Special steels and alloys for harsh operating conditions

When designing and operating equipment for various industries, be it chemical, oil and gas or food, it is necessary to take into account the impact on materials of aggressive environments and extreme temperatures. Under such conditions, corrosion-resistant, heat-resistant and heat-resistant steels and alloys that are able to maintain their properties despite external influences are of particular importance.

Corrosion resistant materials

Corrosion is one of the main problems faced by engineers in chemical, oil and gas and other industries. The destruction of metals under the influence of an aggressive external environment can lead to serious economic and environmental consequences. Therefore, the use of corrosion-resistant steels and alloys is not just a choice, but a necessity.

The main types of corrosion-resistant materials include:

1. Chrome steels
   • Examples: 12X13, 20X13.
   • They contain chromium, which forms a protective chromium oxide film on the surface that prevents corrosion.
   • The minimum chromium content for protection is 13%.
2. Austenitic steels
   • Examples: 12X18N9, 12X18H10T, 12X18N9SMR, 10X17N13M3T.
   • They contain nickel and chrome, which form a protective film.
   • They have high plasticity and impact strength compared to chromium steels.
3. Ferritic steels
   • Examples: 12X17, 08X17T.
   • They have a different chemical composition and structure compared to chromium and austenitic steels, but also have increased resistance to corrosion.

Heat-resistant materials

In the aviation, missile and nuclear industries, where the operating temperature of components and equipment can exceed 1000°C, conventional materials lose their properties. Heat-resistant steels and alloys remain resistant to oxidation and retain their functionality at extreme temperatures.

The main types of heat-resistant materials:

1. Nickel alloys
   • Examples: H20N80N, H15N60N.
   • They contain a high percentage of nickel, which provides heat resistance.
2. Corundum ceramics
   • It consists of oxide aluminum and has a high heat resistance.
3. Iron-based alloys with chromium and aluminum
   • Examples: X15YU5, X23YU5, X23YU5T.

Heat-resistant materials

Heat-resistant steels and alloys retain their mechanical properties under increased loads and extreme temperatures, which is necessary in power engineering, aviation and space technique.

Examples of heat-resistant materials:

1. Martensitic steels
   • Examples: 40X9S2, 15X11MF.
   • They are known for their high strength and hardness, but they have relatively low plasticity.

Innovative and popular alloys

Inconel they are characterized by high strength, corrosion resistance and heat resistance, which makes alloys of this family popular in various industries.

• Inconel 600
  • Alloy-based gland, nickel and chromium combines high resistance to stress corrosion cracking and the ability to maintain strength when exposed to elevated temperatures.
  • It is used in the chemical and petrochemical industries, nuclear power and the automotive industry.
• Inconel 625 
  • A niobium-stabilized Ni-Cr-Mo alloy with resistance to aggressive environments, including crevice corrosion and pitting corrosion.
  • Used in aerospace and the chemical industry, oil and gas production, and shipbuilding.
• Inconel 718
  • Rafting, hardened by aging, maintains high strength up to 700°C, has corrosion resistance and good weldability.
• Inconel 725
  • It has corrosion resistance similar to Inconel 625, but has increased strength achieved by aging.
• Inconel C-276
  • An alloy with high resistance to reducing and slightly oxidizing media, as well as resistance to local effects and stress corrosion cracking.
  • It is used in the chemical and oil refining industries to work in aggressive environments.

The tensile strength of these alloys in the annealed state is approximately 700—800 MPa, and after aging — 1200—1400 MPa.

Areas of application

Modern technologies require materials that can withstand extreme operating conditions. Let's look at the main applications of Inconel special alloys and their importance in various industrial sectors.

Aerospace engineering

Aerospace industry has extremely high requirements for materials. Inconel alloys have unique heat resistance and corrosion resistance, which makes them indispensable in the production of various elements of propulsion systems. They are used for:

• in power turbines — withstand extreme temperatures, maintaining strength and stability;
• in exhaust systems — allow you to minimize the thermal effect on other components of the system;
• in equipment for the production of composites — their strength and heat resistance are necessary when creating complex composite materials.

Such alloys are used in airplanes, helicopters and spacecraft, where reliability and safety come first.

Automotive equipment

The automotive industry also needs materials that are highly durable and resistant to high temperatures. The constant tightening of environmental standards and increasing requirements for engine efficiency contribute to the expansion of the use of special alloys. The use of such materials is especially important:

• in valves and ignition devices — ensure the stability of engines under extreme operating conditions;
• to exhaust systems — resistance to high temperatures and corrosion contributes to an increase in the service life of the system.

Thus, modern cars are becoming more reliable and environmentally friendly due to the introduction of innovative materials.

Chemical and processing industry

Equipment for these industries should be developed taking into account the impact of various corrosive environments in which conventional materials are rapidly destroyed. Inconel alloys, which are highly corrosion-resistant, are used:

• in process vessels — ensure the durability of equipment, despite the effects of aggressive chemicals;
• in pipelines — materials are resistant to corrosion and withstand high pressure and high temperatures;
• in pumps and valves — the use of special alloys reduces the risk of leaks and accidents.

These materials can significantly improve the safety and efficiency of production processes.

Oil and gas industry

In the oil and gas industry, equipment is operated under conditions of high temperatures, pressure and exposure to corrosive media. Inconel alloys are used to create:

• borehole pipes — withstand the effects of various gases and petroleum products;
• wellhead equipment — ensure reliable operation in extreme conditions;
• processing equipment — the corrosion resistance of alloys extends the life of components and assemblies.

These alloys are especially in demand on offshore platforms and in deep-water wells, where equipment reliability requirements are highest.

Refining and petrochemical industry

Production processes in oil refining and petrochemistry require the use of high-temperature corrosion-resistant alloys. They are used for:

• in reactors and heat exchangers — resistance to high temperatures and chemical effects makes it possible to extend the service life of the equipment;
• in pyrolysis pipes and collectors — ensure stable operation of systems under extreme loads;
• in transfer pipelines — ensure the reliability and safety of transporting processed products.

Such materials help reduce the risks of process shutdowns and accidents at continuous production facilities.

Energy

Energy industry, including thermal and nuclear power, also places high demands on materials used in production equipment. Inconel alloys are actively used:

• in onshore gas turbines — ensure long-term operation at high temperatures;
• in pipes in coal and gas plants — materials are resistant to corrosion and temperature effects;
• in equipment nuclear power plants — the high corrosion resistance of alloys increases the reliability and safety of operation.

At a time when the reliability and long-term operation of equipment are critical factors, special steels and alloys play an irreplaceable role.

PZPS products

St. Petersburg Precision Alloy Plant produces a wide product range, including corrosion-resistant steels and heat-resistant materials such as:

• alloys similar in chemical composition, structure and properties to Inconel 625, Inconel 718, Inconel S-276;
• corrosion-resistant steels 12X18N9, 12X18H10T, 12X18N9SMR, 10X17N13M3T;
• heat-resistant steels and alloys 20X13, HN78T.

Thanks to constant innovation and rigorous quality control, PZPS guarantees the reliability and durability of its products, which makes them an excellent choice for various industrial sectors. For questions about ordering materials, workings new special alloys, the provision of others production services leave application on the website or contact us at specified phones. Our experts will contact you and answer your questions in detail.

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