A Comprehensive Guide to Incoloy800: Properties and Applications

Most industrial work environments use corrosion-inducing chemicals and high-temperature equipment to carry out operations efficiently. One such alloy that is fit for these industrial environments is Incoloy 800. This article highlights everything you need to know about Incoloy alloy 800, including its properties, manufacturing process, safety considerations, and applications. Let’s dive in!

What Is Incoloy 800?

Incoloy 800 is popular for its strength, high resistance to oxidizing and reducing media, carburization, and elevated temperature defiance. By composition, Incoloy contains chromium and nickel in significant quantities, while other elements like titanium and manganese are in trace quantities. At the center of it, is iron, holding all elements together, as the principal metal.

Unlike other alloys that contain at least 50% of nickel, alloy 800 material contains this element in a smaller quantity than Iron, making it less expensive and ideal for limited-budget industrial applications. Aside from its cost, it also exhibits great resistance to chloride-induced stress and high-temperature sulfur-bearing environments.

Depending on your sector, project, and specific needs, you can find this alloy on the market as Incoloy 800 sheets, plates, flanges, rods, bars, pipes, tubes, and fittings.

Incoloy 800 Chemical Composition

As we stated earler, the Incoloy 800 chemical composition consists primarily of iron as the base metal and a high percentage of nickel, and chromium. This table highlights all the chemical elements that makeup Incolloy 800 and at what quantity they each operate effectively.

What Is Incoloy 800 ASTM Specification

The American Society for Testing and Materials (ASTM) specifications provide specific requirements and directions for its manufacturing, chemical composition, dimensions, mechanical properties, and resistances of Incoloy 800 materials. Here is a detailed display of the Incoloy 800 ASTM specifications for various products.

What Is Incoloy 800 ASTM Specifications? Photo Credit: Hitech

Incoloy 800 Key Properties

Aside from its chemical composition, Incoloy alloy 800 has other impressive physical and mechanical properties, making it ideal for chemical processing equipment, petrochemical applications, and other industries requiring adequate corrosion resistance but not too elevated since Incoloy 800 has lesser nickel content than other alloy metals.

1. Incoloy 800 Physical Properties

2. Incoloy 800 Mechanical Properties

Some of the major Incoloy 800 mechanical properties include the following:

3. High-Temperature Strength

The structural and mechanical integrity of any Incoloy 800 material is essential for its performance and longevity. The Incoloy 800 temperature range allows it to retain its structure even with very high temperature levels.

These impressive characteristics can be linked to the solid solution strengthening effect from the nickel-iron-chromium matrix and other alloying elements.

This temperature strength makes it suitable for production in the petrochemical and pharmaceutical industries. Even with temperatures of 500°C, the Incoloy alloy 800 material will still retain its durability just like other austenitic stainless steels.  

4. Creep and Stress Rupture Properties

The Incoloy 800 alloy has awesome creep and structure properties and can endure temperatures even as high as 760°C. By exposing the alloy to high temperatures (540°C and above) for an extended period, you can cause it to experience an intergranular attack.

Any alloy material must have good creep and stress rupture resistance to maintain its edges from cracking. Without it, products from such materials will have weak edges and become vulnerable to cracking which will eventually lead to structural irregularity and reduced lifetime.

5. Corrosion Resistance

Incoloy alloy 800 is popular for exhibiting high corrosion resistance to reducing and oxidizing media allowing it to maintain its surface integrity and protecting it from the formation of scales and oxides under prolonged exposure to high temperatures. It can also withstand nitridation and carburization.

Incoloy 800 Manufacturing Process

Here is a general overview of Incoloy 800 manufacturing: 

• Melting: The alloy 800 materials are carefully selected and then melted in a controlled environment using electric arc furnaces or induction furnaces. The melting process ensures a uniform composition of all elements and helps eliminate impurities.

• Refining: Once nickel, iron, chromium, and other raw materials are melted, the alloy undergoes refining to remove any remaining impurities. You can employ techniques such as argon oxygen decarburization (AOD) or vacuum refining to achieve the desired purity levels. Then the refined alloy is then cast into various forms, such as ingots or billets. 
• Forming and Shaping: The cast Incoloy alloy 800 is processed into the desired shapes. This can involve several methods, including hot or cold working processes such as forging, extrusion, or rolling to refine the Incoloy 800 microstructure and improve its mechanical properties.

• Heat Treatment: The alloy undergoes controlled heating and cooling cycles to optimize its mechanical properties. As such, the Incoloy 800 heating elements pass through annealing, solution treatment, and age hardening, to achieve the desired strength, toughness, and corrosion resistance.

• Finishing Operations: After heat treatment, the Incoloy alloy 800 undergoes additional finishing operations, such as machining, grinding, or polishing, to achieve the required dimensions, surface finish, and tolerances.

The finished alloy 800 material can be supplied in different forms, including sheets, plates, bars, pipes, and tubes, depending on the specific application requirements.

Applications of Incoloy 800

These are the various applications of the Incoloy alloy 800:

• Heat Exchangers: Shell and tube, plate, finned tube, and air-cooled heat exchangers.

• Power Generation Equipment: Gas turbine components, boiler tubes, steam turbine rotors, condenser tubes, and heat recovery steam generators.

• Chemical Processing Equipment: Reactors, distillation columns, piping systems, and catalysts.

• Petrochemical Industries: Petrochemical reactors, catalyst tubes, high-pressure steam piping, and heat exchangers.

• Oil and Gas Industry: Downhole components, wellhead equipment, heat exchangers, offshore platforms, and pipelines.

• Food Processing Equipment: Mixing tanks, sterilization tools, piping systems for food transfers, industrial ovens, and heat exchangers.

• Aerospace: Jet engine components, exhaust systems, gas turbine combustors, afterburners, and heat exchangers for aircraft engines.

• Pharmaceuticals: Sterilizers, dryers, vessels, reactors for drug synthesis, and distillation equipment for purification.

• Nuclear Industry: Nuclear reactor core, heat exchangers, fuel rods, and steam generators.

• Industrial Furnaces: Annealing furnaces, forging furnaces, melting furnaces, heat treatment furnaces, and sintering furnaces.

Advantages of Incoloy 800

Here are some common advantages of Incoloy 800:

• Incoloy 800 possesses high strength and resistivity to oxidizing agents and environments.
• It is also resistant to reducing media and high temperatures upto 540°C
• It has impressive corrosion resistance in acidic environments and from chloride-induced stress
• alloy 800 material is easily formable and weldable
• It also possesses impressive creep and stress rupture resistance keeping the edges of Incoloy 800 materials, free from cracking and corrosion
• Incoloy 800 can withstand prolonged mechanical stress without losing its integrity.

Limitations of Incoloy 800

Incoloy 800 has certain limitations that make it unsuitable for certain applications and temperature exposures. These limitations include the following:

• In environments containing high sulfur, Incoloy may exhibit reduced performance
• Incoloy 800 is susceptible to corrosion and stress cracking under temperatures above 540°C
• It also has limited usage in reducing environments.

Comparison Among Other Incoloy Variants

All Incoloy alloy variants possess some similar characteristics, but their composition and other factors differ slightly. The table below compares Incoloy 800 vs 825 and Incoloy 800H vs. 825H.

Incoloy 800 Handling and Maintenance

Here are some best practices for handling and maintaining Incoloy 800:

• Store Incoloy alloy 800 materials in a clean, dry environment to prevent moisture and contaminants-induced corrosion.
• Use appropriate lifting equipment when carrying or transporting Incoloy 800 materials to avoid damage or injury.
• Clean Incoloy 800 materials frequently to remove dirt, oil, or grease using a mild detergent or soap and dry with a clean cloth to avoid the growth of water stains.
• During Incoloy 800 welding procedure, ensure the welding material is in good condition with proper calibration.
• Replace any damaged parts to improve the performance and integrity of your Incoloy 800 
• Keep Inventory of your maintenance activities and repairs.

Safety Considerations When Using Incoloy 800

Like every other material for industrial applications, you need certain safety precautions when working with Incoloy 800. Here are some safety practices you can employ during your process:

• Wear personal protective devices like goggles, gloves, protective clothing, and respiratory protection materials.
• Ensure the work area is properly ventilated
• Take appropriate safety fire measures. Always have a fire extinguisher in an easily accessible location in the work area.
• When cutting or welding Incoloy 800, dust and fumes are generated. Use appropriate dust collection channels to control airborne particles.
• Ensure that the Incoloy 800 material handler is trained properly and knows the emergency response procedures in case of any incidents.

Who Is the Best Incoloy 800 Manufacturer

Toulian Metal is the best Incoloy 800 manufacturer for all your needs. Toulian Metal’s Incoloy 800 materials are manufactured with high integrity and efficiency in mind. Over the years, their commitment to customer satisfaction has made Toulian Metal a popular choice for over 100 countries around the globe. 

Whether you’re a food processor, an engineer, or need the perfect material for heat exchangers, the team is always available to manufacture Incoloy 800 products that suit your needs and requirements. 

FAQ

1. What Is Incoloy 800 Price

Many factors can influence Incoloy 800 price, such as manufacturers and suppliers, location, market demand, and shipping. However, the average market cost of Incoloy 800 is between $17-$20 per kg. To get the accurate price plus delivery fees, contact your manufacturer; they will provide the current market price according to the specific material you want.

Is Incoloy 800 Stainless Steel?

No, Incoloy 800 is not stainless steel. Both materials resist corrosive environments, but their chemical composition, properties, and use cases differ. Incoloy 800 is an iron, chromium and nickel alloy with few traces of carbon, aluminium, and titanium. Any steel with chromium content of at least 10.5% is often grouped in the stainless steel family. 

What Is the Difference Between Inconel and Incoloy 800?

The chemical composition of Inconel consists of nickel-chromium and nickel-iron-chromium content. They have 72% nickel content and 14-17% chromium making them stronger than Incoloy 800 materials with only  30-35% nickel and 19-23% content. While Inconel and Incoloy 800 differ significantly, they are ideal for bars, fittings, and sheets used in various applications.

What Is the Difference Between Incoloy 800 and 600?

Although these alloys have their discrepancies, always remember that Incoloy 800 vs. 600 are iron, chromium, and nickel alloys suitable for use in high temperatures. However, their composition varies, with Incoloy 800 having a higher chromium content of 19-23% and Incoloy 600 having a higher nickel content of 72%. 

Incoloy 800 has better applications in elevated temperature environments than Incoloy 600 as it can maintain its properties under such temperatures. Incoloy alloy is fit for producing materials for power generation, chemivcal processing, etc, while Incoloy 600 is best suited for products with high corossion resistance because of its high nickel content. 

Is Incoloy better than copper?

The specification and application of the system will determine the choice of either Incoloy 800 or copper. Incoloy 800 offers higher resistance to corrosive environments than copper for industrial processes and other applications. 

It can prevent rusting and cracking from chloride-induced stress and other corrosive media. However, copper is best for electrical and electronic applications because it has excellent electrical conductivity than Incoloy 800.

Fabrication Processes

Forming

Incoloy 800 has good ductility and malleability. Thus, it can be formed using of hot and cold forming. This material is formed up to 871-1232°C.

Cold forming

Cold-forming techniques include bending, drawing, and stamping process. Cold forming is utilized to manufacture smaller components.

Hot forming

Hot forming techniques such as forging, extrusion, & hot rolling can be used to shape Incoloy 800. Hot forming is typically used to produce large & complex components that require a high degree of precision.

Welding Process

Incoloy 800 can be welded utilizing:

• Gas tungsten arc welding (GTAW)
• Shielded metal arc welding (SMAW)
• Gas metal arc welding (GMAW)

Annealing

A heat treatment process is used to improve the ductility & toughness of Incoloy 800. The alloy should be annealed at 982°C (1800°F) temperature. The alloy is then cooled slowly to room temperature. This process can reduce the risk of stress corrosion cracking.

Machining

Incoloy 800 is machined utilizing conventional machining techniques. It includes turning, milling, drilling, & grinding.