AUXILIARIES & COMPONENTS
ALLOY
ALTERNATIVES
High-Strength, Corrosion-Resistant Steel For Turbomachinery
BY DR. GREGORY VARTANOV
H
ighly stressed turbomachinery compo-
nents, including impellers, shafts, hous-
ing, and bolts are subjected to severe
loading, oxidation, corrosion, and in
some cases hydrogen embrittlement. High-
strength titanium alloys and high-strength,
nickel-based alloys are widely used for those
components. The main criteria for choosing
materials are strength, specific strength (tensile
strength to density ratio), fatigue strength,
toughness, and corrosion/oxidation resistance.
Titanium alloy Ti-6Al-4V, and the nickel-based
alloy 718 and alloy 625 fit these criteria. Cost
and machining issues limit application.
High-strength, corrosion-resistant (HSCR)
steel is a possible low-cost alternative. Premi-
um-quality HSCR steel ingots are produced by
vacuum melting processes. A powdered form of
HSCR steel is produced by atomization pro-
cesses, including vacuum atomization.
Components can be manufactured from
HSCR steel by four processes:
• Hot working (HW) of ingots by forging or
rolling followed by machining and hardening. Figure 1A: Impeller made by PM HIP from Ti-6Al-4V alloy powder (A) (Source: LNT PM).
• Powder metallurgical-based, hot isostatic
pressing (PM HIP) to near net shapes (NNS)
followed by finish machining, and harden-
ing (NNS PM HIP).
• Additive manufacturing (AM) followed by
surface finishing and heat treatment.
• Vacuum casting followed by hot isostatic
pressing, finish machining, and hardening
(Casting + HIP).
Hardening of HSCR steel consists of aus-
tenitizing and rapid cooling, optional refriger-
ating, and tempering at low, medium, and high
temperatures (secondary hardening) depending
on the required properties. Formation of NNS
by PM HIP enables manufacturing of various
complex-shaped components. The process pro-
vides precise geometry and properties close to
the forgings. Also, PM HIP supplies a homoge-
neous microstructure through any cross section.
The cost of components made by PM HIP is Figure 1B: Gas compressor impeller made by PM HIP from Inconel alloy 625M powder.
generally higher than the same products made (Source: LNT PM).
36 www.turbomachinerymag.com November/December 2020 • Turbomachinery International
AUXILIARIES & COMPONENTS
PM HIP + CASTING
PROCESSES HW + HARDENING ANNEALING
HARDENING + HIP
Materials HSCR Ti-6-4 718 HSCR Ti-6-4 718 HSCR Ti-6-4 718 HSCR
Density (ρ), lb/in3 0.280 0.160 0.296 0.280 0.160 0.296 0.280 0.160 0.296 0.280
Modulus Elasticity (E), ksi 30100 16670 29800 28900 16000 29800 29000 16500 29800 28000
Specific Stiffness (E/ρ) 107500 104160 100675 103210 100000 100675 103570 103130 100675 100000
Tensile Strength (UTS), ksi 294 165 195 290 159 190 291 162 200 275
Specific Strength (UTS/ρ) 1050 1030 660 1037 994 642 1039 1013 675 980
Yield Strength (YS), ksi 226 151 165 220 145 160 223 148 170 210
Fatigue Limits (S) at 107 120 80 90 100 80 90 100 75 80 80
Cycles, ksi
Elongation (El), % 10 10 25 10 9 25 8 10 15 8
Reduction of Area (RA), % 36 34 40 40 30 40 30 25 35 30
Fracture Toughness (K1C), 60 70 80 60 75 80 60 65 75 60
ksi√in
Charpy V-Notch Impact 22 16 24 20 14 24 16 14 20 15
Toughness Energy (CVN), ft-lb
Table 1: Mechanical properties of HSCR steel, Ti-6Al-4V alloy, and Inconel alloy 718 made by four different processes.
by HW. However, small batches of complex
products produced by PM HIP are economically 100% 100%
98%
100% 100% 100%
feasible compared to HW (Figures 1A & B). 97%
94%
NNS components made by PM HIP are cost 88%
91%
effective due to waste minimization and their 83% 81%
buy-to-fly ratio (mass of raw material to mass of 75%
product) being lower than HW components. 67%
The high cost of titanium alloy and nick- 63%
el-based alloy powders, as well as issues with
machining, limit their application. Critical
components made by PM HIP from HSCR
steel powder are a good alternative to those
made from titanium nickel-based alloys due to
lower cost and better machinability for the
same lifetime and durability.
COMPARING PROCESSES Specific
Stiffness
Specific
Strength
Fatigue
Limits
Fracture
Toughness
Impact
Toughness
The components made by AM have a buy-to-fly
ratio lower than the components produced by PM “HSCR” “Ti-6Al-4V” “718”
HIP. However, the high cost of powder for AM,
high-energy consumption, and issues with surface Figure 2: The room-temperature mechanical properties of HSCR steel, Ti-6Al-4V alloy
finishing limit application of AM processes. and Inconel alloy 718.
Casting + HIP has the lowest cost among
processes. But it supplies lower strength com- of techniques are employed, depending on the
pared to HW, PM HIP and AM. A combina- material. HW + hardening of forged HSCR
tion of casting + HIP is feasible for manufac- steel, for example, is accomplished by quench-
turing of components from HSCR steel. The ing, refrigerating, tempering, and finally air
projected cost reduction of critical components cooling. Forged Ti-6Al-4V alloy and Inconel
is 65% (more when compared to the same alloy 718 are hardened by heat treatment.
weight of components made by A M from Fig ure 2 shows a compar ison of t he
Ti-6Al-4V alloy and alloy 718 powders). mechanical properties of vacuum melted,
The various processes used produce differ- forged, and hardened HSCR steel, Ti-6Al-4V
ent mechanical properties (Figure 2). A variety alloy, and Inconel alloy 718. HSCR steel pos-
Turbomachinery International • November/December 2020 www.turbomachinerymag.com 37
AUXILIARIES & COMPONENTS
Material Ti-6Al-4V1 Inconel 7181 Inconel 625 17-7 PH1 HSCR steel1 Steel 316 Aluminum-based alloys
Qualitative Rating for HEE severe extreme high extreme extreme negligible negligible
1hardened condition
Table 2: Qualitative rating for HEE of materials tested at 75°F under hydrogen pressure of 9.8 ksi. Those deemed negligible or small risk can
be utilized in the specified hydrogen pressure & temperature range. Those graded high can be cautiously utilized only for limited
applications; the extreme and severe classes are not recommended.
sesses higher specific stiffness (E/ρ) and specific
strength (UTS/ρ), higher fatigue limits (S), 100% 100% 100% 100%
lower fracture toughness (K1c) and higher
i mpa c t tough nes s (C V N ) compa red to 90% 90%
92%
90%
Ti-6Al-4V alloy. Additionally, HSCR steel has
a higher elevated temperature strength up to
950°F compared to Inconel alloy 718 and a 70%
higher elevated temperature strength up to
60%
1200°F compared to Ti-6Al-4V alloy.
HSCR steel also has greater workability and 50%
machinability, and better wear resistance. Alloy
718 and Ti-6Al-4V alloy have better corrosion 35%
and oxidation resistance compared to HSCR
steel; but HSCR steel has no rust after a salt
spray test (ASTM B117 using a 5% NaCl concen-
tration, natural pH, at 95°F, for 200 hours).
Given its mechanical properties, critical
components made by HW, PM HIP, and AM
HW PM +HIP AM Casting + HIP
processes from Ti-6Al-4V alloy and alloy 718 vs. AM
can be replaced by HSCR steel without sacri- “HSCR” “Ti-6Al-4V” “718”
ficing stiffness, durability or lifetime (Table 1).
In terms of cost, HSCR steel is an attrac-
Figure 3: Cost comparison between HSCR steel, Ti-6Al-4V alloy and alloy 718.
tive alternative (Figure 3). There is a signifi-
cant reduction in cost for components made by
HW, PM HIP, and AM using HSCR steel. At coatings (thermostability up to 500°F). Compo-
the same time, utilization of HSCR steel nents made from HSCR steel and protected by
reduces dependency on Ti, Ni, Mo, and Nb. such coatings can be utilized with hydrogen-fu-
Efforts by Siemens Energy, GE Gas Power, eled gas turbines. A more robust approach con-
Mitsubishi Power, Ansaldo Energia, and oth- sists of plating or cladding of HSCR steel com-
ers to develop hydrogen-fueled turbines have ponents with 316 stainless steel.
shifted into high gear. Los Angeles-based LNT PM and Synertech
Hydrogen embrittlement of critical compo- PM have developed NNS PM HIP technology
nents is a major challenge. The hydrogen envi- for critical gas turbine components. This
ronment embrittlement (HEE) rating of mate- includes hydrogen-fueled parts made by PM
rials varies widely (Table 2). Ti-6Al-4V, Inco- HIP from HSCR steel powder. Pilot production
nel alloy 718, Inconel alloy 625 and HSCR steel of these parts is underway. ■
should not be utilized for hydrogen-fueled gas
turbine components.
High-strength aluminum alloys 2000 and
Dr. Gregor y Var tanov is
7000 series are a better choice; however, their chief engineer at Advanced
strength up to 70 ksi at 75°F and up to 30 ksi at M a t e r i a l s D eve l o p m e n t
400°F limits application. Similarly, Type 316 Corp., a Toronto-based com-
austenitic stainless steel has a negligible HEE pany that develops high-
rating, but possesses strength of only 90 ksi at strength steels and alloys.
75°F and 80 ksi at 400°F. That is not enough He holds an M.S. and Ph.D.
for the highly stressed components. in materials science and met-
A protective coating or plating is required. allurgy. For more information and more details on
For prevention of HEE in high strength steels, these materials, please contact info@amdoncorp.
the most attractive are Zn-Ni and Zn-Ni-Me com or visit amdoncorp.com
38 www.turbomachinerymag.com November/December 2020 • Turbomachinery International
