HIGH TEMPERATURE MATERIALS

NI RESIST

Advanced materials shaping the future

OUTLINE
Why make high
temperature materials

Market development
and typical products

Alternative routes
(SiMo, SiMoCr and NI
resist)

SiMo SiMoCr Ni Resist

Composition Composition Composition

microstructure microstructure microstructure

Elkem products Elkem products Elkem products

treatment & inoculation treatment & inoculation treatment & inoculation

Typical problems and Typical problems and Typical problems and

defects defects defects

Advanced materials shaping the future

WHY MAKE HIGH TEMP MATERIALS ?
WHAT DO YOU NEED TO CONSIDER ?
• High cyclic temperatures cause • Design and production considerations
• Oxidation • Design and Flow Characteristics
• Thermal mechanical fatigue due to • Minimize Hot Spots
• thermal expansion and mechanical constraint • Minimize Thermal Strains
• cyclic thermal stress • Mounting Strategy

• Example application • Engine Test Parameters

• Peak Temperature
• Turbo charger
• Time at Peak Temperature
• Length of Test
• Cooling Cycle
• Materials Selection
• Material Properties
• Oxidation Resistance
• Microstructure Stability
• Foundry Processes/Materials
• Quality, Raw Materials
• Quality, Systems & Procedures

Left side Right side

Hot exhausts Inlet of air
(High Temp Cast Iron) (Al-housing)

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MARKET DEVELOPMENT, TRENDS AND PRODUCTS
Trend: Turbo charge increase
• Growth due to boosting of both diesel and gasoline
engines.
• Shift towards Ni-Resist and Stainless Steel due to
Manifold higher gas temperatures.

Classic Cast iron – decrease due to:

• Increase in Asian automakers using
fabricated exhaust manifolds.
• Introduction of engines with integrated
Turbo Turbo manifold
manifolds into the aluminum head.
20.0
• Less cylinders per engine - fewer and
smaller manifolds. 15.0
Gas NiResist
• Increased exhaust temperatures beyond 10.0
Diesel NiResist
typical cast iron endurance. May Diesel SiMoCr
5.0
increase Ni-Resist and stainless steel Diesel SiMo
manifolds. -
2008
2009
2010
2011
2012
2013
2014
2015
• Electric vehicles – no manifolds.

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WHAT IS NI-RESIST?
• The name Ni-Resist – because it resists acid, caustic, salt solutions and high
temperatures.
UTS Yield
min stress Elong C Si Mn P Ni Cr Hardness
Type [MPa] [MPa] [%] [%] [%] [%] [%] [%] [%] [HB] Applications
Valve stem bushings, valve and pump bodies in petroleum,
0.7- 1.75- salt water and caustic service, manifolds, turbocharger
D-2 400 207 8 3 1.5-3 1.25 0.08 18-22 2.75 139-202 housings, air compressor parts.
0.7-
D-2B 400 207 7 3 1.5-3 1.25 0.08 18-22 2.75-4 148-211 Turbocharger housings, rolls.
1.8-
D2-C 400 193 20 2.9 1-3 2.4 0.08 21-24 0.5 121-171 Electrode guide rings, steam turbine dubbing rings.
2.5- Turbocharger nozzles and housings, steam turbine
D-3 379 207 6 2.6 1-2.8 1 0.08 28-32 3.5 139-2020 diaphragms, gas compressor diffusers.
1-
D-3A 379 207 10 2.6 1-2.8 1 0.08 28-32 1.5 131-193 High temperature bearing rings requiring resistance to galling.
4.5-
D-4 414 2.6 5-6 1 0.08 28-32 5.5 202-273 Diesel engine manifolds, manifold joints.
Guidance system housings, gas turbine shroud rings,
D-5 379 207 20 2.4 1-2.8 1 0.08 34-36 0.1 131-185 glass rolls.
Optical system mirrors and parts for dimensional stability,
D-5B 379 207 6 2.4 1-2.8 1 0.08 34-36 2-3 139-193 stators for compressors.
4.9- 1.75- Manifolds, turbine housings, turbochargers where high
D-5S 448 207 10 2.3 5.5 1 0.08 34-37 2.25 131-193 temperatures and severe thermal cycling occur
2.2- 1.5- 3.75- Compressors, expanders pumps and other pressure-
D-2M 448 207 30 2.7 2.5 4.50.08 21-24 0.2 121-171 containing parts requiring a stable austenitic matrix at minus -234C.
Ref: Ductile Iron Data for Design Engineers, Ductile Iron Society, www.ductile.org

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GENERAL PROPERTIES Held at temperature for
200h

• Typical Properties
• Corrosion, erosion and wear resistance
• Strength, ductility and oxidation resistance
at high temperature
• Toughness and low temperature stability
• Thermal expansion, magnetic and
electrical properties are different due to the
austenitic structure
• Castability and machinability
Oxidation resistance (mm/year)
Test 1 Test 2
Alloy (700 C) (900 C)
Si 2.5% SG 1.1 12.7
Si 5.5% SG 0.1 1.3
Ni Resist type D-2 1.1 43.4
Ni Resist type D-2C 1.8 0
Ni Resist type D-4 1.1 0
Gray Ni Resist type 2 2.5 7.6
Stainless steel Cr 18%/Ni 8% 0 0
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A GOOD MICROSTRUCTURE

• Etched sample, mainly ferritic, high • Enlarged, showing the presence of

nodularity containing only islands of Chromium Carbides
disconnected carbides

100μm
100μm

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EXAMPLE OF A TYPICAL PRODUCTION FOR D-5S
• Raw materials • Mg 0.06% nominal
• Typical Returns 65% • S <0.02%
• Steel 19% • RE is prohibited
• Nickel 12.5%
• Ferro Chrome 1.5%
• Tap and Pouring
• Shrinkage and Yield
• Tap temperature 1570-1590 ºC
• Lower C of around 2.3 % will increase
• Nodularization NiMg added at 0.5%
tendency for high shrinkage – larger risers,
gating is needed • Sandwich ladle
• Lower yields due to shrinkage, sometimes • Inoculation
up to 80% returns are used due to low • FG FeSi ladle grade at 0.4%
yields • FG FeSi MSI at 0.07%

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MATERIALS AND MFS CASE STUDIES – D5S
• Nodularization - Common usage • Case study of MgFeSi
• NiMg,5 to 15%Mg, very common • MgFeSi treated iron had different
• MgFeSi needs to be RE free – or problems pouring characteristics with increased
with chunky fluidity.

• Europe Alternative examples • Improved shrinkage behaviour.

• A part with 30-35 % scrap using NiMg
• Site 1: Wire feed 60-40% Si-Mg
dropped to 5% with MgFeSi.
• Site 2 : Wire feed MgFeSi
• The overall scrap rate dropped from
• Site 3 : ⅔NiMg+⅓MgFeSi 18% to 5%.
• Site 4 : MgFeSi, tundish ladle • The original castings had to be heat
• Inoculation treated due to the retained grain
boundary carbides, normally around
• NiMg treated iron is inoculated as usual
10-15%.
• MgFeSi treated irons might need
• The MgFeSi treated iron had less than
adjustment
5% carbides and in some cases these
were in the modified condition.

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TYPICAL DEFECTS
• Chunky graphite • Excessive carbide
• Main cause : RE and pour inoculation • Main cause: High Cr and/or insufficient
inoculation

Advanced materials shaping the future

SUMMARY

Price, raw material and production

Production difficulties

is t
R es
Ni

r
oC
M
Si

o
M
Si

Performance, oxidation
resistance, stability etc

Advanced materials shaping the future

Advanced materials shaping the future