solution
for many applications.
Incoloy is high temperature strength and resistance to seawater, brine, sour gas, and chloride make it
ideal for use in the oil and gas industries. It is also used for propeller shafts, hot vessels for food and
water, chemical processing equipment, gas turbines, aircraft, and tank trucks. Alloying Incoloy with
other elements can further increase its resistance to chemically corrosive environments such as
sulfuric and phosphoric acids, and nuclear fuel.

References:
1.

https://books.google.co.in/books?
id=ul6UBgAAQBAJ&pg=PA37&lpg=PA37&dq=46XX+steel&source=bl&ots=iwIRyAExi4&sig=ICp
D_Lzrx9sM9SEeMrNLuekZsM&hl=en&sa=X&ved=0ahUKEwjAvcvJtfHOAhUFvI8KHWGABZYQ6AEIOjAG#
v=onepage&q=46XX%20steel&f=false

2.

http://www.imoa.info/molybdenum-uses/molybdenum-grade-alloy-steels-irons/heat-treatableengineering-steel.php

3.

http://www.google.co.in/patents/EP2166123B1?cl=en

4.

http://www.sandvik.coromant.com/engb/industrysolutions/condensing_power/generators/pages/generator-shaft.aspx?Country=in

5.

http://www.google.co.in/patents/US5548174

6.
7.
8.
9.
10.

http://www.steelforge.com/alloy-steel-4340/
http://www.nickel-alloys.net/nickel_chrome_alloys.html
http://www.totalmateria.com/Article32.htm
https://en.wikipedia.org/wiki/Inconel
http://metalspecialist.continentalsteel.com/blog/what-is-the-difference-between-hastelloy-and-incoloy