Inconel Forgings & Nickel-Based Superalloys

Superalloys are a high temperature and corrosion-resistant group of alloys that also have low thermal expansion.  Superalloys are oftentimes known as nickel-based alloys because they have high amounts of nickel, but depending on the alloy, they can also contain significant amounts of other elements like steel, iron, cobalt or copper among many others.

Superalloys are commonly used anywhere high strength at extreme temperature and/or corrosion resistance is required.  Several industries that require superalloys include aircraft engines, commercial space applications, oil and gas, power generation, chemical and petrochemical processing and anywhere else there may be an application within a harsh environment.  Superalloys can be produced in a number of metalworking methods but are commonly made into custom forgings.

Superalloys can be divided into a number of different categories are often identified by brand names from various manufacturers and vary depending on the main components of the final alloy. We will focus on what feel are the three most commonly used which are Monel, Inconel, and Incoloy.

In Monel alloys, nickel accounts for at least 63% of the final alloy. Copper is the secondary material, usually resulting in 28% – 34% of the final alloy. Adding a significant amount of copper to Monel alloys provide strength and heat conduction. There are also trace amounts of aluminum (Al), titanium (Ti), magnesium (Mg), and other materials in Monel alloys.

For Inconel alloys, nickel is the base of these materials and typically accounts for 50% – 70% of the final alloy. In addition to their base material, chromium (Cr) is the secondary material for these alloys, accounting for 14.0% – 23.0%. Chromium gives Inconel alloys their high resistance to corrosion in extreme elements. Inconel alloys also consist of measurable percentages of copper (Cu), niobium and tantalum (Nb and Ta) and iron (Fe).

Incoloy alloys differ from Inconel alloys in that nickel accounts for less than 50% of the final alloy. Cobalt (Co) is the secondary material, accounting for 12% – 17% of the final alloy, and measurable amounts of niobium (Nb) as well. These two materials allow Incoloy alloys to have greater strength. Trace amounts of other materials can be found in Monel, Inconel and Incoloy alloys, which can include molybdenum (Mo), aluminum (Al), titanium (Ti), carbon (C), and other materials.

Monel, Inconel and Incoloy Forging Capabilities

At Weldaloy Specialty Forgings, we are committed to producing nickel-based forgings for our clients. Whether you are in need of simple open die forged parts or require more intricate specifications through the use of semi closed dies, Weldaloy stands ready to be your forging partner! Our team of quality, engineering and metallurgists ensure every nickel-based superalloy part we forge will meet your requirements.

Below are our forging capabilities for nickel-based superalloys.

ITEM OUR CAPABILITIES
ROLLED RINGS 50” MAX OD
FLAT BAR / BLOCKS 16” MAX
CYLINDERS / SLEEVES 40” MAX OD
DISKS/ HUBS / SPECIAL SHAPES 24” MAX OD/WIDTH
ROUND / SHAFTS 12” MAX OD/WIDTH
CUSTOM DIE PRESS 24’’ MAX OD/WIDTH

*Please note – this sizing table is for general reference only. Contact us or speak with your sale

 

Properties of Nickel-based Superalloys  

 

There are many types of Monel, Inconel and Incoloy alloys, composed of different levels and nickel and other metals. Superalloy 625 and 718 as they are commonly referred to in the industry are by far the most commonly used. Here is a complete list of nickel-based superalloys alloys that Weldaloy can forge for you.

*Nickel-based superalloys graphs go here (grouped by Monel, Inconel and Incoloy alloys)

 

Read more about Inconel 625.

Read more about Inconel 718.

 

Let Weldaloy Specialty Forgings be your nickel-based superalloy forging partner! Send us a request for quote today and discover the Weldaloy difference!

quoting@weldaloy.com

 

Why Weldaloy?

Why is Weldaloy Specialty Forgings the ideal partner for your aerospace company? There are several key components that prove Weldaloy is ideal for your business.

Our Process

Weldaloy Specialty Forgings strives to meet every expectation that our customers require, with quality work at every level of production—from RFQ to the order’s delivery. Our processes allow us to keep the customer at the center of everything we do, making them a vital member of our team!

Our Capabilities

Weldaloy Specialty Forgings has a wide range of capabilities for your most challenging job. Forging, heat treat, rolled rings and machining are just some of the services we offer. Our facilities span over 115,000 sq. ft. of office and manufacturing space that house a ring mill, a 2,000-ton press, and five drop hammers ranging from 2,000-4,000 lbs. We are continuously making updates to our facilities to expand our capabilities, and to ensure we continue to meet the demands of our clients.

Engineering Capabilities:

  • CAD/CAM system-SolidWorks
  • FORGE Forging Simulation Software
  • SOP for control of CNC Machine Programs

Testing Capabilities:

  • Chemical composition analysis
  • Mechanical testing (tensile-yield-elongation)
  • Microstructural and Grain Size Analysis
  • NDT Testing (dye penetrant, UT, radiographic)
  • Hardness & Conductivity
  • Roamer Absolute Dimensional Measuring

 

Our Team

When you work with Weldaloy Specialty Forgings, you have a whole team behind your order that ensures our work is meeting the required standard. Weldaloy employs a highly skilled team of metallurgists with aerospace industry experience for projects with specific grain size and direction requirements to ensure that our finished products meet mechanical and other testing standards. Weldaloy also has a well-staffed team of engineers who oversee production processes, at every step of production, and team of Quality experts who verify that our products meets customer requirements.

We focus on the small details to make sure our customers are getting the best quality in our products!

Our Certifications

Weldaloy Specialty Forgings is committed to making sure our accreditations are always up to date, ensuring a culture of consistency and attention to detail.

Our qualifications include:

  • AS9100D
  • ISO 9001:2015
  • ITAR Compliant
  • DNV GL Approved

 

 

Open Die

Closed Die

Rolled Rings

“Weldaloy is responsive, knowledgeable, and honest.”

Learn About Our Services

We’re here for you. We’re flexible and enjoy building long term relationships with our customers. For over 70 years, we’ve been providing industry leading companies services such as those listed below.