Monels, corrosion

It is extensively used for making stainless steel and other corrosion-resistant alloys such as Invar(R), Monel(R), Inconel(R), and the Hastelloys(R). Tubing made of copper-nickel alloy is extensively used in making desalination plants for converting sea water into fresh water. 

Fluorine can be handled using a variety of materials (100—103). Table 4 shows the corrosion rates of some of these as a function of temperature. System cleanliness and passivation ate critical to success. Materials such as nickel, Monel, aluminum, magnesium, copper, brass, stainless steel, and carbon steel ate commonly used. Mote information is available in the Hterature (20,104). 

Molybdenum hexafluoride is classified as a corrosive and poison gas. It is stored and shipped in steel, stainless steel, or Monel cylinders approved by DOT. Electronic and semiconductor industries prefer the cylinders equipped with valves which have Compressed Gas Association (CGA) 330 outlets. 

Stainless steel alloys show exceUent corrosion resistance to HCl gas up to a temperature of 400°C. However, these are normally not recommended for process equipment owing to stress corrosion cracking during periods of cooling and shut down. The corrosion rate of Monel is similar to that of mild steel. Pure (99.6%) nickel and high nickel alloys such as Inconel 600 can be used for operation at temperatures up to 525°C where the corrosion rate is reported to be about 0.08 cm/yr (see Nickel and nickel alloys). 

Chemical-Process Vessels. Explosion-bonded products are used in the manufacture of process equipment for the chemical, petrochemical, and petroleum industries where the corrosion resistance of an expensive metal is combined with the strength and economy of another metal. AppHcations include explosion cladding of titanium tubesheet to Monel, hot fabrication of an explosion clad to form an elbow for pipes in nuclear power plants, and explosion cladding titanium and steel for use in a vessel intended for terephthaHc acid manufacture. 

Nickel—Copper. In the soHd state, nickel and copper form a continuous soHd solution. The nickel-rich, nickel—copper alloys are characterized by a good compromise of strength and ductihty and are resistant to corrosion and stress corrosion ia many environments, ia particular water and seawater, nonoxidizing acids, neutral and alkaline salts, and alkaUes. These alloys are weldable and are characterized by elevated and high temperature mechanical properties for certain appHcations. The copper content ia these alloys also easure improved thermal coaductivity for heat exchange. MONEL alloy 400 is a typical nickel-rich, nickel—copper alloy ia which the nickel content is ca 66 wt %. MONEL alloy K-500 is essentially alloy 400 with small additions of aluminum and titanium. Aging of alloy K-500 results in very fine y -precipitates and increased strength (see also Copper alloys). 

Materials of Construction and Operational Stress. Before a centrifugal separation device is chosen, the corrosive characteristics of the Hquid and soHds as weU as the cleaning and saniti2ing solutions must be deterrnined. A wide variety of materials may be used. Most centrifuges are austenitic stainless steels however, many are made of ordinary steel, mbber or plastic coated steel. Monel, HasteUoy, titanium, duplex stainless steel, and others. The solvents present and of course the temperature environment must be considered in elastomers and plastics, including composites. 

Shipment and Storage. Much of the trichloromethanesulfenyl chloride produced is used captively. However, it can be shipped in dmms. Standard materials for storage and handling are nickel. Monel, and glass. Trichloromethanesulfenyl chloride is not corrosive to nickel and Monel when dry, but cate must be taken to prevent its contact with moisture. 

Titanium resists erosion—corrosion by fast-moving sand-laden water. In a high velocity, sand-laden seawater test (8.2 m/s) for a 60-d period, titanium performed more than 100 times better than 18 Cr—8 Ni stainless steel. Monel, or 70 Cu—30 Ni. Resistance to cavitation, ie, corrosion on surfaces exposed to high velocity Hquids, is better than by most other stmctural metals (34,35). 

Copper—Nickels. The copper—nickel alloy system is essentially single phase across its entire range. Alloys made from this system are easily fabricated by casting, forming, and welding. They are noted for excellent tarnishing and corrosion resistance. Commercial copper alloys extend from 5 to 40 wt % nickel. Monel is a nickel—copper alloy that is outside of this range and contains 29—53 wt % of copper. 

The reaction mixture is filtered. The soHds containing K MnO are leached, filtered, and the filtrate composition adjusted for electrolysis. The soHds are gangue. The Cams Chemical Co. electrolyzes a solution containing 120—150 g/L KOH and 50—60 g/L K MnO. The cells are bipolar (68). The anode side is monel and the cathode mild steel. The cathode consists of small protmsions from the bipolar unit. The base of the cathode is coated with a corrosion-resistant plastic such that the ratio of active cathode area to anode area is about 1 to 140. Cells operate at 1.2—1.4 kA. Anode and cathode current densities are about 85—100 A/m and 13—15 kA/m, respectively. The small cathode areas and large anode areas are used to minimize the reduction of permanganate at the cathode (69). Potassium permanganate is continuously crystallized from cell Hquors. The caustic mother Hquors are evaporated and returned to the cell feed preparation system. 

Flexible Metal Hose Deeply corrugated thin brass, bronze, Monel, aluminum, and steel tubes are covered with flexible braided-wire jackets to form flexible metal hose. Both tube and braid are brazed or welded to pipe-thread, union, or flanged ends. Failures are often the result of corrosion of the braided-wire jacket or of a poor... 

Clad Tube Sheets Usually tube sheets and other exchanger parts are of a solid metal. Clad or bimetallic tube sheets are usecito reduce costs or because no single metal is satisfactory for the corrosive conditions. The alloy material (e.g., stainless steel, Monel) is generally bonded or clad to a carbon steel backing material. In fixed-tube-sheet construction a copper-alloy-clad tube sheet can be welded to a steel shell, while most copper-alloy tube sheets cannot be welded to steel in a manner acceptable to ASME Code authorities. 

Virtuallv evety alloy system has its specific environment conditions which will prodiice stress-corrosion cracking, and the time of exposure required to produce failure will vary from minutes to years. Typical examples include cracking of cold-formed brass in ammonia environments, cracking of austenitic stainless steels in the presence of chlorides, cracking of Monel in hydrofluosihcic acid, and caustic embrittlement cracking of steel in caustic solutions. 

Monel 1500 High corrosion resistance. Good against most acids and alkalies, but attacked by strong hydrochloric and strong oxidizing acids. 

Nickel additions reduce corrosion due to both caustic solutions and ammonia. Monel is resistant to attack in ammonia-containing waters and vapors. Reactions with ammonia are as follows ... 

Nickel and its alloys form another important class of non-ferrous metals (Table 1.3). The superb creep resistance of the nickel-based superalloys is a key factor in designing the modern gas-turbine aero-engine. But nickel alloys even appear in a model steam engine. The flat plates in the firebox must be stayed together to resist the internal steam pressure (see Fig. 1.3). Some model-builders make these stays from pieces of monel rod because it is much stronger than copper, takes threads much better and is very corrosion resistant. 

Monels Superalloys Ni -r 30 Cu 1 Fe 1 Mn Ni -r 30 Cr 30 Fe 0.5 Ti 0.5 Al Ni -r 10 Co 10 W 9 Cr 5 A1 2 Ti Strong, corrosion resistant heat-exchanger tubes. Creep and oxidation resistant furnace ports. Highly creep resistant turbine blades and discs. 

Because the plates are made of thin pressed metal, materials resistant to corrosive attack can be easily selected. Plates are standard and mass-produced,. Specific applications are dealt with by changing plate arrangements. Stainless steels, monel, titanium, aluminum bronze, and other exotic metals... 

Many fluorides are corrosive to glass and some metals Even the very corrosive anhydrous fluorides, however, can be handled at room temperature in steel, stainless steel, copper, and Teflon equipment For reactions at higher temperature, nickel and Monel metal are indispensable More data on corrosion of matenals are given in pages 22 and 23 of Chemistry of Organic Fluorine Cowjpoundi, published in 1676... 

The non-ferrous alloys include the misleadingly named nickel silver (or German silver) which contains 10-30% Ni, 55-65% Cu and the rest Zn when electroplated with silver (electroplated nickel silver) it is familiar as EPNS tableware. Monel (68% Ni, 32% Cu, traces of Mn and Fe) is used in apparatus for handling corrosive materials such as F2 cupro-nickels (up to 80% Cu) are used for silver coinage Nichrome (60% Ni, 40% Cr), which has a very small temperature coefficient of electrical resistance, and Invar, which has a very small coefficient of expansion are other well-known Ni alloys. Electroplated nickel is an ideal undercoat for electroplated chromium, and smaller amounts of nickel are used as catalysts in the hydrogenation of unsaturated vegetable oils and in storage batteries such as the Ni/Fe batteries. 

Tower shells may be ferrous, non-ferrous, stainless alloys or clad (such as monel-clad-steel). The trays are usually light gage metal consistent with the corrosion and erosion problems of the system. The velocity action of vapors flowing through holes and slots accentuates the erosion-corrosion problems, and often a carbon steel tower will use... 

Monel, galvanized or other corrosion resistant metals... 

---