Hastelloy C-276 Plate/Pipe/Bar

Hastelloy C-276 Plate/Pipe/Bar production process

The production process of Hastelloy pipes involves several steps that ensure the pipes' durability, corrosion resistance, and overall high performance. Here is a general overview of the process:

1. Raw Materials: The process begins with raw materials. The primary alloying elements for Hastelloy include nickel, molybdenum, chromium, and iron, but the specific composition depends on the Hastelloy grade.

2. Melting: The raw materials are placed into an electric furnace and melted at temperatures often exceeding 1200°C. Some grades may also include an electroslag remelting process for enhanced uniformity and cleanliness.

3. Removal of Impurities: The melted alloy is then processed to remove impurities. This typically involves ladle refining, where adjustments can also be made to the alloy composition.

4. Casting: The refined, molten alloy is then cast into large, semi-finished shapes such as ingots, billets, or slabs.

5. Hot and Cold Working: The cast alloy undergoes hot working (at high temperatures), typically through processes such as forging or rolling. After the hot working processes, the alloy undergoes cold working (at or near room temperature). This could be further rolling or drawing to decrease the cross-sectional area, increase hardness, and improve surface finish.

6. Heat Treatment: A heat treatment process is then implemented to fine-tune the alloy's microstructure for its specific mechanical properties. This can include solution annealing, quenching, and aging.

7. Pipe Forming: The treated materials are then formed into pipes using methods such as extrusion or rotary piercing for seamless pipes, or bending and welding for welded pipes.

8. Finishing: Depending on the end use of the pipe, it may undergo different finishing processes. This can include cutting the pipe to length, treating the ends, or surface finishing to ensure a smooth pipe wall. Some pipes may have an additional heat treatment at this stage.

9. Inspection and Testing: The final step involves inspections and testing to make sure the pipe meets all necessary quality and performance standards. This usually includes checks for dimensional accuracy and surface quality, as well as mechanical testing, non-destructive testing, and corrosion resistance testing.

Throughout these steps, the process needs to be monitored and controlled closely to ensure the pipe meets the specific requirements for the Hastelloy grade. The manufacturing process will vary slightly between different Hastelloy grades and based on the specific applications the pipe will be used for.

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2. Advanced Technology: Our facilities are equipped with state-of-the-art technology for both standard and custom metal production.

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Hastelloy C276 Chemical Composition

The Hastelloy C-276 is a versatile corrosion-resistant alloy very widely used in the severest environments. The high molybdenum content makes the alloy particularly resistant to pitting and crevice corrosion. The lower carbon content greatly minimizes grain boundary carbide precipitation during welding to maintain resistance to corrosion in heat-affected zones of welded joints. It's often used in pollution control, chemical processing, pulp and paper production, waste treatment, and sour natural gas wells.

Typical composition of Hastelloy C-276 is as follows:

• Nickel: Balance

• Chromium: 16.00-18.00%

• Molybdenum: 15.00-17.00%

• Tungsten: 3.00-4.50%

• Iron: 4.00-7.00%

• Cobalt: 2.50% max

• Carbon: 0.01% max

• Manganese: 1.00% max

• Silicon: 0.08% max

• Vanadium: 0.35% max

• Copper: 0.50% max

Note: The above composition is an approximation, and exact specifications may vary based on requirements.

Common Applications

Hastelloy C276 offers excellent resistance to a wide variety of chemical process environments, including strong oxidizers like ferric and cupric chlorides, hot contaminated media (organic and inorganic), chlorine, formic and acetic acids, acetic anhydride, seawater and brine solutions. Specific applications can include:

1. Chemical Processing: This alloy is ideal for use in processes that contain various corrosive elements. It maintains excellent corrosion resistance even in challenging conditions.

2. Pollution Control: Hastelloy C276 pipes are used in systems designed to control pollution, especially in waste treatment due to their corrosion-resistant properties.

3. Pulp and Paper Production: This alloy is used in bleach plant heat exchangers.

4. Industrial: Due to the strong resistance to stress corrosion cracking and pitting, Hastelloy C276 finds wide applications in the construction of components exposed to the harshest environments in a wide range of industries.

5. Oil and Gas Industry: Hastelloy C276 is used in the recovery of sour natural gas with its excellent resistance to pitting, stress-corrosion cracking and oxidizing atmospheres up to 1900°F (1038°C).

Please note that while Hastelloy C276 is highly resilient and offers excellent performance in many applications, it is essential to evaluate all operational conditions before choosing it or any other material.

Common forms of Hastelloy pipe

Hastelloy pipes are available in various forms to cater to the specific requirements of different applications. The most common forms are:

1. Seamless Pipes: These are pipes that are manufactured from a solid round billet which is heated and pushed over a form until the Hastelloy is shaped into a hollow tube. Seamless pipes are typically used in applications where the high pressure, high temperature, or high mechanical stress requires robust performance, typically in process industries.

2. Welded Pipes: These pipes are manufactured from a plate or sheet which is rolled into the desired shape. The edges are then heated and fused together using a variety of welding techniques. Welded pipes are typically used in applications where the pressure is not as high, and where the pipe shape or size requires a larger diameter or non-standard dimensions.

3. Round Pipes: This is the most common form of Hastelloy pipe, used in a wide variety of applications where circular cross-section is adequate for the fluid or gas flowing through it.

4. Square and Rectangular Tubes: While not as common as round pipes, Hastelloy is sometimes formed into square or rectangular tubes for specific applications that need these shapes.

5. Hastelloy Pipe Fittings: Apart from the pipes themselves, Hastelloy is also used to manufacture various pipe fittings such as elbows, tees, flanges, and reducers to join pipes together in a piping system.

Advantages of Hastelloy pipe

Hastelloy pipes, particularly those made of grades like C276, offer multiple advantages for use in a wide variety of industries, especially those requiring strong resistance to heat, pressure, and corrosion. Here are some key advantages:

1. Corrosion Resistance: Hastelloy pipes are renowned for superb corrosion resistance, even in extreme conditions. They can resist a wide variety of corrosive environments, including strong oxidizers, hot contaminated media, chlorine, formic and acetic acids, acetic anhydride, seawater, and brine solutions.

2. Heat Resistance: Hastelloy pipes can withstand high temperatures while maintaining a high degree of formability and weldability. This makes them appropriate for many high-heat applications such as heat exchangers or chemical processing.

3. Mechanical Strength: Hastelloy pipes provide superior tensile strength, even when faced with high temperatures or increased pressure. This makes them particularly reliable in tough conditions.

4. Versatility: Hastelloy can be formed and welded into various shapes and sizes, making it highly versatile for different applications. Whether the application requires seamless, welded, round, or square pipes, Hastelloy can cater to these needs.

5. Longevity: Despite the higher cost compared to other materials, Hastelloy pipes tend to have a longer lifespan due to their superior durability. This can lead to lower operational costs over time as replacements are needed less frequently.

6. Stress Corrosion Cracking Resistance: Hastelloy C276, for instance, is resistant to stress corrosion cracking and pitting. These types of corrosion damage can lead to catastrophic failure in normal steels and even some stainless steels, but Hastelloy is designed to resist this type of damage.

Hastelloy's benefits contribute to its widespread use in industries such as oil and gas, chemical processing, power generation, pharmaceuticals, and more. However, due to material cost and machining requirements, it's often deployed in those environments where its unique properties can add the most value.

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