Hastelloy Castings — A Review (Hastelloy - ‘C’ Family) Shreepad A. Bothe ~ Flat No. 5, Varadan Palace ‘Sphurti Chowk, Dhamani Road Vishrambag, Sangli - 416 415 (Maharashtra) Email: bothe.sa@gmail.com 1. INTRODUCTION AND BRIEF HISTORY Hastelloys are basically Nickel-base alloy groups. Those Who were working with small induction furnaces during 1970-2000 might be well conversant with Hastelloys, specifically B, C, D grades. At that time these were the costliest castings, and were weighed in terms of the grammes. Mostly, Impellers, Shaft Sleeves (shaft protecting), Impeller Nuts, Casing Covers of Small Pumps were the common components, for the pump manufacturers. The chemical industries were rising, specifically, acids like Hydro Chloric acids (HCI), Sulphuric Acids, Phosparic acids etc. with their various concentrations and temperatures, Presently the arrival of stainless, duplex steels, and with. their comparatively low cost, non repeatability; the consumptions of these alloys has reduced. Even in these grades, there is a tremendous research, and more precise alloys have been developed. The story of Haynes International spans almost a century. It was started by Elwood Haynes in Kokomo, Indiana. Elwood Haynes was an inventor, teacher, experimenter, businessman, and philanthropist, in Dec. 1912. It is equally interesting to note that he is one of the pioneers, to develop horseless carriages. The success of the “Pioneer” led Haynes to form an automobile company producing high-end automobiles through the mid 1920s. It was during 1887 that Haynes began experimenting with metals in search of a material that would resist, tarnishing and be suitable for Cutlery. After a number of years of unsuccessful experiments, he began working with nickel-chromium and cobalt-chromium alloys. He was awarded with two patents: 1. for Nickel Chrome alloys, and 2. for Cobalt Chrome alloys, in 1907. Dedicated in loving memory of my beloved child Pragati whom we lost due to Covid on 27th April 2021 Reminiscence of her will remain forever in our hearts and thoughts. ‘Om shanti } Additions with Molybdenum, and Tungsten, in Cobalt- Chrome alloys lead to a new series, known as Stellite, and were patented 1n 1912. Stelite is derived from Latin, Stella — shining like stars. After machining, the components used to shine like stars. (Later on Stellite is a registered trademark of Deloro Stellite, Inc., Belleville, ON, Canada.) In October 1915, a new company was incorporated Known as Haynes Stellite Company. He also started experimenting on Nickel Chrome alloys, for which he was given the patent as mentioned earlier. Ha (short form of Haynes) + Stell (short form of Stelite) + Alloy - HASTELLOYS were patented, and trademarked, In 1921, first Hastelloy-B (1923) was borned to combat the corrosion. About 1926 work was beginning on nickel-molybdenum-chromium alloys for improved corrosion resistance in oxidizing environments. From this research Hastelloy C was born. Today the fifth generation of this alloy (Hastelloy C-20006) is being supplied to the chemical process industry by Haynes International. Hastelloy D, a nickel-silicon-copper alloy was also invented during the 1920s, The research still has continued to generate, new alloys in the field of Nickel-Cobalt-Molybdenum based alloys. The applications have more criticality, like turbo jet high temperature, high pressure applications, Since the subject becomes very vast, the limitation could be only few already existing alloys. FOUNDRY 59 ‘JULY/AUGUST, 2021‘The original HASTELLOY C alloy (Ni-16Cr-16Mo-5Fe- 4W.-0.7Si-0.5Mn-0.2V-0.06C) was patented in 1931 by Russell Franks (US Patent No. 1,836,317). The addition of Cr was beneficial for both high temperature oxidation as well as oxidizing acid solutions. Since the Mo level was also relatively high, the resistance to reducing acids was also quite good, Originally introduced as a cast alloy wrought processing techniques were soon developed HASTELLOY D alloy (Ni-9Si-3Cu) was developed for sulfuric acid resistance and was used almost exclusively in cast form. The patent for this alloy was US Patent No. 1,753,904, issued in 1930 to Clayton E. Plummer of Electro Metallurgical. The modern-day adaptation is HASTELLOY D-205 alloy, which is a wrought product known primarily for its resistance to sulfuric acid, particularly for very high concentrations. Due to thei success in gas turbine applications, the early HASTELLOY alloys (particularly B and C) have been identified as the predecessors to the modern soli solution strengthened super alloys (from 100+ Years of wrought alloy). 2. DEVELOPMENT AT HAYNES INTERNATIONAL Even though these alloys are from non ferrous, these are covered under ASTM A-494, The much about Nickel- base alloys was discussed in my earlier article “Nickel Alloy Castings — A Review’, focus on Monel Castings appeared in Sepl/Oct,2020 of ‘FOUNDRY’ magazine. Wrough products are covered under ASTM B series. The NACE standard 15156-3 is meant only for precipitation hardenable nickel-base alloys, (refer table A-31-A-37) ‘These become high performance alloys, and expectation of properties, unless properly treated, is equally high, {or the application point of view. Table-1 Hastelloy Family Hastelloy | Nominal Chemical Composition Family | (Wt%) Alloy | Ni-20Mo-20Fe AlloyB | Ni-30Mo Alloy | Ni-16Cr-16Mo-4W AlloyD | Ni-10Si-2Cu AlloyF | Ni-20Cr-6Mo-20Fe AlloyG | Ni-20Cr-6Mo-20Fe-2Cu AlloyX | Ni-22Cr-9Mo- 18 Fe 3. C-FAMILY OF HASTELLOY ALLOYS Forcorrosion-resistance application ‘©’ family alloys are mostly used Basically Hastelloy C was introduced in 1932. The Hastelloy are always under continuous research for the improvements in their corrosion and high temperature application properties. The micro structural auality improvements in this field is very important. The castings are prone for sensitization. The grain boundary precipitation of carbides and inter metallic are Possible. The grain boundary precipitation and depletion Zones are the easiest path for the corrosion attacks. The more than 50% service failures are attributed to inter granular corrosions. This is often due to improper heat treatment, compositional effects, and inappropriate casting techniques Improvements in the elemental mixes have vast improvements in sensation. Lower Carbon (0.02%max.) and lower Silicon contents have given more thermal stability. The experimental variations in Chromium, Tungsten canted have enhanced the properties. The castabilty, formability and weldability have been improved. Low Carbon has reduced Carbide formation, and additional Chromium has controlled depletion. Table-2 ‘C’ Family of Hastelloys Hastelloy | Development] Cast Grade Composition (Wt %) Alloy Date Description | Designation [cr| Mo |W] ¢ | Si c 1932, c cwiamw | t6] 16 | 4 [o12"| 1.0" c276 | 1967 c cwiamw | 16] 16 | 4 fo12"| 1.0" cg 1975 cae cw2M 16| 16 | - |o.02"| os c22m | 1985 c22 cxemw | 22] 13 | 3 |o.02"| os “Maximum FOUNDRY 60 JULYAUGUST, 2021For the foundrymen like us, this is most important to follow, is to control over the given Chemistry. Moulding ‘The castings can be cast by any process like sand moulding, shell moulding investment casting, centrifugal casting. The type of sand processes are similar to Stainless and Duplex stainless steel castings. The venting, painting of the moulds, follow the same criteria, As earlier discussed, applications of ceramic / foam {fiters becomes the necessary to control the inclusions. Melting and Handling As far as the quality is concern, melting the metal and handling the liquid metal are separate subjects, ‘The melting involves not only the building of elemental chemistry, but to get refined, free from dissolved gases, and control over the siag formations etc. At present the neutral lining gives the much advantages. Core-less Induction of smaller capacity, higher the melting rate, and minimum holding just above melting points have given the best results. This builds the highest quality in liquid stage only. Better to use, ingots from AOD. The degassing is an equally important; and use of conventional process like, calcium Silicide, Ferro Titanium, Columbium is recommended. The vacuum degassing could be final process part. Melting is simplified when pure metals are used. But master ingots of known analysis (preferably vacuum- refined) are equally applicable, Other charge materials, such as selected scrap of known analysis, or foundry returns may also be used. Raw materials of low hydrogen, nitrogen and oxygen contents are essential during air induction meiting. Hydrogen solubility is lower in nickel-base than in iron-base alloys, but the effects of hydrogen are slightly different. When chromium is one of the alloying elements, the melt becomes susceptible to hydrogen and nitrogen pick-up during ‘melting in air All charge materials should be free of moisture, grease, cil or any other contaminants. Pre-heating or baking will help to ensure this. Raw materials sampling is essential in any case. The laboratory must be equipped with an adequate range of Spectrographic standards. Scrap sizing inspection will check suitability for charging and melting n relation to furnace size. Ferro-alloys as used in steelmaking may contain Sulphur and Nitrogen, and their use should be ruled out (unless a satisfactory certificate of analysis is available). In general, harmful elements will limit the choice of furnace charge materials. Melting ~ Refining by boiling is best done on an MgO lining or an alumina-magnesia spinel forming lining, because of the high temperatures involved. Reaction from other linings, even neutral alumina, might be sufficient to cause dificulty in controlling the boil. Nickel oxide is the best available agent for promoting the boil, but superheating the meit is necessary to start it ‘A 2% addition of nickel oxide will be expected to boil out about 0.15% carbon. Obviously, additions should be made with caution, restricting, where possible, the boil to the top of the furnace to avoid overflow of the metal and erosion at the mid-height of the fining, The refining of foundry returns, when air induction melting is possible by boiling argon purging and calcium de- sulphurisation. This may be done in preparation for directly pouring into moulds, and also for the pouring of ingots that can be fully analyzed for use as metting stock. Foundry Retums may be used, but only under well regulated and monitored conditions. In the case of the nickel-copper alloys, there is no restriction on the proportion of foundry returns that can be used when making up a furnace charge. For the other alloy types (NiMo, N-Cr-Mo, Ni-Cr-Fe) no more than 50% of the charge weight should consist of Foundry Returns furnace size. ‘As a suggestion, when we use foundry retums, we can adopt the process (all materials should be kept ready in hand), 4. Charge Order (a) Nickel and Molybdenum (b) calculated clean foundry returns (runners, risers, flashes and rejections) Melt down up to in the range 1490 °C - 1540 °C. Charge the Chromium as fast as possible without freezing the melt. 4, Raise the temperature to 1565 °C - 1600 °C (for the recovery of Tungsten and pure Molybdenum) 5, Add Manganese, Silicon Tungsten (don't use lumps, Use granules) Vanadium to match the specifications. 6. De-oxidize with Calcium Silicide, Magnesium treatment. Use higher quantity, proportional to % of foundry returns). If the facility for argon purging exists, even in the ladle itis highly welcome. FOUNDRY 6 JULY/AUGUST, 20217. Tap in the hottest, clean ladle, carry the ladle as fast. as possible (no delays ) pour immediately in the range of lowest practical temperature (preferably 1840 °C -1510 °C) Calcium suppresses pin holing, and also has the advantage of improving castabilty and surface quality Magnesium will also control porosity and because ofits desulphurising effec, its use as a deoxidantis preferred. There would be no objection to using both calcium and magnesium An addition of 0.1 % titanium may be made to the niiobium-containing Ni-Cr-Mo alloys, in order to tie up any nitrogen especially when using foundry returns, in which high nitrogen build-up can be expected) before adding niobium, which itself is a strong nitride former. Handling: It covers the ladies. A clean ladle, heated up to the maximum possible, covered with lid is recommended. Carrying by the crane and or manual should be fast. The poring lip should be as close as possible to the sprue of the mould, and fast poring are the regular expected procedures Solidification Nickel alloyed with molybdenum and/or chromium solidifies as a single phase (austenite), but at lower temperatures solid solubility decreases, leading to phase separation. In addition to impurities, elements titanium, tungsten, vanadium or iron may be present, but at room temperature the alloy is essentially single phase and is not amenable to age hardening. Phases present in the as-solidified structure may be y (Gamma prime), o (sigma), j1 (mu), P (Laves) collectively known as TCP phases; carbides may also be present. ‘TCP phases can be detrimental to properties, especially at elevated temperatures, and the high-temperature alloys (super alloys) are usually melted, poured and solidified in vacuum to minimize the presence of unwanted elements, Methoding ‘The casting follows guidelines of stainless steel castings only. The directional solidification path is to be followed ‘The use of alumina or foam filters is a very good practice. For riser! feeder designs, itis better to go for H = 2D, instead of H = 1.5 D (H = height, and D = diameter of the Risers, using 1.5 MEF.) Casing properties of Hasay C, composton 0 05%, 05S, 058, A8KCr, T7HMo, 45% W, 6H Fe balance (Aer R Weod and. F Grego, the Bsn Foundryman, 187, Jn, 214, Fig. 1 : Fluidity Vs. Pouring Temperature for Hastelloy-C Shrinkage Allowance for the Patterns The pattemmaker's shrinkage allowance for nickel and nickel-base alloys is 0.25 inches and a nickel-base alloy is 0.25 inches per foot (2%). Fluidity The fluidity depends to a large extent on the degree of superheat, but casting quality (a properly of greater importance) is related to chemical composition rather than to superheat. Below given graph is a self explanatory. Foundry Practice — Fettling The earliest knock-out is the best procedure. It will avoid unwanted precipitations. For the separation of runners, risers, flashes, any conventional methods can be used, Shot blasting with steel shots to be totally avoided. The shots, powder, and dust may get entrapped in the surface porosity or cracks, and may become prone sight for the corrosion. Please note, these alloys are for critical applications, and to be treated as a separate identity only. Sand blasting and ceramic bid blasting are recommended, where there is NO contamination of iron in any form is possible. Heat Treatments, During 1970-1990 the heat treatment furnace manufacturers and users had only in mind of stainless. FOUNDRY 62 JULY/AUGUST, 2021Table-3 Effect of Solution Treatment Temperature on the Tensile Properties of Hastelloy C-4 Solution Ys uTSs el | RA Temp. (°C) | (Nimme) | (Nimm?) | (%) | _(%6) 1175 310 554 at | 24 1230 284 67 60 | 49 steels. The family needed only 1050-1100 °C. But the present alloys needed 1175 °C as a minimum. Many a times the castings were accepted without any heat treatment or as cast condition. Ordinary shot blasting ‘was a one of the cleaning process. The technology has developed, and users are aware the criticality of the applications. ASTM A-494 specifies the heat treatment as a mandatory. But the furnaces should be capable of meeting the temperature requirements, Proper heat treatment of these alloys is usually necessary to enhance corrosion resistance and, in some cases, lo meet mechanical properties. Minimum heat- treat temperatures are specified; however, it is sometimes necessary to heat treat at higher temperatures, hold for some minimum time at ‘temperature, and then rapidly cool the castings in order to enhance the corrosion resistance and meet mechanical properties. (ASTM Fig. 2 : Microstructure of Hastelloy C carbides and grain ‘boundries (reference: ASM Hand Book on Micro Structures) redissolve the secondary acicular precipitates and thereby optimize corrosion resistance. The effect of temperature upon tensile properties is illustrated in Table-3. In the USA, Hastelloy CW-2M and Hastelloy CW-6M (both are the family members of Hastelloy C group) are more frequently poured than the other three Hastelloys Both Hastelloys, CW-2M and CW-6M have excellent castabilty, physical and mechanical properties and they are regularly used in manufacturing ‘wetted end” pump components, Metallography ‘The Hastelloys are resistant to strong mineral acids, these may need vigorous strong re agents, which tend to form pits or etch out inclusions. Alternate polishing and etching may be necessary; electrolytic etching frequently gives better results than immersion or swab, 4-494 6.1 note) Table-t Etching Re-agents for Nickel-base Alloys Heat to 2150 °F (1175 °C) minimum, hold for suficient time [Reagent ee SS ionic (es HNO,, 500 cc HC, immerse uni sroctre to heat castings to temperature, Liesteled, —_ quench in water or rapid cool by one oce other means (Table-2 of the 0 to make up 1000 cc standard). Ithas been observed [Nene Distenimonic ech wih gheera_| immerse using less than 1175 °C has usualy in $050 proportions. | given the detrimental effects, Nanrncetic $0.6c HNO,, 25 ce glacial acetic | immerse | cid, 25 00140 | Hastelloy C-type alloys (¢.9. | Gratcaaa 10.ce oxalic acid, 100 ecH,0 | §-20 seconds at 6v using -4, C-22 and 0-276) are platinum cathode. Sigma normally solution treated at _ Itachi frst, ten eabies 1180 °C to 1280°C, followed by [Lacie aca 15ecHG! SccHNO, 10ee | 25v. 20A/Gm?. For scanning water immersion. G0, 75 eonso caamamsaia. | ‘Sulphuric 5 eoH,S0, 95 ce v.01 05am, 5t0 15 The higher temperatures in this |°“*"™" oles Game. | range are necessary to FOUNDRY 63 JULY/AUGUST, 2021ERE EE Wilding peed om mi Fig. 3 : Welding Parameters for Nickel-base Alloys etching. A number of reagents can be used, a few of Which are listed in Table-4. Welding The removal of the casting defects, and up gradation of the casting, needs welding, which have been permitted by standards, and ASME. Section IX indicates as P No. 43. The rule of major and minor, post weld heat treatments are applicable. There is no stress relieving, and full original heat treatment cycle needs to be followed. ‘Among the HASTELLOY C-type alloys examined, a resistance to hot-cracking ranking can be given as follows: C-4 > C-22 > C-276. All alloys would be expected to be readily weldable in most situations. The associated defects could be hot cracks. The cracks usually develop, due to intermetallic segregation effect, and differential cooling rates For all welding processes, weld parameter selection, as it relates to heat input, is extremely important due to the greater possibility of hot cracking as heat input increases. The due care has to be taken for the rising heat input. Ni-Cr-Mo alloy such as C-276 (UNS N10276) alloy has lower thermal expansion, lower thermal conductivity, and higher electrical resistivity. The weld metal is sluggish when deposited and has a low fluidity. It does not readily diffuse with side parent metal ‘This is the main reason for the cracking tendency. AS such, pre heating is not essential, butin order to remove the moisture condensation, itis warmed, such that no presence of any atmospheric moisture is present. The effects of the welding process and design variables. a) Travel speed on and weld pool shape, b) Heat input and bead shape on solidification cracking; ¢) Bead depth-to-width ratio on solidification cracking, The castings are easily machinable in both conditions of as cast. and duly heat treated. The procedures of Duplex Stainless steels are to be followed, Common Defects: The defects of steels, stainless steels, and duplex stainless steels are all applicable to Hastelloys. Nitrogen, Hydrogen and Oxygen can cause the porosity in our discussion castings. Attention at the melting stage is, therefore, of prime importance, necessitating the careful choice of charge materials, short metting cycles and deoxidation prior to pouring Pin holes are gauged and welded. The cracking is one of the major defects. Cracking in nickel-base alloy castings is usually a form of hot tearing (solidification cracking) which takes place immediately Prior to the completion of solidification, when a small volume of liquid is stil present. Since this liquid will be rich in impurities, it follows that impurity elements such as S, P, Pb. Cu, Sn, Sb etc should be minimized in the furnace charge material Action taken to minimize hot tearing include attention to casting design, using a low pouring temperature, details concerning gating and risering, and choice of moulding materials. This point we have discussed in almost all of my previous articles, Hot Cracking in the solid state immediately following solidification is also a possibility as a result of embrittlement of grain boundary areas by segregation ofimpurty elements. This is more ikely to occurin highly stressed regions and in the heat affected zone during welding Similarly, quench cracking in those alloys which need to be rapidly cooled from heat treatment temperatures is possible. Precautions, including casting design, should be taken. Small castings may even be rapidly cooled in air to alleviate a quenching problem. FOUNDRY 64 JULY/AUGUST, 2021In all, any types of cracks are NOT acceptable, in any applications. ‘The most of the castings are cast in sand molding due to very low quantity requirements, and low weights. This may invite sand inclusions. Major attention has to be given for gatings, spues, ingates and placement offers. These are very costly materials and limited quantity, the defects and rejections are not affordable. ‘The surface defects are NOT acceptable, since they come across highly corrosive applications. All areas are to be gauged, upgraded and welded and heat treated as per the procedures. Non Destructive Testing (NDT) Liquid Dye Penetrant (LDP) test can be used as per ASTM A-802 procedures. Surface inspection can be conducted for LDP as per ASTM E-443. Corrosion Testings can be conducted, on samples. ASTM G-48 Method D can be conducted to find critical crevice temperature. The method covers all Nickel base alloys. Ferric chloride test also be conducted. ASTM G-28 specifies IGC testings, loss of weight, in terms of millsyear (mpy) tested in ferrtic sulphate. ‘The Radiography results are not reliable, since the grains are course. As a general, in the supplementary S2 it has been menstioned. It can be used for the development of the castings, in-house purposes. Ultrasonic Testing (UT) : The grain size of nickel alloys in comparison to ferric or martensitic steels, and also to austenitic Cr-Ni-steels is in many cases significantly larger. In Ultrasonic Testing, this can lead to an increase in wave attenuation due to scattering and, therefore, results in a reduction of the signal-to-noise ratio. The heat treatment has a crucial role to play, on grain size. During solidification the coarse and directionally oriented grains develop. The coarse structure leads to an additional grain boundary, surface, causing the scattering and reflection phenomena. The elastic anisotropy of the material influences the ultrasonic propagation on a macroscopic scale such as Ultrasonic velocity, scattering, sound beam divergence, and the direction of energy propagation. These variables are dependent on the relative orientation of the grains and angle of incidence, and the wave mode and are therefore influenced by changes in the microstructure. Due to these phenomena, the interpretation of the ultrasonic signal is complicated, and small defects might not be detected with sufficient signal-to-noise-ratio. Differentiating between grain boundaries and interface reflections, or reflections on actual defects s significantly more difficult, in particular when additional geometrically caused reflections are present (e.g. from an ungrounded root pass). Hence the UT is not conducted in regular use. In modern developments the instruments are available, but the study is beyond the scope of this article The castings are non magnetic, therefore magnetical particle testing is not applicable. Major Application Basically these alloys are corrosion-resistant and high temperature services. Based on these facts, this metallurgy suits for pumps and valve components. 4. CONCLUDING REMARKS 1. Hastelloys have a long history of developments, and still prone for experiments and alloy developments. 2. The use of alloys is meant for giggly critical applications like mineral acids, petro chemicals and high temperature services. Formation of Hastelloys is from Ha (Haynes) Stell (Stellites) alloys, combinations of two companies, trade mark given in 1923. 8. Several thoughts are given to use in as cast conditions, But it necessary to go for the heat treatments with modified heat zone of furnaces. 4, Specific re-agents are used. Since for comman re- agents the material does not respond. due to high Corrosion Resistance. 5. Cracking tendency, during solidification and welding needs to be attended too. Acknowledgement 1. | thank all my Friends, Colleagues, and Seniors who requested and helped me to prepare ths article. 2. My special thanks to the “FOUNDRY” Editor and his staf 3. When this paper was in progress, | lost my daughter. Because of the mouming, the paper was discontinued But | was feeling her presence, and this insisted me to complete the paper. FOUNDRY 65 JULY/AUGUST, 2021References 41. Standards ~ (a) ASTM A-496, (2) G-48; G 28, 2, ASM Hand Books Vo (a) Speciaty Hand Book on Nickel and Cobalt, and ther alloys, (b) Vou. 15 Castings 6. National Bureau of Standards Nickel and its Alloys — NBS Monograph 108; US Dept. of Commerce (G.0.); Nickel and its Alloys-Chapter- §; 7. H. Sassford, Jim Hosier; inco Alloys International, Inc. Huntington, West Virginia Material Fact Sheets, Section-L: Nickel-base Alloy Castings ee.1994 (rst publication) (6. {ey Vou 138 Conlon Materials 8 Wag fel ans As by Lat Anarn, TE Ardoren (4) Vo. 13 and 134 Corrosion 3 (d) Vo. 17 Non destructive evaluation and quality conto. 9, Weldabilty of Nicketbase Alloys, Haynes Intemational 6.0.) (@) Vo. 6 Welding and Brazing 10. Hynes Corrosion Resistant Alloys, ©:22 (G.D.) 3, Nicbased Super Alloy: Casting Technology, Metallurgy, 11. The Welding Metalurgy of Hastolloys O-4; 6-22 and 6-276; Development, Properties and Applications, Intl Joumal of Engg, M.JCleslak, T.Headiey, and A.D Romig; Jr. Metallurgical Sciences & Research Tectnolagy, Fabruary, 2016 (G.0,) Transactions, Vol. 17A; Nov.1886 (@.D.) 4, 100+ Years of Wrought Alloy Development at Haynes 12. Corrosion Resistant Nickel Alloys (Part2), Paul Crook; Haynes International, ath ternational Symposium on Super Alloy 778 International Inc. Kokomo, Indiana (G.0.) and Derivatives, Haynes Intemational (G.0" indcatos downloaded trom Googlo search) 5, History of Haynes International, Inc.; by Charle Sponaugle, Haynes Intemational, Ino. (G0. " (ep) (Two Annexures on the facing page) > Wusinge from GS Dear Readers, during this pandemic period many of us are operating from our homes and as a part of our responsibility land sharing the burden with our better halves, we have to indulge in household activities, including cooking the meals. This reminded me of an incident which happened with a close friend of mine during the start of his family after getting married. Take it as a Case Study of Management Lessons. “A TRUE STORY” ‘A Young Engineering Graduate took up an additional course of Industrial Engineering. ‘Time and Motion’ study fascinated him. In his Industrial career, he made its best use in dealing with movements of men and materials. With his innovative approaches, he came out with many bright and ‘out of the box’ cost cutting ideas in resetting the setup that lead to higher productivity and better utilisation of space. He, thus, became a prominent figure in the Organisation. Eventually, he married to start his family. Now from Bachelorhood to Married life he started realising that he gets late to his work place and the cause was late breakfast served by his wife. He then studied this issue and realised that there were many unwanted or repeated operations done by her in preparing the breakfast. He drew his plan and told his wife ‘Dear, if you made certain changes in the setup of your kitchen, you could prepare breakfast faster by 15 minutes and it will also be less tiring for you. The wife responded ‘Well, | don't believe in what you say and it’s not practicable. I's not Engineering and in this affair your knowledge is zero, What I'm doing is the fastest possible time in preparing breakfast.’ He tried to convince her with his logic behind the idea, but in vain. And she stuck to her version. Finally, he said that on a weekend he would reset the kitchen gadgets and prepare a breakfast himself to demonstrate the time saving idea. She agreed with him and then the whole exercise was cartied out. Coming to the actual ‘demonstration, the young Engineer really made breakfast in less than 15 minutes time. And Lo! The poor fellow is stil preparing breakfast tll date, in addition to that for his wife. Moral of the Story: Tell the ideas and logics ONLY to an audience who listens, follows you and comprehend what's being talked about’. ‘Wiahaut Malice to anyont, Remain Safe & Fit. Regards FOUNDRY 6 JULY/AUGUST, 2021AWS AS.11/A5.11M AWS AS.14/A5.14M AWS AS.34/A5.34M AWS B2.1/B2.1 M AWS B4.0M AWS D17.1/D17.1M AWS G2.1M/G2.1 Annexture-1 The applicable standards are : AWS (American Welding Society) Welding Standards Methods for Mechanical Testing of Welds ((SO- Intemational Standards Organization) ‘Specification for Fusion Welding for Aerospace Applications Guide for the Joining of Wrought Nickel-Based Alloys ‘Specification for Nickel and Nickel-Alloy Welding Electrodes for SMAW Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods Specification for Nickel-Alloy Electrodes for FCAW Specification for Welding Procedure and Performance Qualification Iso 5817 ‘Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) — Quality levels for Imperfections. Weldability of Nickel-Base Alloys 157 ISO 9606-4 Approval Testing of Welders ~ Fusion Welding (Part 4: Nickel and Nickel alloys) Iso 14172 ‘Welding Consumables — Covered electrodes for manual metal aro welding of nickel and nickel alloys ~ Classification, ISO 15792-4 ‘Welding Consumables — Test Methods (Part 1: Test Methods for all- WM Test Specimens in Steel, Nickel and Nickel Alloys) Iso 18274 Welding Consumables ~ Solid Wire Electrodes, Solid Strip Electrodes, Solid Wires and Solid Rods for Fusion Welding of Nickel and Nickel alloys ~ Classification, Table is attached. Annexture-2 Welding Parameters ‘Aiey type] Alloy | Preparation™ Eieewrode Preheat Postweid Designation AWS EA ‘Others Dia ca) | won a a — o— ‘earner 2 05m ce woe kee Taint [eco umnseone | saws | me paw cone 7 we ences meee rT Treas ce Tae too eam maven nescen| vomavere | oa acne | taoomvase seme [pon te ma veawnes cor rn see oorecy SSnercanoe | voorwnet sours ora woemetener| eee ed Tatas [neenarmane | ow oatoee | mene Wo em er = Temmew | eworet Pawen am Tae awe = FOUNDRY 67 JULY/AUGUST, 2021