Material Basics – Monel

Introduction to Material Basics – Monel

This blog provides, basic information about Monel 400 (UNS N04400), MONEL alloy K-500 (UNS N05500) and Monel Alloy R-405 (UNS N04405) material basics like, its properties, applications etc.

Monel is a high tensile strength nickel-copper alloy that was discovered in 1905. It was found to be highly resistant to atmospheric corrosion, to seawater/ salt water, various acid and alkaline solutions and steam at high temperatures as well as to salt and caustic solutions.

MONEL^® 400 (UNS N04400)

Alloy 400 is is the basic nickel-copper alloy (Ni 66.5 Cu 31.5) widely used where excellent corrosion resistance in a wide variety of media and moderate high or low temperature properties are needed.. Excellent corrosion resistance over wide range of temperatures and conditions, good weldability and moderate to high strength characterize the alloy. Alloy 400 can be magnetic depending upon composition and previous work history.

Notched-bar impact test shows Monel 400 is very tough. Monel 400 has structural strength, yet ductile, and excellent corrosion resistance in most environments. Conventional shop working practices can be used to fabricate Monel 400.

The alloy has been used in a variety of applications. It has excellent resistance to rapidly flowing brackish water or seawater. It is particularly resistant to hydrochloric and hydrofluoric acids when they are de-aerated. The alloy is slightly magnetic at room temperature. The alloy is widely used in the chemical, oil and marine industries.

Properties

Characterized by;

1. Good/ high general corrosion resistance – Corrosion resistance in an extensive range of marine and chemical environments, from pure water to non-oxidizing mineral acids, salts and alkalis.
2. Good weldability
3. Good mechanical properties from subzero temperatures up to about 480C.
4. Slightly magnetic at room temperature
5. Impervious to the effects of steam, gas, salt water, ammonia, calcium chloride, and the acids associated with food products even at high temperatures.
6. This alloy is more resistant to nickel under reducing conditions and more resistant than copper under oxidizing conditions, it does show however better resistance to reducing media than oxidizing.
7. Good resistance to sulphuric and hydrofluoric acids. Aeration however will result in increased corrosion rates. May be used to handle hydrochloric acid, but the presence of oxidizing salts will greatly accelerate corrosive attack.
8. Resistance to neutral, alkaline and acid salts is shown, but poor resistance is found with oxidizing acid salts such as ferric chloride.
9. Excellent resistance to chloride ion stress corrosion cracking

Applications

1. Feed water and steam generator tubing, feed water heaters and other heat exchangers.
2. Brine heaters, seawater scrubbers in tanker inert gas systems.
3. Sulphuric acid and hydrofluoric acid alkylation’s plants.
4. Pickling bat-heating coils.
5. Heat exchangers in a variety of industries
6. Petroleum refining and production equipment
7. Transfer piping from oil refinery crude columns.
8. Plant for the refining of uranium and isotope separation in the production of nuclear fuel
9. Pumps and valves used in the manufacture of perchlorethylene, chlorinated plastics
10. Monoethanolamine (MEA) reboiling tube
11. Cladding for the upper areas of oil refinery crude columns
12. Propeller and pump shafts
13. Marine engineering – fixtures, fasteners, electrical, and electronic components
14. In the electrical and marine field as acid and alkali tanks
15. Chemical and hydrocarbon processing equipment, valves, pumps, shafts, fittings and hardware, fasteners, diaphragms, and connectors

Welding

The commonly used welding methods work well with this alloy. Matching alloy filler metal should be used. Monel alloy 400 can be easily welded, in all positions, using Monel 190 electrodes. For submerged arc, MIG and TIG welding, use Monel 60 filler wire.

If matching alloy is not available then the nearest alloy richer in the essential chemistry (Ni, Co, Cr, Mo) should be used.

Machinability

Conventional machining techniques used for iron based alloys may be used. This alloy does work-harden during machining and has higher strength and “gumminess” not typical of steels. Heavy duty machining equipment and tooling should be used to minimize c

Forming

This alloy has good ductility and may be readily formed by all conventional methods. Because the alloy is stronger than regular steel it requires more powerful equipment to accomplish forming. Heavy-duty lubricants should be used during cold forming.

Cold forming requires forces between those of mild steel and AISI T304. Hot forming is readily accomplished within the range of 1200-2150°F.

Corrosion Resistance

Resists corrosion from water, including seawater, and resistant to chloride stress-corrosion cracking. Good corrosion resistance to sulfuric acid, hydrochloric acid, hydrofluoric acid, and alkalis.

Heat Treatment

Not heat treatable, but may be annealed after cold working.

Forging

No data, however the alloy is readily forged.

Hot Working

No data, but the alloy may be hot worked.

Cold Working

Cold forming may be done using standard tooling although plain carbon tool steels are not recommended for forming as they tend to produce galling. Soft die materials (bronze, zinc alloys, etc.) minimize galling and produce good finishes, but die life is low.

Annealing

Annealing may be done at 1700 F. A stress-relief anneal may be done at 1050 F for 1 to 2 hours, followed by slow cooling.

Hardening

Hardens due to cold work only.

Related Metals

• Nicorros ™
• Silverin 400(tm)
• Nickelvac 400(tm)
• CM 400(tm)

Specifications

ASTM B17, B127, B163, B164 CLASS A, B165, B366, B513, B564, F467, F468, F96, QQ-N-281, CLA, MIL-N-894, MIL-T-842, MIL-N-24106, MIL-T-23520, MIL-T-1368, AMS 4544, 4574, 4575, 4675, 4730, 4731, 7233, UNS N04400, DIN 2.4360, DIN 2.4366.

For ASME add “SB” prefix to ASTM specification numerals.

Reference	Bar	Sheet	Plate	Tube	Pipe	Fittings	Forgings	All Forms
AMS 4675	X						X
ASTM B127		X	X
ASTM B163				X	X
ASTM B164	X
ASTM B165				X	X
ASTM B366						X
ASTM B564							X
QQ-N-281	X
UNS N04400								X
DIN 2.4360								X
17752	X
17750		X	X
17754							X
17751				X	X
NA 13								X
3076	X
3072		X	X
3074				X	X

Availability

Wire

Item Description	Grades
Monel Wire .003” To .250”	400 K500

Wire is spooled to order and sold by the foot or meter.

Sheet

Item Description	Grades
Monel Sheet .010” to .250”	400 K500

Sheet is cut to order and sold by the square inch or square foot.

Powder, Shot, Pellets, & Ingot

Item Description	Grades
Monel Pellets 0.125”L X 0.250”D	400 K500
Monel Pellets 0.250”L X 0.250”D	400 K500

Powder, shot, pellets, and ingots are packaged to order and sold by the gram or kilogram.

MONEL^® alloy R-405 (UNS N04405)

Alloy R-405 is a nickel-copper-sulphur alloy (Ni 66.5 Cu 31.5 S 0.04) (Similar to MONEL alloy 400) Solid solution strengthened alloy with high strength and toughness over a wide range of temperatures. Corrosion resistant and oxidation resistant to 1000°F. Controlled sulphur added for improved machinability over alloy 400. Water meter parts, screw machine products, fasteners, valve parts.

MONEL^® alloy K-500 (UNS N05500)

Alloy K-500 is a non-magnetic nickel-copper alloy with the addition of Aluminium and titanium (Ni 65.5 Cu 29.5 Al 2.7, Ti 0.6). It is a age-hardenable version of MONEL alloy 400 for increased strength and hardness. It combines the corrosion resistant properties of Monel alloy 400 with the added advantage of extra strength and hardness achievable by precipitation hardening.

Alloy K-500 has added aluminum and titanium for age hardening. It is totally nonmagnetic and spark resistant. Good strength and ductility from -423 to 1200°F. Pump shafts, doctor blades and scrapers, oil well drill collars and instruments, electronic components, springs, valve trim, fasteners.

The alloy is non-magnetic. The alloy should be annealed when performing welding or forming operations, and the weldment then stress relieved before aging. This is true with any precipitation hardenable material, for optimum corrosion resistance. When heat-treated, the hardness can reach as high as Rc 35, and sometimes harder by specification.

Uses: K-500 is used for gyroscope application and anchor cable aboard minesweepers. It is also used for propeller shafts on a wide variety of vessels and exhibits high fatigue strength in seawater. There is also application in chemical process applications for handling of organic acids, caustic and dry chlorine.

Monel alloy K-500 is supplied in the following conditions:

• Cold Drawn, Spring Temper, Soap Coated
• Cold Drawn, Spring Temper
• Cold Drawn, Annealed

This alloy should be welded when annealed and the weldment then stress relieved before aging. Curie temperature °F (annealed)-210 – (age hardened)- 150. Monel alloy K-500 should be welded with Monel 190 electrode or Monel 60 filler metal

Composition

Typical Analysis – Impurities In Percent
Element	Monel – Alloy 400	Monel – Alloy K – 500
Aluminium – Al	–	2.7 to 2.75
Al + Ti		3.5
Carbon – C	0.3 Max
Copper – Cu	31.0	30.0
Iron – Fe	2.50 Max	2.0
Manganese – Mn	2.0 Max	1.50
Nickel – Ni	66.5	66.5 (63.0 Min.)
Silicon – Si	0.50 Max	0.50
Sulphur – S	0.024 Max	0.10
Titanium – Ti	–	0.5 to 0.6
Werkstoff Nr.		2.4375
UNS Designation	N 04400	N 05500

Physical Properties

Physical Properties	Alloy 400	K – 500
Density	8.85 g/cm3 (0.318 Lbs./Cu. In)	8.44 g/cm³ (0.305 lbs/in³)
Specific Heat	430 J/kg K	0.100 Btu/Lb./°F at 700 F
Electrical Resisitivity	51.3 micro ohms cm
Curie Temperature	7 to 10 C (20 – 50o F)
Melting Point Range	1300 to 1350 C (2370-24600 F)
Maximum Use Temperature in Air	4500 C
Thermal Expansion (106K)	15.8 (20300 C)
Coefficient of expansion at 200 – 1000C	13.9 – 14.1 (x10-6 K-1)
Modulus of Elasticity	185 GPa
Modulus of Elasticity – Tension	26.0
Modulus of Elasticity – Compression	26.0
Modulus of Elasticity – Torsion	9.5
Young’s Modulus		179 kN/mm² (26.00 x 106 psi)
Rigidity Modulus		66 kN/mm² (9.50 x 106 psi
Electrical Conductivity		4 0/o IACS
Electrical Ressistivity		48 – 58 Micro Ohm/ cm (µOhmcm)
Poisson’s Ratio	0.32
Brinnell Hardness No	125 – 190
Izod Impact	110-140 J m-1
Rockwell Hardness No.	B 68
Thermal Conductivity @RTP	21.7(Wm-1K-1 )

Average Physical Properties of Alloy 400
Physical Property	Temp., °F	British Units	Temp., °C	Metric Units
Density	Room	0.319lb. cu. in	Room	8.83g/cm
Electrical Resisitivity	70 200 400 600 800	20.1 micro ohm-in 20.9 micro ohm-in 22.0 micro ohm-in 22.4 micro ohm-in 23.2 micro ohm-in	21 93 204 316 427	0.51 micro ohm-m 0.53 micro ohm-m 0.56 micro ohm-m 0.57 micro ohm-m 0.59micro ohm-m
Mean Coefficient of Thermal Expansion	70-200 70-400 70-600 70-800	7.7micro inches/in-°F 8.6micro inches/in-°F 8.8micro inches/in-°F 8.9micro inches/in-°F	21-93 21-204 21-316 21-427	13.9X10-6 m/m*K 15.5X10-6 m/m*K 15.8X10-6 m/m*K 16.0X10-6 m/m*K
Thermal Conductivity	70 200 400 600 800	151 Btu-in/ft-hr-°F 167 Btu-in/ft-hr-°F 193 Btu-in/ft-hr-°F 215 Btu-in/ft-hr-°F 238 Btu-in/ft-hr-°F	21 93 204 316 427	21.8 W/m*K 24.1 W/m*K 27.8 W/m*K 31.0 W/m*K 34.3 W/m*K
Modulus of Elasticity	Room	26.0X10 psi	Room	179 GPa

Mechanical Properties

Mechanical Properties	Alloy 400	K – 500
Tensile strength	79/90 Kpsi (485N/mm sq.)
Tensile strength – Annealed		700-750 N/mm² (100-109 Ksi)
Tensile strength – Spring Temper & Aged		1100-1380 N/mm² (160-200 Ksi)
Tensile strength – Cold Drawn Rod	100,000 psi
Tensile strength – (Hot Finished and Aged Bar)		160,000 psi
Yield strength	24/40 Kpsi	130,000 psi
Yield strength –     Cold Drawn Rod	75,000 psi
Yield strength –    (Hot Finished and Aged Bar)
20 C Temp	195 N/mm sq.
100 C	150 N/mm sq.
200 C	135 N/mm sq.
300 C	130 N/mm sq.
400 C	130 N/mm sq.
Elongation in two inches	60/ 35% (35% Min)
Elongation – Cold Drawn Rod	28 %
Elongation -(Hot Finished and Aged Bar)		24 %
Density (nominal)	0.319 lbs/cubic inch

Recommended Service Temperature		Minimum: -100°C (-148°F) Maximum: 260°C 500°F)
Heat Treatment		After cooling age at 530-550°C for 4-6 hours, furnace cool to 450°C at a rate of 8-15°C/hour, then air cool

 

Minimum Room Temperature Tensile Data of Alloy 400
Form	Condition	Ultimate Tensile Strength, Ksi (MPa)	Yield Strength at 0.2% offset Ksi(MPa)	Elongation in 2in. (50.8mm) or 4D, percent
Sheet, Plate, Strip	Annealed	70.0 (480)	28.0 (185)	35
Bar	Annealed	70.0 (480)	25.0 (170)	35

Comparison of Corrosion Resistance

Letter	Means		Letter	Means
A	Excellent	D	Poor
B	Good	F	Not Suitable
C	Fair

	Chrome	440 SS	302 SS	316 SS	Brass	Monel
Industrial Environment	C	B	B	B	C	C
Domestic Water	D	B	A	A	C	A
Steam	D	B	A	A	B	C
Salt Air	F	C	A	A	C	A
Sea Water	F	F	A	A	C	B
Food Products	F	B	A	A	D	D
Dairy Products	F	C	A	A	D	C
Fruit & Vegetable Juices	F	B	B	A	D	D
Hot Sulphite	F	F	A	B	C	A
Dye	F	D	D	D	D	A
Nitric Acid	F	F	F	F	F	F
Phosphoric Acid	F	F	F	A	C	C
Ammonia	B	C	A	A	F	A

Comparison of Rockwell Hardness

Material	Rockwell Hardness
Chrome Steel 52100	Rc 60-67
Corrosion Resisting Hardened Steel   440 420	Rc 58-65 Rc 52 min
Corrosion Resisting Unhardened Steel   302 304 316	Rc 25-39 Rc 25-39 Rc 25-39
Carbon Steel	Rc 60 min
Aluminium 2017	Rb 54-72
Aluminium Bronze	Rb 94-98
Brass	Rb 75-87
Bronze	Rb 75-98
Monel 400	Rb 85-95
K-Monel	Rc 27 min
Tungsten Carbide	Ra 84-91.5