1. 2 Their evolution beyond the first prototypes depended on materials becoming available with hitherto unknown resistance to temperature, stress and.

1

2

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!

3

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.

4

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.

5

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.

6

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®

7

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

8

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

9

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

10

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

11

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%.

12

Typical Chemistry

13

Mechanical Properties

14

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.

15

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.

16

17

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.

18

• 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.

19

• 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.

20

Typical Chemistry

21

•Physical Properties

22

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.

23

•Mechanical Properties

24

Mechanical Properties

25

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.

26

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.

27

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.

28

• 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.

29

Typical Chemistry (%)

30

• 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.

31

• 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.

32

Physical Properties

33

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.

34

• 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.

35

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.

36

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.

37

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.

38

• 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.

39

Mechanical Properties

40

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.

41

• 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.

42

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.

43

• 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.

44

• 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.

45

Typical Chemistry

Titanium alloy powder

preparation for selective

laser sintering

46

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.

47

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.

48

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

49

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.

50

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)

51