properties of waspaloy(tm)

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Super Alloy Waspaloy(tm)

Chemistry Data

Aluminum

1.2 - 1.6

Boron

0.006 min

Carbon

0.03 - 0.1

Chromium

18 - 21

Cobalt

12.5 - 14

Copper

0.5 max

Iron

2 max

Manganese

1 max

Molybdenum

3.8 - 4.6

Nickel

Balance

Phosphorus

0.03 max

Silicon

0.75 max

Sulphur

0.03 max

Titanium

2.5 - 3.5

Zirconium

0.05 - 0.07

General Information

Principal Design Features

A nickel base alloy with good strength and oxidation resistance at high temperatures. Available in wrought forms as bar, sheet and forgings.

Applications

Gas turbines for aircraft or land/marine use.

Machinability

Conventional machining techniques used for iron based alloys may be used. This alloy does work-harden during machining and has higher strength and "gumminess" not typical of steels. Heavy duty machining equipment and tooling should be used to minimize chatter or work-hardening of the alloy ahead of the cutting. Most any commercial coolant may be used in the machining operations. Water-base coolants are preferred for high speed operations such as turning, grinding, or milling. Heavy lubricants work best for drilling, tapping, broaching or boring. Turning: Carbide tools are recommended for turning with a continuous cut. High-speed steel tooling should be used for interrupted cuts and for smooth finishing to close tolerance. Tools should have a positive rake angle. Cutting speeds and feeds are in the following ranges: For High-Speed Steel Tools For Carbide Tooling Depth Surface Feed Depth Surface Feed of cut speed in inches of cut speed in inches inches feet/min. per rev. inches feet/min. per rev. 0.250" 25-35 0.030 0.250" 150-200 0.020 0.050" 50-60 0.010 0.050" 325-375 0.008 Drilling: Steady feed rates must be used to avoid work hardening due to dwelling of the drill on the metal. Rigid set-ups are essential with as short a stub drill as feasible. Heavy-duty, high-speed steel drills with a heavy web are recommended. Feeds vary from 0.0007 inch per rev. for holes of less than 1/16" diameter, 0.003 inch per rev. for 1/4" dia., to 0.010 inch per rev. for holes of 7/8"diameter. Milling: To obtain good accuracy and a smooth finish it is essential to have rigid machines and fixtures and sharp cutting tools. High-speed steel cutters such as M-2 or M-10 work best with cutting speeds of 30-40 feet per minute and feed of 0.004"-0.006" per cutting tooth. Grinding: The alloy should be wet ground and aluminum oxide wheels or belts are preferred.

Forming

This alloy has good ductility and may be readily formed by all conventional methods. Because the alloy is stronger than regular steel it requires more powerful equipment to accomplish forming. Heavy-duty lubricants should be used during cold forming. It is essential to thoroughly clean the part of all traces of lubricant after forming as embrittlement of the alloy may occur at high temperatures if lubricant is left on.

Welding

The commonly used welding methods work well with this alloy. Matching alloy filler metal should be used. If matching alloy is not available then the nearest alloy richer in the essential chemistry (Ni, Co, Cr, Mo) should be used. All weld beads should be slightly convex. It is not necessary to use preheating. Surfaces to be welded must be clean and free from oil, paint or crayon marking. The cleaned area should extend at least 2" beyond either side of a welded joint. Gas-Tungsten Arc Welding: DC straight polarity (electrode negative) is recommended. Keep as short an arc length as possible and use care to keep the hot end of filler metal always within the protective atmosphere. Shielded Metal-Arc Welding: Electrodes should be kept in dry storage and if moisture has been picked up the electrodes should be baked at 600 F for one hour to insure dryness. Current settings vary from 60 amps for thin material (0.062" thick) up to 140 amps for material of 1/2" and thicker. It is best to weave the electrode slightly as this alloy weld metal does not tend to spread. Cleaning of slag is done with a wire brush (hand or powered). Complete removal of all slag is very important before successive weld passes and also after final welding. Gas Metal-Arc Welding: Reverse-polarity DC should be used and best results are obtained with the welding gun at 90 degrees to the joint. For Short-Circuiting-Transfer GMAW a typical voltage is 20- 23 with a current of 110-130 amps and a wire feed of 250-275 inches per minute. For Spray-Transfer GMAW voltage of 26 to 33 and current in the range of 175-300 amps with wire feed rate of 200-350 inches per minute are typical. Submerged-Arc Welding: Matching filler metal, the same as for GMAW, should be used. DC current with either reverse or straight polarity may be used. Convex weld beads are preferred.

Heat Treatment

This alloy is strengthened, or hardened, by heat treatment. A typical annealing, or solutioning, treatment is done at 1975 F, 4 hours at temperature followed by air cooling. Then heating at 1550 F, 24 hours and air cooled and further aging at 1400 F for 16 hours and air cool. This procedure develops the optimum high temperature properties for the alloy.

Forging

Hot forging may be done in the 1900F to 2200F range. Air cooling following forging should be used as liquid cooling may cause cracking on subsequent hot working. For very heavy sections a slow furnace cool is best after hot working.

Hot Working

See the comments under "Forging".

Cold Working

Cold forming may be done using standard tooling although plain carbon tool steels are not recommended for forming as they tend to produce galling. Soft die materials (bronze, zinc alloys, etc.) minimize galling and produce good finishes, but die life is somewhat short. For long production runs the alloy tool steels ( D-2, D-3) and high-speed steels (T-1, M-2, M-10) give good results especially if hard chromium plated to reduce galling. Tooling should be such as to allow for liberal clearances and radii. Heavy duty lubricants should be used to minimize galling in all forming operations. Bending of sheet or plate through 180 degrees is generally limited to a bend radius of 1 T for material up to 1/8" thick and 2 T for material thicker than 1/8".

Annealing

Solution anneal at 1975F, 4 hours followed by air cool.

Aging

The alloy is age hardenable after solution annealing at 1975F it is given a 24 hour time at 1550F followed by air cool then 16 hours at 1400F followed by air cool.

Hardening

See notes under heading "Aging"

Other Physical Props

Mod. of elasticity value at 1000 F.

Other Mechanical Props

Form-Condition Temp. Yield Str. Tensile Str. Elong. in 2% Deg.F 0.2% offset Bar-1975 F 70 115 ksi 185 ksi 25 soln. anneal 1000 105 170 23 & aged, air 1400 98 115 28 cool. 1800 20 76 -- 100 hr. 0.2% 100 hr.Rupture 1000 hr.Rupture Creep Str. Strength Strength 1200 ------ 110 ksi 89 ksi 1400 ------ 60 42 1600 ------ 25 16 1800 ------ 6.5 ----

Physical Data

Density (lb / cu. in.)

0.29

Specific Gravity

7.9

Specific Heat (Btu/lb/Deg F - [32-212 Deg F])

0.11

Melting Point (Deg F)

2475

Thermal Conductivity

74

Mean Coeff Thermal Expansion

7.5

Modulus of Elasticity Tension

30

Mechanical Data

Form

Sheet

Condition

Solution Annealed & Aged

Temper

70

Tensile Strength

190

Yield Strength

122

Elongation

30

Form

Sheet

Condition

Solution Annealed & Aged

Temper

1000

Tensile Strength

160

Yield Strength

120

Elongation

30

Form

Sheet

Condition

Solution Annealed & Aged

Temper

1200