M AT E R I A L Catalogue

A STAINLESS STEEL & LOW ALLOY STEELS Cobalt Street Plant General information on stainless steel & low alloy steels Austenitic cast alloys Martensitic & ferritic cast alloys Duplex cast alloys Steel & low alloy steels Special cast alloys 9 9 8 7 4 3 2

B IRON BASE ALLOYS Tungsten Street Plant 10 General information on iron base alloys 11 12 13 14 14 15 16 Flake graphite irons Spheroidal graphite irons Austenitic cast irons Ni-hard martensitic cast iron Carbon & carbon manganese steels Low alloy steels

C CASTINGS FOR THE PETROCHEMICAL INDUSTRY Introduction to heat and creep

Typical creep rupture strength table Typical creep limiting strength table

20 21

D THE CASTING PROCESS

22

INDEX

resistant alloys

17

C O B A LT S T R E E T P L A N T

Steloy Castings Cobalt Street facility produces high integrity, high performance stainless steel and alloy castings. Equipment enables the production of castings ranging from 1kg to 2 000kg. An ARL emission spectrometer ensures compliance with all the relevant grades of materials and enables the foundry to analyse materials where the specification is unknown. Moulding is carried out on a cold box machine for castings up to 30kg fettled mass, or by means of the no-bake process for castings up to 2 000kg fettled mass. A shell moulding facility is used for castings to higher tolerances. A fully automatic LP gas fired temperature heat treatment furnace with temperature recorder, coupled to a water quench facility, enables the heat treatment of all grades of castings produced in-house. In addition, a fully equipped pattern shop ensures independence from outside services. One of the first foundries to receive the ISO 9002 quality award, Steloy Castings is a leader in quality standards and fully conversant with international standards, currently accredited for ISO 9002/2000.

MATERIAL GROUP AUSTENITIC CAST ALLOYS Corrosion resistant Heat resistant

METALLOGRAPHIC STRUCTURE Austenitic

TYPICAL APPLICATIONS Impellers, pumps, casings valve bodies Furnace components, hangers, brackets, tube sheets, tube bends

ENVIRONMENT Corrosive environments general and severe Low temperatures Petrochemical industry, high temperatures in oxidising and/or reducing atmospheres Creep resistant Heat treatment applications Corrosive environments, general and severe High strength may be required Stress corrosion, general and severe General and high stress High temperatures Low temperatures High corrosion and abrasive applications

Austenitic

MARTENSITIC & FERRITIC CAST ALLOYS

Martensitic and/or Ferritic

Impellers, valve bodies, casings

DUPLEX CAST ALLOYS STEEL & LOW ALLOY STEELS

Austenitic/Ferritic Ferritic/Pearlitic/Martensitic

Impellers, pumps, casings Pumps, valves, structural components, pressure containing parts Special requirements for strength, corrosion, wear and heat

SPECIAL CAST ALLOYS

Austenitic/Ferritic/Martensitic

G E N E R A L I N F O R M AT I O N O N S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Austenitic Cast Alloys

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

C Max Mn Max Si Max P Max S Max Cr Ni Mo Others

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES

Yield Tensile Elongation Point % Strength MPa Min MPa Min Min

GERMAN DIN

AUSTENITIC CAST ALLOYS: CORROSION RESISTANT

Steloy - CF 8 Steloy - CF-8M Steloy - CF-3 Steloy - CF-3M Steloy - CG-8M Steloy - CN-7M Steloy - 90 Steloy - CH20 Steloy - 28/31 Steloy - CF-8C ASTM A743 CF-8 ASTM A743 CF-8M ASTM A743 CF-3 ASTM A743 CF-3M ASTM A743 CG-8M ASTM A743 CN-7M ASTM A743 CH20 ASTM A351 CF8C 304C 15 316C 16 304C 12 316C 12 317C 16 1,4308 1,4408 1,4306 1,4404 1,4448 1,4500 1,4563 1,4552 G-X6CrNi18 9 G-X6CrNiMo18 10 G-X2CrNi18 9 G-X2CrNiMo18 10 G-X6CrNiMo17-13 G-X7NiCrMoCuNb25-20 XlNiCrMoCu31-27-4 G-X5CrNiNb19-11 0,08 0,08 0,03 0,03 0,08 0,07 0,07 0,20 0,03 0,08 1,50 1,50 1,50 1,50 1,50 1,50 1,00-1,25 1,50 2,00 1,50 2,00 2,00 2,00 1,50 1,50 1,50 0,7-1,0 2,00 1,50 2,00 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,02 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,015 0,04 18,0-21,0 18,0-21,0 17,0-21,0 17,0-21,0 18,0-21,0 19,0-22,0 20,25-23,0 22,0-26,0 27,0 18,0-21,0 8,0-11,0 9,0-12,0 8,0-12,0 9,0-13,00 9,0-13,0 27,5-30,5 27,7-29,0 12,0-15,0 31,0 9,0-12,0 2,0-3,0 2,0-3,0 3,0-4,0 2,0-3,0 4,25-5,0 3,5 0,50 Cu1,0 Nb 1,00 max, 8x%C 3,0-4,0Cu Cu2,75-3,25Nb0,5 205 205 205 205 240 170 200 205 215 205 485 485 485 485 520 425 450 485 450 485 35 30 35 30 25 35 30 30 30 30

NOTE: ASTM A743 is for castings, iron-chromium, iron-chromium-nickel, corrosion resistant for general applications. ASTM A744 is for castings, iron-chromium-nickel, corrosion resistant for severe service. Selected alloys are produced in accordance with ASTM A990 which is the specification for iron-nickel-chromium and nickel alloys, specially controlled for pressure retaining parts for corrosive service.

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

C Max Mn Max Si Max P Max S Max Cr Ni Mo Others

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES

Yield Tensile Elongation Point % Strength MPa Mpa Min MPa Min Mpa Min

GERMAN DIN

AUSTENITIC CAST ALLOYS: HEAT RESISTANT

Steloy - HT Steloy - HU Steloy - HX Steloy - HC Steloy - HF Steloy - HD Steloy - HE Steloy - W Steloy - HK40 HK40 Steloy Steloy - HH Steloy - HK ASTM A297 HT ASTM A297 HU ASTM A297 HX ASTM A297 HC ASTM A297 HF ASTM A297 HD ASTM A297 HE ASTM A351 A351 HK40 HK40 ASTM ASTM A297 HH ASTM A297 HK 330C 12 331C 40 334C 11 452C 11 309C 30 309C 40 309C 32 310C 40 1,4865 1,4826 1,4823 2,4879 1,4848 1,4837 1,4848 G-X40NiCrSi38 18 G-X40NiCrSi38-18 G-X40CrNiSi22 9 G-X40CrNiSi22-9 G-X40CrNiSi27 4 G-X40CrNiSi27-4 G-NiCr28W G-X40CrNiSi25-20 G-X40CrNiSi25-12 G-X40NiCrSi25-20 0,35-0,75 0,35-0,75 0,35-0,75 0,5 0,2-0,40 0,5 0,2-0,50 0,35-0,55 0,35-0,45 0,35-0,45 0,2-0,5 0,2-0,6 2,00 2,00 2,00 1,00 2,00 1,50 2,00 2,00 1,50 1,50 2,00 2,00 2,50 2,50 2,50 2,00 2,00 2,00 2,00 1,50 1,75 1,75 2,00 2,00 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,045 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,04 0,030 0,04 0,04 0,04 0,04 15,0-19,0 17,0-21,0 15,0-19,0 26,0-30,0 18,0-23,0 26,0-30,0 26,0-30,0 27,0-30,0 23,0-27,0 23,0-27,0 24,0-28,0 24,0-28,0 33,0-37,0 37,0-41,0 64,0-68,0 4,0 max 8,0-12,0 4,0-7,0 8,0-11,0 47,0-50,0 19,0-22,0 19,0-22,0 11,0-14,0 18,0-22,0 0,5 max 0,5 max 0,5 max 0,5 max 0,5 max 0,5 max 0,5 max 0,5 max max 0,5 0,5 max 0,5 max W4,0-5,5 240 240 275 240 240 240 240 240 450 450 415 380 485 515 585 440 425 425 515 450 4 4 25 8 9 4 10 10 10 10

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Austenitic Cast Alloys (continued)

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Austenitic Cast Alloys (continued)

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

C Max Mn Max Si Max P Max S Max Cr Ni Mo Others

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES

Yield Tensile Elongation Point % Strength MPa Mpa Min MPa Min Mpa Min

GERMAN DIN

AUSTENITIC CAST ALLOYS: HEAT RESISTANT (continued)

Steloy - HP HT Steloy - HU S333 Steloy - HX Steloy - HC 1.4852 mod Steloy - HF Steloy mod Steloy HH - HD Steloy Steloy 1.4849 - HE Steloy - W Steloy IN657 Steloy - HK40 Steloy 1,4859 ASTM A297 HP HT ASTM A297 HU ASTM A297 HX HP ASTM A297 HC (mod) ASTM A297 HF ASTM ASTM A447 A297 HD ASTM A297 HE ASTM A560 ASTM A351 HK40 ASTM A351 CT15C 330C 12 331C 40 334C 11 452C 11 309C 30 309C 40 1,4857 1,4865 2,4608 1,4852 1,4826 1,4823 1,4849 2,4879 2,4680 1,4859 G-X40NiCrSi35 25 G-X40NiCrSi38 18 NiCr26MoW G-X40NiCrSiNb35-25 G-X40CrNiSi22 9 G-X40CrNiSi27 4 G-X40NiCrSiNb38-18 G-NiCr28W G-NiCr50Nb G-X10NiCrNb32-20 0,35-0,75 0,35-0,75 0,10 0,35-0,75 0,5 0,4-0,5 0,2-0,40 0,20-0,45 0,5 0,30-0,50 0,2-0,50 0,35-0,55 0,10 0,35-0,45 0,05-0,15 0,5-1,50 2,00 2,00 2,00 2,00 1,00 1,50 2,00 2,50 1,50 1,5 2,00 2,00 0,30 1,50 0,15-1,50 1,0-2,50 2,50 2,50 1,50 2,50 2,00 1,2-1,8 2,00 1,75 2,00 1,0-2,5 2,00 1,50 0,50 1,75 0,50-1,50 0,045 0,04 0,04 0,03 0,04 0,04 0,025 0,04 0,05 0,04 0,035 0,04 0,045 0,02 0,04 0,03 0,030 0,04 0,04 0,03 0,04 0,04 0,015 0,04 0,05 0,04 0,030 0,04 0,030 0,02 0,04 0,03 24,0-28,0 15,0-19,0 17,0-21,0 24,0-27,0 15,0-19,0 26,0-30,0 23-27 18,0-23,0 23,0-28,0 26,0-30,0 17,0-19,0 26,0-30,0 27,0-30,0 47,0-52,0 23,0-27,0 19,0-21,0 33,0-37,0 37,0-41,0 44,0-48,0 64,0-68,0 4,0 max 32-36 8,0-12,0 10,0-14,0 4,0-7,0 36,0-39,0 8,0-11,0 47,0-50,0 BAL 19,0-22,0 31,0-34,0 0,5 max 0,5 max 2,5-4,0 0,5 max 0,5 max 0,5 0,5 max 0,5 max 0,5 max 0,5 max W 2,5-4,0 Co 2,5-4,0 Nb 0,8-1,2 V 0,10 Ti 0,1-0,3 N 0,2 max Nb 1,20-1,80 Nb 1,4-1,7 W4,0-5,5 Fe 1,0 max max N 0,16 Nb 0,50-1,50 235 240 250 240 240 220 275 345 240 170 430 450 450 550 415 380 450 485 550 515 400 585 440 550 425 435 4,5 4 4 30 6 25 4 8 5 9 4 5 10 20

NOTE: ASTM A297 is for steel castings, iron-chromium and iron-chromium-nickel, heat resistant for general application. Alloys in this range contain varying percentages of Cr and Ni. Cr is mainly intended for oxidisation resistance whereas Ni is mainly intended for carburisation resistance and high temperature ductility (thermal shock resistance). ASTM A447 is for steel castings chromium-nickel-iron alloy (25-12 Class) for high temperature service. Selected alloys have been microalloyed with Nb, Ti, Zr and R.E. to enhance creep rupture properties.

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

C Max Mn Max Si Max P Max S Max Cr Ni Mo Others

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES

Yield Tensile Elongation Point % Strength MPa Min MPa Min Min

GERMAN DIN

MARTENSITIC AND FERRITIC CAST ALLOYS

Steloy - CA-15 Steloy - 13 Steloy - CA-40 Steloy - CB-30 Steloy - CB-7Cu ASTM A743 CA-15 ASTM A743 CA-40 ASTM A743 CB-30 ASTM A747 CB-7Cu1 410C 21
420C24/C29

1,4006 1,4027 1,4028 1,4059 1,4542 1,4313 1,4340 1,4138

G-X12Cr13 G-X20Cr14 G-X30Cr13 G-X22CrNi17 X5CrNiCuNb17-4 G-X5CrNi13-4 G-X40CrNi27-4 G-X120CrMo29-2

0,15 0,16-0,23 0,2-0,4 0,30 0,07 0,06 0,50 0,9-1,30

1,00 1,00 1,00 1,00 0,70 1,00 1,00 1,00

1,50 1,00 1,50 1,50 0,5-1,0 1,00 1,50 2,00

0,04 0,045 0,04 0,04 0,035 0,04 0,04 0,045

0,04 0,030 0,04 0,04 0,030 0,03 0,04 0,030

11,5-14,0 12,5-14,5 11,5-14,0 18,0-21,0 15,5-17,7 11,5-14,0 26,0-30,0 27,0-29,0

1,0 max 1,0 max 1,0 max 2,0 max 3,6-4,6 3,5-4,5 4,00

0,5 max 0,5 max 0,4-1,0 2,00-2,50 Cu2,5-3,2Nb0,15-0,35

450 465 485 205 1000 550 880-1080

620 690 690 450 1170 755 380

18 11 15 5 15

425C 11

Steloy - CA-6NM ASTM A743 CA-6NM Steloy - CC-50 Steloy - 2802 ASTM A743 CC-50

NOTE: ASTM A743 is for castings, iron-chromium, iron-chromium-nickel, corrosion resistant for general application. ASTM A747 is for steel castings, stainless, precipitation hardening.

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Martensitic & Ferritic Cast Alloys

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Duplex Cast Alloys

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

C Max Mn Max Si Max P Max S Max Cr Ni Mo Others

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES

Yield Tensile Elongation Point % Strength MPa Min MPa Min Min

GERMAN DIN

DUPLEX CAST ALLOYS

Steloy CD-4MCu Steloy - 225 Steloy - 2507
Steloy - CD-3MCuN Steloy - CD-4MCuN

ASTM A890gr 1A ASTM A890gr 4A ASTM A890gr 6A ASTM A890gr 1C ASTM A890gr 1B ASTM A890gr 3A ASTM A890gr 2A

322C 13 1,4462

0,040 0,030 0,030 0,030 0,040 0,060 0,080

1,00 1,50 1,00 1,20 1,00 1,00 1,00

1,00 1,00 1,00 1,10 1,00 1,00 1,50

0,040 0,040 0,030 0,030 0,040 0,040 0,040

0,040 0,020 0,025 0,030 0,040 0,040 0,040

24,5-26,5 21,0-23,5 24,0-26,0 24,0-26,7 24,5-26,5 24,0-27,0 22,5-25,5

4,75-6,00 4,50-6,50 6,5-8,5 5,60-6,70 4,7-6,0 4,0-6,0 8,0-11,0

1,75-2,25 2,50-3,50 3,0-4,0 2,90-3,80 1,7-2,3 1,75-2,50 3,0-4,5

Cu2,75-3,25 Cu1,00 max N0,10-0,30 Cu0,5-1,0 W0,5-1,0 N0,20-0,30 Cu1,40-1,90 N0,22-0,33 Cu2,7-3,3 N0,10-0,25 N0,15-0,25 N0,10-0,30

485 415 450 450 485 450 450

690 620 690 690 690 655 655

16 25 25 25 16 25 25

Steloy - CD-6MN Steloy - CE-8MN

NOTE: Duplex stainless steels have been developed to render increased resistance to Stress Corrosion Cracking (SCC) particularly for deep sour wells (CI and H2S) in oil exploration. Other advantages are higher resistance against pitting and crevice corrosion, general increased resistance to sensitisation and increased yield strength. ASTM A890 is the specification for Corrosion Resistant Duplex Stainless Steels for general application. ASTM A995 is the specification for Duplex Stainless Steels for pressure-containing parts. By virtue of specific requirements to ensure casting integrity materials and components manufactured in accordance with the latter specification can be applied in conditions of combined high pressures and corrosion. ASTM A923 is the specification for standard test methods for detecting detrimental intermetallic phases in Duplex Austenitic/Ferritic Stainless Steels. It is currently only intended for mill (wrought) products. Future editions will, however, also include A890- and A995 Grade 4A (CD3MN). This specification is intended to ensure freedom of intermetallic phases which could influence toughness and corrosion resistance detrimentally.

CODES

CHEMICAL COMPOSITION (% BY WEIGHT)

STELOY CODE

Related International Codes

USA ASTM STANDARDS BRITISH STANDARDS BS 3100 STD No

MECHANICAL PROPERTIES AT ROOM TEMPERATURES Mo Others

Yield Point MPa Min Tensile Elongation % Strength Min MPa Min

GERMAN DIN

C Max

Mn Max

Si Max

P Max

S Max

Cr

Ni

STEEL AND LOW ALLOY STEELS

Steloy - WCB Steloy - LCC Steloy - LC2 Steloy - LCB Steloy - LCA Steloy - C5 ASTM A216 WCB ASTM A352 LCC ASTM A352 LC2 ASTM A352 LCB ASTM A352 LCA ASTM A217 C5 A1 B5 1,0619 1,1156 1,7363 GS-C25 GS-Ck24 G-X12CrMo5 0,30 0,25 0,25 0,30 0,25 0,20 1,00 1,20 0,50-0,80 1,00 0,70 0,40-0,70 0,60 0,60 0,60 0,60 0,60 0,75 0,040 0,040 0,040 0,040 0,040 0,040 0,045 0,045 0,045 0,045 0,045 0,045 0,50 0,50 0,50 0,50 4,0-6,5 0,50 0,50 2,0-3,0 0,50 0,50 0,50 0,20 0,20 0,20 0,20 0,45-0,65 Cu 0,30 max V0,03 max 250 485-655
485-655 Impact 485-655 Impact 450-620 Impact 415-485 Impact

22 22 24 24 24 18

275 Cu 0,30 max 20J AT - 46C 275 20J AT - 73C 240 Cu 0,30 max V0,03 max 18J AT - 46C 205 Cu 0,30 max V0,03 max 18J AT - 32C

Cu 0,50 max W0,10 max

415

620-795

SPECIAL CAST ALLOYS

Steloy - N-12MV Steloy - M-35-1 Steloy - 825 ASTM A494 N-12MV ASTM A494 M-35-1 2,4858 64%Ni, 29%Mo 66%Ni, 30%Cu
21%Cr, 42%Ni 3%Mo, 2%Cu, 1%Ti

Steloy - CW-12MW Steloy - IN657 Steloy - CrCo40

ASTM A494 CW-12MW 2,4680

17,5%Cr, 54%Ni, 17%Mo 50%Cr, 48%Ni, 1%Nb 40Co, 30Cr, 20Ni, 1,5Mo

Steloy - CZ-100 Steloy - 600

ASTM A494 CZ100 2,4816

95%Ni min 15%Cr, 76%Ni, 8%Fe

NOTE: ASTM A216 is for steel castings, carbon, suitable for fusion welding for high temperature service. ASTM A217 is for steel castings, martensitic stainless and alloy, for pressure containing parts, suitable for high temperature service. ASTM A352 is for steel castings, ferritic and martensitic, for pressure containing parts suitable for low temperature service. ASTM A494 is for castings, nickel and nickel alloy.

S TA I N L E S S S T E E L A N D L O W A L L O Y S T E E L S Steel and Low Alloy Steels, Special Cast Alloys

10 TUNGSTEN STREET PLANT

Founded in 1990, Steloy Castings Tungsten Street facility is equipped with state-of-the-art technology to produce a full range of cast iron, SG iron, nickel irons and a variety of carbon steel castings. Equipment includes two high frequency induction furnaces each with a capacity of 1 500kg. An ARL emission spectrometer ensures compliance with all the relevant grades of materials and allows the analysis of materials where the specification is unknown. Moulding facilities include a cold box machine for the semi-automated mass production of castings from 2kg to 50kg and three resin bonded moulding lines light, medium and floor for castings from 2kg to 2 200kg. A shell moulding facility is used to produce castings to higher tolerances. A fully automatic LP gas fired temperature heat treatment furnace with temperature recorder, enables the heat treatment of all the various grades of materials in-house. A fully equipped pattern shop on the premises ensures independence from outside services.

MATERIAL GROUP FLAKE GRAPHITE IRONS

METALLOGRAPHIC STRUCTURE Various size flake graphite in a mainly pearlitic structure

TYPICAL APPLICATIONS Pump casings, impellers, brackets, support bends, valve bodies, pulleys Pump casings, impellers, brackets, supports, bends, valve bodies, shafts, gear pulleys, chains, sprockets

ENVIRONMENT General engineering non-corrosive environment High strength casting applications

SPHEROIDAL GRAPHITE IRONS

Ferritic matrix for lower grade. Ferritic/pearlitic matrixes for intermediate grades. Pearlitic/tempered martensitic structure higher grades

AUSTENITIC CAST IRONS

Flake graphite austenitic

Pumps, valves, furnace, piston ring carriers for light components, bushing, alloy metal parts, non magnetized castings

Corrosion resistant to alkalis, diluted acids, sea water, salt solution

Ni-HARD MARTENSITIC CAST IRON CARBON AND CARBON MANGANESE STEELS LOW ALLOY STEELS

Martensitic Ferritic/Pearlitic

Pumps, mill liners, slurry pumps, pipe bends Pumps, valves, impellers, pipe bends, brackets, supports, flanges

Corrosion resistant to alkalis, diluted acids Pressure containing parts, high strength but ductile components For use at elevated temperatures and higher tensile strengths

Pearlitic/Martensitic

Valves, brackets, shafts, furnace components

11

G E N E R A L I N F O R M AT I O N O N I R O N B A S E A L L O Y S

12

I R O N B A S E A L L O Y S Flake Graphite Irons

STELOY CODE

RELATED INTERNATIONAL CODES

S.A. U.S.A. BRITISH GERMAN %C %Mn

CHEMICAL COMPOSITION (% BY WEIGHT)

%Si %P %S %Cr %Mo %Cu Others

MECHANICAL PROPERTIES
Yield Point Tensile Elongation Hardness MPa Min Strength %Min Brinell 0,2%Proof MPa Min Charpy V-Notch Min

FLAKE GRAPHITE IRONS

SABS 1034-1975 000PB10 000PB12 000PB14 000PB17 000PB20 000PB23 Grade 150 Grade 200 Grade 200 Grade 250 Grade 300 Grade 350 ASTM A48-03 Class 20 Class 25 Class 30 Class 35 Class 45 Class 50 BS 1452-1990 Grade 150 Grade 180 Grade 220 Grade 250 Grade 300 Grade 350 DIN 1691-1985 GG15 0,6015 GG20 0,6020 GG20 0,6020 GG25 0,6025 GG30 0,6030 GG35 0,6035 3,003,60 3,103,60 3,103,50 2,903,40 2,803,30 2,703,20 0,300,70 0,400,75 0,400,80 0,500,90 0,601,00 0,701,10 2,002,70 2,002,50 1,902,40 1,802,30 1,602,00 1,50,1,90 0,25 max 0,25 max 0,25 max 0,20 max 0,20 max 0,20 max 0,12 max 0,12 max 0,12 max 0,12 max 0,12 max 0,10 max 0,20 max 0,30 max 0,300,80 0,501,00 %Ni 0,500,70 150 180 220 250 300 350 150190 160200 170210 180220 190250 200260

Castings will be supplied in the as-cast condition. Composition may vary with casting section thickness. Chemical compositions are nominal lower and upper values. Tensile strength on standard 30mm test bar. Tensile strength of cast on test bar will vary with casting section thickness. Hardness values will vary with casting section thickness.

STELOY CODE

RELATED INTERNATIONAL CODES

S.A. U.S.A. BRITISH GERMAN %C %Mn

CHEMICAL COMPOSITION (% BY WEIGHT)

%Si %P %S %Cr %Mo %Cu %Mg

MECHANICAL PROPERTIES
Yield Point Tensile Elongation Hardness MPa Min Strength %Min Brinell 0,2%Proof MPa Min Charpy V-Notch Min

SPHEROIDAL GRAPHITE IRONS

SABS 936-1969 PNG2417 SG38 SG42 PNG2712 PNG3207 PNG3903 PNG4502 PNG5202 PNG5802 PNG6807 PNG7804 SG50 SG60 SG70 SG80 80-55-06 100-70-03 120-90-02 ASTM A89790 A.D.I. 1050-700-7 ASTM A89790 A.D.I. 1200-850-4 65-45-12 400/18 420/12 SNG 27/12 450/10 500/7 SNG 32/7 600/3 SNG 37/2 700/2 SNG 42/2 SNG 47/2 800/2 900/2 ASTM A536-03 60-40-18 BS 2789-1985 350/22 370/17 SNG 24/17 DIN 1693-1977 GGG40,3 0,7043 GGG40 0,7040 GGG50 0,7050 GGG50 0,7050 GGG60 0,7060 GGG70 0,7070 GGG80 3,003,80 3,003,80 3,103,80 3,103,80 3,203,80 3,203,90 3,303,90 3,404,00 3,204,00 3,203,80 3,203,80 0,100,20 0,100,20 0,150,30 0,150,30 0,200,50 0,350,60 0,500,90 0,400,70 0,400,50 0,400,70 0,400,70 2,202,70 2,202,70 2,202,70 2,202,70 2,202,80 2,302,90 2,302,90 4,005,00 2,302,90 2,202,70 2,202,70 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,02 max 0,300,50 0,30 max 0,40 max 0,350,60 0,700,95 0,801,20 0,901,20 0,901,20 0,701,20 0,801,30 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 0,020,05 220 250 270 320 320 370 420 480 600 700 850 350 400 420 450 500 600 700 800 900 1050 1200 22 18 12 10 7 3 2 2 2 7 4 <160 <179 <212 160221 170241 192269 229302 248352 302359 302363 341444 17J at 20C 14J at 20C 80J at 22C 60J at 22C

Heat treatment of castings will be done at the discretion of the manufacturer to obtain mechanical properties. Composition may vary with casting section thickness. Chemical compositions are nominal lower and upper values. Tensile, yield and elongation values applicable to 14 mm test bar. Hardness values applicable to the end area of the parallel portion of a 14 mm test bar.

13

I R O N B A S E A L L O Y S Spheroidal graphite irons

14

I R O N B A S E A L L O Y S Austenitic & Ni-hard Martensitic Cast Irons

STELOY CODE

RELATED INTERNATIONAL CODES

S.A. U.S.A. BRITISH GERMAN %C %Mn

CHEMICAL COMPOSITION (% BY WEIGHT)

%Si %P %S %Cr %Cu %Ni Others

MECHANICAL PROPERTIES
Yield Point Tensile Elongation Hardness MPa Min Strength %Min Brinell 0,2%Proof MPa Min Charpy V-Notch Min

AUSTENITIC CAST IRONS

OPL1562 OPL1563 ASTM A436-03 Type 1 Type 1B BS 3468-1974 LNiCuCr 1562 LNiCuCr 1563 DIN 1694-1981 GGL.NiCuCr 1562 GGL.NiCuCr 1563 3,00 max 3,00 max 0,501,50 0,501,50 1,002,80 1,002,80 A.L.A.P. A.L.A.P. A.L.A.P. A.L.A.P. 1,002,50 2,503,50 5,507,50 5,507,50 13,5017,50 13,5017,50 170 190 140200 150250

Castings will be supplied in the as-cast condition. Tensile strength on 25 mm test bar.

STELOY CODE

S.A.

U.S.A.

BRITISH

GERMAN

%C

%Mn

%Si

%P

%S

%Cr

%Mo

%Cu

Others

Yield Point Tensile Elongation Hardness MPa Min Strength %Min Brinell 0,2%Proof MPa Min

Charpy V-Notch Min

Ni-HARD MARTENSITIC CAST IRON

SABS 1338-1991 NiHARD1 NiHARD2 NiHARD4 Grade 2B Grade 2A Grade 2E ASTM 532 Class 1 Type A Class 1 Type B Class 1 Type D BS 4844-1986 2B 2A 2E 3,203,80 2,803,40 2,803,60 0,200,70 0,300,70 0,400,60 0,80 max 0,80 max 1,502,00 0,10 max 0,10 max 0,10 max 0,30 max 0,30 max 0,30 max 1,502,50 1,504,00 7,509,00 %Ni 2,004,00 2,00 4,00 4,50 6,00 550 min 500 min 600 min

Castings will be supplied in the heat treated condition. Hardness values after heat treatment.

STELOY CODE

RELATED INTERNATIONAL CODES

S.A. U.S.A. BRITISH GERMAN %C %Mn

CHEMICAL COMPOSITION (% BY WEIGHT)

%Si %P %S %Cr %Mo %Cu Others

MECHANICAL PROPERTIES
Yield Point Tensile Elongation Hardness MPa Min Strength %Min Brinell 0,2%Proof MPa Min Charpy V-Notch Min

CARBON & CARBON MANGANESE STEELS

SABS 1465-1988 00PDSA1 00PDSA2 00PDSA3 00PDSA4 00PDSA5 C2 C3 C4 C5 C6 ASTM A216-03 WCA WCB WCC BS 3100-1991 A1 A2 A3 A4 A5 DIN 1621 GS-45 1,0446 GS-52 1,0552 GS-60 1,0558 DIN17205 GS-30Mn5 1,1165 DIN17205 GS-30Mn5 1,1165 0,25 max 0,35 max 0,45 max 0,180,25 0,250,33 0,250,33 0,400,50 0,500,60 0,90 max 1,00 max 1,00 max 1,201,60 1,201,60 1,201,60 1,00 max 1,00 max 0,60 max 0,60 max 0,60 max 0,60 max 0,60 max 0,60 max 0,60 max 0,60 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,05 max 0,30 max 0,15 max 0,30 max %Ni 0,40 max 230 260 295 320 430 490 540 540690 620770 690850 620 690 22 18 14 16 130163 140179 170192 152207 179229 201255 27J at 20C 20J at 20C 18J at 20C 30J at 20C 25J at 20C 25J at 20C

370

13

00PDSA6

C7

A6

0,30 max 0,30 max

0,15 max 0,15 max

0,30 max 0,30 max

0,40 max 0,40 max

495 325 370

13 12 8

00PAW2 00PAW3

AW2 AW3

Castings will be supplied in either the normalized, normalized and tempered, oil quench and tempered or water quenched and tempered condition. To obtain required mechanical properties unless otherwise specified by purchaser. Mechanical tests as per specification.

15

I R O N B A S E A L L O Y S Carbon & carbon manganese steels

16

I R O N B A S E A L L O Y S Low alloy steels

STELOY CODE
LOW ALLOY STEELS

RELATED INTERNATIONAL CODES

S.A. U.S.A. BRITISH GERMAN %C %Mn

CHEMICAL COMPOSITION (% BY WEIGHT)

%Si %P %S %Cr %Mo %Cu Others

MECHANICAL PROPERTIES
Yield Point Tensile Elongation Hardness Brinell MPa Min Strength %Min 0,2%Proof MPa Min Charpy V-Notch Min

SABS 1465-1988 00000B1 00000B2 00000B3 00000B4 00000B5 0000BT1 0000BT2 0000BT3 E1 E2

ASTM A217-03 WC1 WC6 WC9 C5

BS 3100-1991 B1 B2 B3 B4 B5 BT1 BT2 BT3

DIN 17245 GS-22Mo5 1,5419 GS-17CrMo55 1,7357 GS-12CrMo9-10 1,7380 GS-12CrMo19-5 1,7353 0,20 max 0,20 max 0,18 max 0,25 max 0,20 max 0,230,28 0,230,28 0,270,32 0,401,00 0,500,80 0,400,70 0,300,70 0,400,70 0,701,00 0,701,00 0,701,00 0,200,60 0,60 max 0,60 max 0,75 max 0,75 max 0,300,60 0,600,60 0,300,60 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,03 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,04 max 0,03 max 0,30 max 1,001,50 2,002,75 2,503,50 4,006,00 0,600,80 0,600,80 0,650,85 0,450,65 0,450,65 0,901,20 0,350,60 0,450,65 0,350,55 0,350,55 0,350,55 0,30 max 0,30 max 0,30 max 0,30 max 0,30 max

%Ni 0,40 max 0,40 max 0,40 max 0,40 max 0,40 max 0,801,20 0,901,30 1,501,80 260 280 325 370 420 495 585 695 460 480 540 620 620 690 850 1000 18 17 17 13 13 11 8 6 130192 140212 156235 179255 179255 201279 248327 293362 20J at 20C 30J at 20C 25J at 20C 25J at 20C 25J at 20C 35J at 20C 25J at 20C 20J at 20C

Castings will be supplied in either the normalized and tempered, air hardened and tempered, oil quenched and tempered or water quenched and tempered condition. To obtain required mechanical properties unless otherwise specified by the purchaser. Mechanical tests as per specification.

CASTINGS FOR THE PETROCHEMICAL INDUSTRY

Introduction Castings for the petrochemical industry usually require corrosion resistance as well as heat and creep resistance. Corrosion resistant alloys are covered under Austenitic Cast Alloys: Corrosion Resistant on page 4. Heat and creep resistant alloys are produced for both the heat treatment and petrochemical industries. Due to the more expansive application of these alloys in the petrochemical industry this will be discussed in more detail. Castings are classified as heat resistant if they are capable of sustained operation while exposed (intermittently or continuously) to temperatures that will result in metal temperatures of 650C and higher. Of paramount importance are: Corrosion and scaling resistance at high temperatures Dimensional stability, i.e. resistance to warping, cracking and thermal fatigue Resistance to plastic flow, i.e. creep strength. Properties Chromium is primarily responsible for resistance to oxidisation (scaling) and to uniform corrosion.

17

C A S T I N G S F O R T H E P E T R O C H E M I C A L I N D U S T RY

18

C A S T I N G S F O R T H E P E T R O C H E M I C A L I N D U S T RY (continued)

Nickel promotes an austenitic microstructure, thereby promoting thermal shock resistance and the prevention of sigma phase formation. Nickel also promotes resistance to excessive carburisation and nitriding. Creep strength is obtained through micro-alloying with elements like Nb, Ti and Zr, which strengthen the material through secondary carbide precipitation. The significance of secondary carbides lies in the fact that they actually precipitate during operation at high temperatures. Precipitation takes place at operating temperature within the austenite grains, contributing to strength and creep resistance. Further elements recently used internationally for micro-alloying are Mo, Si, W and R.E.

Steloy Castings produces the whole range of heat resistant castings as indicated in ASTM A297. This specification is, however, only intended for general applications. Further development and modifications have taken place, using selected ASTM A297 alloys as a basis, in order to meet the stringent conditions of the petrochemical industry: ASTM A447 the standard specification for Steel Castings, Chromium-Nickel-Iron-Alloy (25-12 Class) for High Temperature Service is an example where the industry, producers and designers have realised the limitations of the standard ASTM A297 Gr HH specification. This specification is intended for (amongst others) petroleum still tube supports and similar applications up to 1095C. It further contains a number of mandatory and supplementary requirements aimed at ensuring sufficient casting integrity and material properties.

 Two other industry driven modifications of the original ASTM A297 specification are HK40 (i.e. HK with limitation on %C range) and HP45 (i.e. HP with limitation on %C range). Supports, bends and tube sheets are produced for the petrochemical industry in both these materials. The alloy HP45 is of further importance since it can be regarded as the basis of most of the recent material developments for applications in the petrochemical industry. In order to improve the creep resistance of this SCHEMATIC REPRESENTATION OF APPLICATION material, the concept of micro-alloying and subsequent DRIVEN ALLOY DEVELOPMENT secondary carbide precipitation has been applied extensively. One of the alloys produced by Steloy Castings (1.4852mod) is an example of a modified/developed Grade HP45. This alloy contains the standard (HP45) 25Cr35Ni0.45C with micro quantities of Nb and Ti. Components manufactured in this alloy include tube sheets, supports, hangers and similar products for high temperature applications.
25Cr-20Ni ASTM A297 HK 25Cr-12Ni ASTM A297 HH 25Cr-35Ni ASTM A297 HP

25Cr-20Ni-0,4C ASTM A351 - HK 40 25Cr-12Ni-N ASTM A447 25Cr-35Ni-0,45C HP 45 25Cr-35Ni-Nb-Ti Steloy 1,4852 mod

N QA
C

Steloy HH mod

19

C A S T I N G S F O R T H E P E T R O C H E M I C A L I N D U S T RY (continued)

TYPICAL CREEP LIMITING STRENGTH (Rp1/10 000 in N/mm2)

MAXIMUM TEMPERATURE OF OXIDISATION RESISTANCE IN AIR C 450 450 620 850 900 1000 1100 1050 1100 1150 950 1150 1130 26 83 74 98 95 15 65 58 82 80 49 44 50 71 62 69 85 70 60 78 36 33 36 53 45 53 68 54 45 64 25 23 26 40 33 40 51 38 35 48 17 15 18 28 23 30 39 27 20 35 10 12 20 16 20 28 17 15 25 9 13 10 14 19 11 8 17 6 8 6 9 13 6,5 5 11,3 4 5 3,1 6 8 3,4 2 6,5 2,2 2,8 5 3 LIMITING STRESS (in MPa) FOR 1% CREEP IN 10 000HRS AT TEMPERATURE INDICATED IN C

STELOY ALLOY

RELATED SPECIFICATION

600

650

700

750

800

850

900

950

1000

1050

1100

Steloy WCB Steloy WC9 Steloy C5 Steloy CF8C Steloy HF Steloy HH mod Steloy HK40 Steloy 1,4859 Steloy HP45 Steloy W Steloy IN657 Steloy S333 Steloy 1,4852 mod

ASTM A216gr WCB ASTM A217gr WC9 ASTM A217gr C5 ASTM A743 CF8C ASTM A297gr HF ASTM A447 ASTM A351gr HK40 ASTM A351gr CT15C ASTM A297 HP mod 2,4879 ASTM A560 2,4608 ASTM A297HP mod

21

C A S T I N G S F O R T H E P E T R O C H E M I C A L I N D U S T RY (continued)

20

C A S T I N G S F O R T H E P E T R O C H E M I C A L I N D U S T RY (continued)

TYPICAL CREEP RUPTURE STRENGTH (Rm 100 000 in N/mm2)

STELOY ALLOY RELATED SPECIFICATION TYPICAL MECHANICAL PROPERTIES AT ROOM TEMP. UTS Steloy WCB Steloy WC9 Steloy C5 Steloy CF8C Steloy HF Steloy HH mod Steloy HK40 Steloy 1,4859 Steloy HP45 Steloy W Steloy IN657 Steloy S333 Steloy 1,4852 mod ASTM A216gr WCB ASTM A217gr WC9 ASTM A217gr C5 ASTM A743 CF8C ASTM A297gr HF ASTM A447 ASTM A351gr HK40 ASTM A351gr CT15C ASTM A297 HP mod 2,4879 ASTM A560 2,4608 ASTM A297 HP mod 500 550 650 485 485 550 425 435 430 440 550 550 450 YS 250 275 415 205 240 240 170 235 240 345 240 250 Elong. % 22 20 18 30 25 4 10 20 4,5 4 5 30 6 15 75 65 92 120 4 60 50 75 75 45 35 35 57 60 60 70 62 60 68 30 25 25 44 45 44 55 45 38 55 20 18 19 30 32 33 42 30 30 42 13 12 13 21 22 23 31 20 17 32 7,5 8 15 15 16 22 13 9 23 5 10 9 11 15,5 7,5 6 16 3 6 5 6 10 3,5 3,5 10 1,2 3 2 3,5 6,4 1,5 5,5 1,4 1,5 3,4 2,5 600 650 STRESS TO RUPTURE (in MPa) IN 100 000 HOURS AT TEMPERATURE INDICATED IN C 700 750 800 850 900 950 1000 1050 1100

22

THE CASTING PROCESS

1. Introduction

The design and manufacture of cast components is a complex process requiring a close partnership between designer, customer and foundry to achieve the desired result. The end product has to be clearly defined from the outset in terms of material standards, integrity levels, quantities and delivery sequence. Benefits of choosing the casting process include the following: Greater versatility than other metal-forming processes. Design flexibility, which allows castings to be produced in complex and concave shapes, to various sectional thicknesses and with hollow cavities. It may offer the shortest route to the end product. Most metals can be cast. It is the most economical process. 2. Design and specifications

A wide range of international specifications is available to assist and simplify design. With clearly defined casting parameters, any design can be optimised to the best advantage of the customer. Care should be taken to avoid over designing or over specifying, which can be costly. Reverse engineering and stress analysis can also be done at this stage. 3. Determination of casting technique

The selected process, design and specification need to marry and complement each other. Aids such as modern simulation programmes, solidification time calculations and trial castings are used in order to determine the correct casting technique. It is important that this is done before any pattern is made. Quality levels are pre-set, as quality cannot be inspected into a casting at a later stage.

4.

Moulding material preparation

Sand of varying grades is used to complement the various processes. The control, preparation, handling and mixing of sand is done to the latest international standards and modern, statistically controlled binder systems are used. Mould feeding aids are used to optimise yields and costs. 5. Pattern making

Patterns should be friendly to the foundry process and extremely accurate and stable to ensure dimensional stability. Patterns can be manufactured by hand or by using threedimensional machines. It can be made to all sizes, shapes and degrees of complexity, for long or short runs. Materials include metal for shell moulding, soft wood for short-run jobbing moulding and fibre for long runs. The 6. pattern maker should: Use the least number of cores (make self-coring). Give all cores proper supporting prints. Place cores in the bottom of the mould if possible. Ensure that cores are not misplaced or inverted. Use slip core-boxes where possible. Mount all patterns on boards. Moulding and core-making

A well-defined production control system will direct moulds and cores to the melting process in the shortest time, shortening production cycles by batching for melting and heat treatment. Sand is mixed to stringent, statistically controlled specifications and vibrated and compacted to produce moulds and cores to the highest international standards. To assist with temperature control, closing and casting take place close to the melting facility. Shell moulding and core-making together with cold-box moulding and core-making complement selfset moulding and core-making. Any combination of these processes can be used to adhere to customer requirements.

23

THE CASTING PROCESS

24
7.

THE CASTING PROCESS

Furnace charge and preparation

This involves furnace selection and size, maintenance and operation, scrap selection and handling together with alloy control and melting practices. Well formalised and documented, the charging and preparation of the furnace is scheduled and executed with precision. Stringent spectrographic control forms the basis for incoming scrap selection, and cleanliness and sizing are of paramount importance. 8. Metal melting

Melting takes place in high frequency induction furnaces to international standards. Melting has been standardised into works instructions that are controlled by spectrographic analysis. Refining and deoxidation is done to works instructions to optimise mechanical properties. Successful melting requires clean steel with the correct chemical composition, deoxidised at the required temperature into the mould. The chemical composition is certified for each casting. 9. Casting

Molten metal is poured into and solidified in a mould with cores to produce the required casting. Casting dimensions depend on mould dimensions as generated by the pattern, material chemistry depends on the melt, and mechanicals depend on the melt and subsequent heat treatment. Casting integrity depends on the mould, metal, ingate and feeding system. 10. Fettling

Fettling gives the casting its final, finished appearance. If too rough, it looks unfinished, if over fettled, it will look fabricated. 11. Heat treatment

Heat treatment is conducted to promote homogeneity and enhance mechanical properties. The number of heat treatment cycles, heat treatment temperature and the cooling rate after soaking will be determined by the alloy composition and the required final properties. Cooling rates can vary from a very slow furnace cool to a very rapid water quench but is also subject to casting geometry.

12.

Finishing

This can be done in three stages if required: Shot blasting to clean the casting of any oxides that may have formed during heat treatment and to ensure an even surface finish. Pickling (for stainless steel only) Machining according to a wide spectrum of specifications. Dimensions can be certified at this stage. 13. Inspection and testing

All castings are inspected and tested to ensure adherence to prescribed standards. Methods include: X-ray examination Magnetic particle inspection Dye penetrate testing Pressure testing All requirements can be certified. 14. Black casting

Black castings should be properly identified with heat numbers, serial numbers and order numbers. Certification must be available for traceability.

25

THE CASTING PROCESS