What Is Nickel Alloy Properties, Uses, and Components ?

What Is Nickel Alloy?

Nickel alloy is a versatile class of alloys combining nickel with other metals, and incorporating selected properties of the alloying elements. The primary component is nickel, which can be combined with different metals with unique properties. These metals include: copper, cobalt, titanium, aluminum, and chromium.

The combination of nickel with one or more of these metals produces a nickel alloy that is highly versatile, strong and tough, corrosion-resistant, oxidation-resistant, and can tolerate extremes of temperature, depending on the metal used.

Some nickel-based alloys are commonly referred to as superalloys or high-performance alloys, owing to their high-temperature strength, creep resistance, and oxidation resistance.

What Is Nickel Alloy Made Of?

Nickel alloy is made from the combination of various metals with nickel. The common metals combined with nickel to produce a nickel alloy include: copper, titanium, chromium, cobalt, iron, molybdenum, and aluminum.

The resultant nickel alloy produced has unique, varying properties, some of which include: corrosion resistance, strength and durability, versatility, workability, and resistance to wear and tear.

What Is the Importance of Nickel Alloy?

The importance of nickel alloy is due to its unique combination of properties, which has contributed to its adoption in numerous industries. These properties, however, depend on the metal that was combined with nickel to produce the alloy.

Most nickel alloys have found great use in the oil & gas and chemical processing industries because of their excellent resistance to corrosion and oxidation, making them suitable for use in harsh environments or conditions. The strength and ability of nickel alloys to maintain their integrity at high temperatures have made them the ideal material for power generation plants. This enables them to withstand thermal cycling without undergoing any significant degradation. They are also widely used in producing automotive components because of their high strength and durability.

How Does Nickel Alloy Work?

Nickel alloy works by combining nickel with the unique properties and beneficial effects of alloying elements or metals, which are carefully chosen based on the properties they exhibit. These alloying metals enhance and add to the properties of nickel once they are combined.

During the process of nickel alloy production, the alloying elements form solid solutions and/or precipitates within a nickel matrix. The nickel alloy then undergoes specific heat treatments to optimize its properties. This includes: annealing, solution treatment, aging, and thermomechanical processing (e.g., hot working).

All these processes contribute to the eventual production of the refined nickel alloy. The resultant nickel alloy, after manipulation through metallurgical and heat processes, has the combined and optimized features of both the nickel and the alloying elements.

What Is Nickel Alloy Melting Point?

Nickel melts at about 1455 °C; nickel-based alloys have composition-dependent melting ranges typically around 1250–1450 °C.. This property makes it highly stable at extremes of temperature while maintaining its mechanical strength and structural integrity. It also suits high-temperature applications like jet engines and gas turbines.

What Is the Density of Nickel Alloy?

The density of nickel alloy varies depending on the composition or percentage of metal combined with nickel. Some of the common nickel alloys and their densities include:

1. Inconel ® 625: 8.44 g/cm 3
2. Invar ® 36: 8.05 g/cm 3
3. Monel ® 400: 8.8 g/cm 3
4. Hastelloy ® 276: 8.89 g/cm 3

What Are the Main Components of Nickel Alloy?

The main components of nickel alloy are briefly discussed below:

1. Iron

Iron is one of the most common alloying elements in nickel alloys and usually comprises a significant portion of the alloy composition. When combined with nickel, iron improves the mechanical strength of nickel and enhances its ductility and toughness. However, if iron’s proportion is not adequately balanced in a nickel alloy, it could reduce high-temperature strength and corrosion/oxidation resistance in some grades.

A typical sample end product of a nickel alloy that contains iron is Invar ® , commonly used in precision instruments such as watches and measuring devices.

2. Copper

Copper is also one of the alloying elements used to produce nickel alloys. In nickel alloy, copper enhances nickel’s thermal and electrical conductivity. It also contributes a great deal to the corrosion-resistant properties of the alloy. It can, however, reduce the strength and hardness of the alloy unless it is well-balanced and proportioned.

The sample end product of a copper-containing nickel alloy is Monel ® , which is widely used in engineering and chemical processing industries for equipment like: propellers, pumps, and valves.

3. Chromium

Chromium is an important alloying element that provides excellent corrosion and oxidation resistance. This property is quite indispensable in harsh and demanding conditions. It is also highly stable in extremes of temperature and can maintain the integrity of the alloy in high temperatures. In higher concentrations, however, chromium can reduce ductility and formability.

A typical sample product of a nickel alloy containing chromium is Inconel ® . Inconel ® is widely used in gas turbines in the aerospace industry.

4. Titanium

Titanium is an alloying element known to improve nickel’s strength and corrosion-resistant properties. This is particularly done via precipitation hardening. It enhances strength (often with aluminum via precipitation of γ′) without materially changing density at typical additions.

Compared to other alloying elements, it is relatively expensive and challenging to work with during manufacturing processes. A representative titanium-containing nickel alloy is Inconel® 718, widely used in aerospace and power-generation components.

5. Nickel

Nickel is the primary component in nickel alloys. It is known for its excellent corrosion resistance, high-temperature stability, and mechanical properties like high tensile strength and ductility. It is also oxidation-resistant and has high strength and ductility. Its features are, however, enhanced in the presence of other alloying elements.

Nickel is the base element in nickel-based alloys; composition and processing determine the final properties.

6. Molybdenum

Molybdenum is also one of the alloying elements added to nickel to enhance its features. In nickel alloy, molybdenum strengthens the mechanical properties of the alloy. It is also highly resistant to pitting and crevice corrosion and can stabilize the alloy at high temperatures. It can, however, be difficult to machine when forming the alloy.

A typical sample end product of a nickel alloy containing molybdenum is Hastelloy ® , widely used in chemical processing and flue-gas desulfurization equipment.

What Are the Nickel Alloy Properties?

The properties of nickel alloy include:

1. High corrosion resistance
2. High-temperature stability
3. Good mechanical strength
4. Oxidation resistance
5. Ductility
6. Controlled thermal expansion (grade-dependent; e.g., Fe-Ni Invar alloys)
7. Electrical conductivity
8. Magnetic properties
9. Wear resistance
10. Good weldability
11. Biocompatibility (grade-dependent; e.g., NiTi for implants, others may not be suitable)

Are Nickel Alloys Suitable for High-Temperature Applications?

Yes, nickel alloys are suitable for high-temperature applications. They are designed and structured to maintain their mechanical properties and integrity while resisting degradation when exposed to high temperatures. This performance comes from alloy design and strengthening mechanisms (e.g., solid-solution and precipitate strengthening such as γ′/γ″), oxidation resistance, and phase stability.

How Is Nickel Alloy Produced?

Nickel alloy is produced from a variety of steps and processes, from raw material processing to alloying, melting, casting, and forming.

Nickel is extracted from its ores, like nickel sulfide, through mining processes. The concentrated nickel ore is refined through roasting, smelting, and other similar processes to produce pure nickel. Specific alloying elements like chromium and iron are selected based on their properties to produce the desired nickel alloy. Then, adequate amounts of nickel and the chosen alloying elements are weighed and mixed to create the desired composition. The mixture of nickel and alloying elements is melted in a furnace, such as an induction or vacuum-induction furnace (often followed by VAR/ESR for critical grades) or an induction furnace. During this process, any impurities are removed to improve the quality of the alloy. The resultant molten alloy is poured into molds to form ingots or slabs. Various casting processes are used, including sand casting. The cast alloy can then cool and solidify under controlled conditions to ensure uniform grain structure and minimize defects. The alloy then undergoes certain hot-working and cold-working procedures to improve and enhance the properties of the alloy. The resultant nickel alloy is then machined to final dimensions and shapes using techniques such as milling and grinding.

How Much Is Nickel Alloy?

The price of nickel alloy varies depending on: the cost of raw materials, the alloying elements used, energy costs, labor costs, and other market conditions. Typical stock prices span roughly $30–$100+ per kg by grade, product form, and specification.

What Is Nickel Alloy Mainly Used For?

Nickel alloy is mainly used for applications that require materials with high strength, corrosion resistance, and the ability to withstand extreme temperatures. The main use of nickel alloy can be seen in the following industries:

1. Aerospace: For turbine engines and other structural components of airplanes.
2. Chemical Processing: For reactors, vessels, heat exchangers, and piping systems.
3. Oil & Gas: For tubing, casings, valves, and fittings.
4. Power Generation: For nuclear reactors and steam turbines.
5. Marine Engineering: Propeller shafts, valves, and pumps.
6. Automotive Industry: For turbocharger components and exhaust systems.
7. Electronics and Electrical Engineering: For battery components, conductors, and connectors.

How Is Nickel Alloy Used in Aerospace?

Nickel alloy is used in the aerospace industry for components such as: jet engine turbine blades, discs, exhaust systems, gas turbines, tanks, piping, and other structural components of an aircraft.

How Is Nickel Alloy Used in Medical Equipment?

Nickel alloy is used in medical equipment such as: implants and prostheses, orthopedic tools, MRI machines, hearing aids, pacemakers, dental equipment, needles, and catheters.

How Is Nickel Alloy Used in Oil & Gas?

Nickel alloy is used in oil & gas for: piping, tubing, valves, heat exchangers, drilling tools, storage tanks, pressure vessels, flare systems, and burners.

How Is Nickel Alloy Used in Electrical?

Nickel alloy is used in electrical for batteries, conductors, connectors, thermocouples, spark plugs, IC lead frames, and wires.

How Is Nickel Alloy Used in Marine?

Nickel alloy is used in marine for propellers, heat exchangers, condensers, pipelines, risers, wave energy systems, exhaust systems, and piping systems.

What Are the Types of Nickel Alloy?

The types of nickel alloys include:

1. Nickel-iron alloys
2. Nickel-copper alloys
3. Nickel-chromium alloys
4. Nickel-chromium-iron alloys
5. Nickel-molybdenum alloys

How To Choose a Type of Nickel Alloy to Use

To choose a type of nickel alloy to use, the following factors should be considered:

1. Define and determine the application requirements of nickel alloys, like the performance criteria and the intended operational environment of the nickel alloy.
2. Assess the mechanical properties required of the nickel alloy to possess or exhibit.
3. Assess the compatibility of the chosen nickel alloy with other materials that it will or might come in contact with during its use.
4. Consider the ease of fabrication, welding, and machining of the nickel alloy.
5. Assess whether the nickel alloy can be processed with the available manufacturing techniques.
6. Examine the cost and availability of the nickel alloys to know which best suits your budget.
7. Ensure the nickel alloy meets relevant industry standards and specifications (e.g., ASTM, ASME, ISO).

How To Choose a Nickel Alloy Supplier

To choose a nickel alloy supplier, the following factors need to be considered:

1. Assess the reputation and experience of the suppliers of nickel alloys.
2. Ensure that the supplier adheres to international quality standards of nickel alloys.
3. Examine the product range and availability of the nickel alloys offered by the supplier.
4. Review the manufacturing and processing capabilities of the nickel alloys.
5. Compare pricing and ease of payment from different suppliers, considering the overall value and not just the cost.
6. Inspect the quality and consistency of the nickel alloy by requesting samples or material certificates for verification.
7. Evaluate the suppliers’ customer service, support, and availability to help their customers.

How Can Thomasnet Help You Choose the Right Nickel Alloy?

Thomasnet offers an extensive database of verified nickel alloy suppliers for prospective buyers of nickel alloy. Their detailed product listings and filtering capabilities help users find suitable nickel alloys for their needs.

The platform allows buyers to compare different suppliers and their products side by side. This way, you can compare different suppliers of nickel alloys, which allows you to make informed decisions based on specific criteria such as: location, certifications, and material properties of the nickel alloy.

One of the key benefits of using Thomasnet is access to supplier reviews and ratings, which provide insights into the reliability and quality of potential suppliers. This feedback can help you assess and keep track of the reputation and performance of nickel alloy suppliers, ensuring you only select from the best.

Thomasnet also facilitates direct communication with the suppliers through its Request for Information (RFI) feature and provides contact information for efficient inquiries. This way, you can better communicate your needs and concerns regarding your choice of nickel alloy. Thomasnet streamlines your sourcing process, making it a valuable tool and a meeting point for both buyers and sellers of manufacturing items and materials.

What Are the Characteristics of Nickel Alloy?

Table 1 below highlights the characteristics of nickel alloy:

Table 1: Characteristics of Nickel Alloy

How Long Does a Nickel Alloy Last?

The lifespan of a nickel alloy depends on many factors, including: the alloying elements used, the environmental conditions to which it is exposed, the type of application, and the maintenance. In general, however, nickel alloys have a relatively long lifespan.

What Are the Advantages of Nickel Alloy?

The advantages of nickel alloy include:

1. It has a high-temperature resistance.
2. It is corrosion-resistant.
3. It has a high tensile strength and durability.
4. It is highly versatile.
5. It has a good thermal conductivity.
6. It has excellent electrical conductivity.
7. It has desirable magnetic properties.
8. It is highly resistant to wear and abrasion.
9. Some nickel alloys are biocompatible.

Can Nickel Alloys Be Recycled?

Yes, nickel alloys can be recycled. This practice benefits the environment as it saves energy and conserves natural resources. It also benefits users by saving on part of the cost of purchasing newly mined and processed metal.

What Are the Disadvantages of Nickel Alloy?

The disadvantages of using nickel alloy include:

1. It is usually more expensive than other materials.
2. It is quite difficult to machine.
3. It is prone to pitting in certain conditions.
4. It has high thermal expansion rates.
5. Its mining processing can have significant environmental impacts.

Frequently Asked Questions About Nickel Alloy

Are Nickel Alloys Better Than Stainless Steel in Some Applications?

Nickel alloys are often better than stainless steel in applications requiring extreme temperature resistance, high corrosion-resistance ability, and increased strength. While stainless steel remains highly versatile and widely used, nickel alloys enhance performance in demanding environments and applications.

What Is the Difference Between Nickel Alloy and Brass?

Although nickel alloys and brass are widely used in various industries, they differ significantly in their composition, properties, and applications. Whereas nickel alloys primarily consist of nickel combined with other elements such as: chromium, iron, molybdenum, and copper, brass is an alloy of copper and varying proportions of zinc. Also, while nickel alloys are widely used in aerospace, power generation, chemical processing, and marine applications, brass is commonly used in plumbing, electrical components, musical instruments, and decorative items.