Nb6-2385 5" George C. Marshall Space Fight Center, Huntsville, Alabama

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NASA TECHNICAL
N._,S.a, TM X- 53430
MEMORANDUM
October 1965
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(ACCESSION NUMBER)
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THE MAKING OF NICKEL AND NICKEL-ALLOY SHAPES BY CASTING,
POWDER METALLURGY, ELECTROFORMING, CHEMICAL VAPOR
DEPOS ITION,AND METAL SPRAYING
d
By J. G. Kura, V. D. Barth, W. H. Safranek, E. T. Hall, H. McCurdy, and
H. O. McIntire
Prepared Under the Supervision oLthe
Research Branch, Redstone Scientific Information Center
Directorate of Research and Development
U. S. Army Missile Command
Redstone Arsenal, Alabama GPO Pqi(: _. $
NASA
CFSTI PR_CEiS) $
George C. Marshall
Space Fight Center,
Huntsville, Alabama
TECHNICAL MEMORANDUM X- 53430
THE MAKING OF NICKEL AND NICKEL-ALLOY SHAPES BY
CASTING, POWDER METALLURGY, ELECTROFORMING,
CHEMICAL VAPOR DEPOSITION, AND
METAL SPRAYING
By
J. G. Kura, V. D. Barth, W. H. Safranek, E. T. Hall,
H. McCurdy, and H. O. McIntire*
/
The state of the art of making nickel and nickel-alloy shapes by
methods other than machining from wrought materials is reviewed.
The methods covered are casting, powder metallurgy, electroforming,
chemical vapor deposition, and metal spraying. Of these methods,
casting and electroforming are the most extensively used for making
final shapes of nickel or nickel alloys. Powder-metallurgy methods
are being used to make pure nickel strip for special applications.
Special alloys such as nickel dispersion strengthened with thorium
oxide, Monel, and others are made from powders in the forms of strip
and extrusions. Nickel-alloy shapes are readily made by powder-
metallurgy methods, and it is expected that the recently increased
availability of prealloyed powders may result in more use of this ver-
satile process. Chemical vapor deposition has found little application
in making nickel shapes since it has little to recommend it over elec-
troforming. Metal spraying has been essentially limited to application
of'wear-resistant and/or corrosion- and oxidation-resistant coatings
to other metals.
*Principal Investigators, Battelle Memorial Institute,
Contract No. DA-01-021-AMC-II651(Z)
NASA-GEORGE C. MARSHALL SPACE FLIGHT CENTER
NASA-GEORGE C. MARSHALL SPACE FLIGHT CENTER
TECHNICAL MEMORANDUM X- 53430
THE MAKING OF NICKEL ANDNICKEL-ALLOY SHAPES BY
CASTING, POWDER METALLURGY, ELECTROFORMING,
CHEMICAL VAPOR DEPOSITION, AND
METAL SPRAYING
By
J. G. Kura, V. D. Barth, W. H. Safranek, E. T. Hall,
H. McCurdy, and H. O. McIntire
Prepared for
Manufacturing Engineering Laboratory
In Cooperation with
Technology Utilization Office
Under the Supervision of
Redstone Scientific Information Center
U. S. Army Missile Command
Redstone Arsenal, Alabama
MSFC Order No. H-76715
Report No. RSIC-478
Subcontracted to
Battelle Memorial Institute
505 King Avenue
Columbus, Ohio
Contract No. DA-01-021-AMC-11651(Z)
PREFACE
This report is one of a series of state-of-the-art reports being
prepared by Battelle Memorial Institute, Columbus, Ohio, under
Contract No. DA-01-021-AMC-II651(Z), in the general field of mate-
rials fabrication.
The making of nickel and nickel-alloy shapes by casting, powder
metallurgy, and other processes is reviewed. In addition to casting
and powder metallurgy, consideration was given to production of
shapes by electroforming, chemical vapor deposition, and metal
spraying. The report brings together information from a wide variety
of sources for the purpose of making it available to those who can use
it in industry, in the military, and in the aerospace field.
ii
TABLE OF CONTENTS
Page
SUMMARY .
Castings l
Powder Metallurgy 3
Electroforming 4
Chemical Vapor Deposition . 6
Metal Spraying 6
IN TRODU C TION
CAS T ING
VACUUM-MELTING PRACTICE
ARC-MELTING PRACTICE 15
Dome stic Alloys 15
British Alloys 16
MOLDING PRACTICE 17
Ceramic Molds 17
Methods . 17
Finish and Tolerance ZO
Sand Molds ZZ
Methods . ZZ
Finish and Tolerance Z3
Comparison of Dimensional Tolerances
and Surface Finishes Z3
COMPOSITIONS AND PROPERTIES OF ALLOYS Z4
Domestic Vacuum-Cast Alloys Z4
Inconel 713 G and 713 LC Z4
Inconel 717 C 34
Inconel 718 C 34
Inconel 700 . 35
Inconel 70Z . 35
In-lO0 35
MAR- MZ 00. 36
iii
TABLE OF CONTENTS
(Continued)
Page
Udimet 500 . 37
Udimet 600 and 700 38
Ren_ 41 40
41
Astroloy
1-1360 41
DCM 44
B&B 45
SEL-I and 15 45
GMR-235 and 235D 45
TRW-1800 48
48
Waspaloy
Nicrotung 49
5O
Cosmoloy F
F-342 5O
HDA 8294 51
51
NASA Alloys
52
Domestic Air-Melted Alloys
52
Monel Alloys
CY-40 58
Inconel X 58
NAZZH , 58
59
Thetaloy
59
Supertherm
HOM . 6O
6O
Hastelloy B_ C_ D_ F_ N_ and X
63
HU, HW_ and HX
65
Illium B, G_ and 98
66
British Vacuum-Cast Alloys
EPK 24 66
66
EPD 16
66
EPK 36
M22VC 71
G. 44_ G. 55, G. 64_ G. 67_ G. 74_ G. 84B_ and G. 94 71
72
British Air-Melted Alloys
G. 39 and G. 69 . 72
Nimocast Alloys 73
POWDER METALLURGY 74
Powder Production. 75
iv
TABLE OF CONTENTS
(Continued}
Page
Methods of Compaction 81
Cold Die Pressing 82
Isostatic Pressing 88
Slip Casting 88
Extrusion 89
Cyclic Pressing 93
Powder Rolling 93
Sint ering 105
Nickel-Base Alloys . . if6
Ine rt-Di sper sold- Str engthe ned Nicke 1 IZ2
Standard Definitions of Terms Used in
Powder Metallurgy 128
ELEGTROFORMING 134
Electroforming Procedures . 134
Capabilities and Limitations . 137
Electroforming Solutions. 141
Equipment and Facilities . 143
Properties of Electroformed Nickel 144
Porous Nickel 151
Nickel Alloys 151
Nickel- Cobalt . 151
Nickel- Mangane se 154
Nickel- Chromium 154
Other Alloys 154
Economics 155
CHEMICAL VAPOR DEPOSITION . 156
METAL SPRAYING 158
Fused-Metallized Coatings 159
Coating Materials . 159
Base Metals 161
Surface Preparation. 161
Spraying. 162
Fusing the Sprayed Deposit 164
Finishing the Fused Deposit 165
V
TABLE OF CONTENTS
(Continued)
Page
Properties of Nickel and Nickel-Alloy-
Fused Coatings 165
166
Nickel Aluminide Coatings
169
Plasma Spraying
Flame Plating I74
State of Development and Possible Applications 177
CONCLUSIONS AND RECOMMENDATIONS . 181
Casting 181
Powder Metallurgy. 181
Electro forming 181
Chemical Vapor Deposition . 182
Metal Spraying 183
REFERENCES. 185
vi
LIST OF ILLUSTRATIONS
Figure Title Page
1. Double-Chamber, 30-Pound-Capacity Vacuum-
Induction Furnace Showing Load of Mold Chamber . ii
2o Influence of Leak Rate of Furnace on High-
Temperature Properties of Wrought Udimet 500 13
, Effect of Oxygen Content on Stress-Rupture Life
of Wrought Udimet 500 at 1600 F and 25,000 Psi 13
Control of Grains to Predetermined Sizes in
,
Preselected Areas of a Nickel Base Turbine Blade 19
o Cost for Machined Part Versus Investment Casting ZI
6. Relative Cost for Machined Casting, Forging,
and Investment Casting . 21
, Turbine Nozzle Investment Cast From Inconel 713 C . 3Z
8. Integral Turbine Disk and Buckets Investment
Cast in Inconel 713 C . 33
, Effect of Grain Size on the Stress-Rupture Life
of DCM Alloy at 1800 F and at a Stress of 15,000 Psi. 44
10. Flow Chart of Sherritt Gordon Mines Nickel
Refinery in Fort Saskatchewan . . 78
Examples of Carbonyl Nickel Powders 79
Various Common Processes for the Manufacture
of Sintered Structural Parts 81
13. Examples of Die Fill and Die Movement in the
Conventional Compaction of Metal Powder
in Steel Dies . . 83
14. Design Recommendation for Structural
Metal-Powder Parts. 84
vii
LIST OF ILLUSTRATIONS
Figure • Title Page
15. Distribution of Densities in a Green Nickel
Compact Pressed at i03_040 Psi 87
16. Extrusion of Canned Powder 90
17. Schematic Diagram of Cyclic-Pressing Process 94
18. Stages in the Fabrication by Cyclic Pressing of
an 8Ni-16Fe-4Mo Magnetic Alloy Made From
Electrolyte Nickel Powder. 95
19. Processing Steps Employed in Producing Nickel
Strip From Carbonyl Nickel Powder Using
Cyclic Pressing 95
Diagram of Continuous Powder-Conversion Process 99
Equation That Establishes the Mathematical
Relationship of Compactor Roll Radius_ re to
99
Maximum Compact Thickness_ T Z .
Hopper Feed to Standard Two-High Mill i00
Diagrammatic Illustration of Compacting Rolls
and Powder-Feed Hopper_ Guide-Plate Assembly
and Powder-Head Indicator i00
Z4. Density Increase of Directly Rolled and
Sintered Nickel Strip 103
Z5. Canadian Five-Cent Coin Minted From a Blank
Produced by Sherritt Gordon From Direct-
Rolled Nickel Strip . • 105
Humped-Back_ Boat-Type_ Push-Pull Furnace • 107
Effect of Precompaction Loads and Temperature
on the Densification of Nickel Powders 1o9
Z8. Particle-Size Distribution of Two Nickel Powders • IIZ
viii