Superalloy Ingots by Vacuum Induction Melting
Scope:
- Manufacturers of super alloys, precision alloys, master alloys for precision investment castings used in Automotive, Electronics and Aerospace industries.
- Precision casting with controlled melting and state of art refining process.
- Development of new alloys using small ingots
- Scrap remelting using Air induction and refining using VIM to match required chemistry.
 
 
PML Alloy Matrix's
Process
- Before starting the melting process, a VIM furnace is charged with precharged raw material either in the normal atmosphere or under vacuum.
- The charged material is then melted under vacuum.
- Charging of trace elements for alloy adjustment is also possible without breaking the vacuum.
- Online temperature measurement, Spectro and oxygen meter allows controlled melting and refining process till the desired composition specs of ingots are met.
- The melt is poured in predesigned metallic mould with sophisticated automatic tilting mechanism under vacuum only.
Alloywise chemical composition and mechanical properties
| Chemical composition (Typical) for Nickel & Cobalt base alloys in % | ||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Alloy | Ni | Fe | C | S | Mn | Si | Cu | Cr | Co | Mo | Al | Ti | Nb | Others |
| Nickel 200 | 99.5 | 0.2 | 0.08 | 0.005 | 0.018 | 0.18 | 0.13 | - | - | - | - | - | - | - |
| Nickel 201 | 99.5 | 0.2 | 0.01 | 0.005 | 0.018 | 0.18 | 0.13 | - | - | - | - | - | - | - |
| Nickel 205 | 99.5 | 0.01 | 0.08 | 0.004 | 0.018 | 0.08 | 0.08 | - | - | - | - | 0.03 | - | 0.05 |
| Monel 400 | 64 | 2.5 max | 0.02 max | 0.02 max | 1 | 0.05 max | 32 | - | - | - | - | - | - | - |
| Monel 500 | 63 | 2 max | 0.02 max | 0.01 max | 1.5 max | 0.5 | 30 | - | - | - | 2.9 | 0.6 | - | - |
| Inconel 600 | 72 | 8 | 0.15 max | - | 1 max | - | - | 15.5 | - | - | - | - | 3.7 | - |
| Inconel 625 | 60.3 | 5 | - | - | - | - | - | 22 | - | 9 | - | - | 3.7 | - |
| Inconel 713C | 71.3 | 2.5 max | - | - | 0.25 max | 0.2 | - | 13 | - | 4.5 | 5.5 | 0.5 | 2.5 | - |
| Inconel 713LC | 73.5 | 0.5 | - | 0.005 | 0.05 | 0.10 | 0.3 max |
12.20 | - | 4.6 | 6.1 | 0.65 | 0.2 | - |
| Inconel 718 | 52.5 | 19 | - | - | - | - | - | 19 | - | 3.1 | 0.5 | 0.9 | 5.1 | - |
| 18Ni300 | 18.5 | 66.7 | - | - | - | - | - | - | 9 | 5 | 0.1 | 0.7 | - | - |
| Nimonic 80A | 75.9 | - | - | - | - | - | - | 19.5 | 1 | - | 1.4 | 2.3 | - | - |
| Hastelloy 22 | 57.1 | 5.0 Max | 0.01 | 0.005 | 0.45 | 0.15 Max |
- | 21.75 | 2.0 Max |
13.5 | - | - | - | - |
| Hastelloy 276 | 58.5 | 6 | 0.01 | - | 1 | 0.08 | - | 15 | - | 16 | - | - | - | - |
| NIFE50 | 47.5 | 52.5 | - | - | - | 0.1 max | - | - | - | - | - | - | - | - |
| Ni80Fe20 | 79.5 | 16 | - | - | 0.2 max | 0.2 max | - | - | - | 4.5 | - | - | - | - |
| Vitallium | - | 0.30 Max |
0.01 | 0.005 | 0.5 Max |
1.0 Max |
- | 29.0 | 64.7 | 4.5 | - | - | - | - |
| Stellite 6 | 2.0 | 2.5 Max |
1.07 | 0.005 Max |
0.6 | 1.0 Max |
- | 28.0 | 64.3 | 0.5 Max |
- | - | - | - |
| Fe49Co49V2 | - | 49 | - | - | - | - | - | - | 49 | - | - | - | - | V2 |
| Mechanical properties for Nickel & Cobalt base alloys | ||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Nickel alloy | UTS 21 Deg cen(MPa) | UTS 540 Deg cen(MPa) | UTS 760 Deg cen(MPa) | UTS 21 Deg cen(MPa) | UTS 540 Deg cen(MPa) | UTS 760 Deg cen(MPa) | Tensile elongation at 21 Deg Cen% | Tensile elongation at 540 Deg Cen% | Tensile elongation at 760 Deg Cen% | Remarks | ||||
| Nickel 200 | 462 | - | - | 148 | - | - | 47 | - | - | Chemical & Electronic industry | ||||
| Nickel 201 | 403 | - | - | 103 | - | - | 50 | - | - | Chemical & Electronic industry | ||||
| Nickel 205 | 345 | - | - | 90 | - | - | 45 | - | - | Chemical & Electronic industry | ||||
| Monel 400 | 545 | - | - | 207 | - | - | 48 | - | - | Corrosion resistant alloy | ||||
| Monel 500 | 669 | - | - | 338 | - | - | 44 | - | - | Corrosion resistant alloy | ||||
| Inconel 600 | 660 | 560 | 260 | 285 | 220 | 180 | 45 | 41 | 70 | Super alloys | ||||
| Inconel 625 | 965 | 910 | 550 | 490 | 415 | 415 | 50 | 50 | 45 | Super alloys | ||||
| Inconel 713C | 758 | - | - | 689 | - | - | 3 | - | - | Super alloys | ||||
| Inconel 713LC | 624 | - | - | 382 | - | - | 41 | - | - | Super Alloys | ||||
| Inconel 718 | 1435 | 1275 | 950 | 1185 | 1065 | 740 | 21 | 18 | 25 | Super alloys | ||||
| 18Ni300 | 1034 | - | - | 758 | - | - | 18 | - | - | Maraging steel | ||||
| Nimonic 80A | 1000 | 875 | 600 | 620 | 530 | 505 | 39 | 37 | 17 | Super alloys | ||||
| Hastelloy 276 | 750 | - | - | 310 | - | - | 30 | - | - | Super alloys | ||||
| NI50FE50 | 500 | - | - | 250 | - | - | 40 | - | - | Soft magnetic alloy | ||||
| Ni80Fe20 | 650 | - | - | 280 | - | - | 35 | - | - | Soft Magnetic alloy | ||||
| Vitallium | 960 | - | - | 680 | - | - | 10 | - | - | Medical & dental restorations | ||||
| Stellite 6 | 850 | - | - | 700 | - | - | <1 | - | - | Superalloys | ||||
| Fe49Co49V2 | 600 | - | - | 400 | - | - | 5.5 | - | 49 | Soft Magnetic alloy | ||||
Process capability
| Input : Batch size | Output | Alloying Elements | Chemistry tolerance | Impurities Max |
|---|---|---|---|---|
| 30 kg to 50 Kg | Ingot of required size and shape. | Fe, Ni, Co, Cr, Mn, Cu , Al, Mo, Nb, Ti, V, Si, B, Zr, W,Nd, Y, La | +/- 0.5 % for Higher level % (Above 2 digit) and +/- 0.3 % for lower level % (Single digit) | Oxygen < 30 ppm, Hydrogen < 10 ppm, Nitrogen < 30ppm, All other impurities < 30 ppm including carbon |
Benefits
- It is possible to melt and cast ingots / bars of required size and composition.
- Ensures highest quality on a reproducible basis.
- PML can produce small size 5 ~ 10kg ingots as well as big size up to 80 kgs ingots from VIM
- Possible to restrict gas impurities to the lowest negligible levels. Non ferrous impurities (Sn, Zn, Pb, Sb) evaporates completely in vacuum at high temperatures.
- State of art process reduces non metallic oxide inclusions in the final alloy.
- Surface finish by shot blasting / grinding
- Ready to use ingots for further processing like powder manufacturing for MIM, Strip manufacturing by hot and cold rolling, forging etc.