M AT E R I A L

Catalogue

JUNE 2006
 Steloy Castings (Pty) Ltd
4 Cobalt Street Ekandustria Bronkhorstspruit 1020
PO Box 1591 Bronkhorstspruit 1020 South Africa
Tel +27 (0)13 933-3331 Fax +27 (0)13 933-3653
E-mail info@steloy.com Website www.steloy.com
A INTRODUCTION 2
B CORROSION AND HEAT RESISTANT
STAINLESS STEELS AND LOW ALLOY
STEELS
Cobalt Street Plant 3
Chamdor Plant 4
General information on stainless 5
steels and low alloy steels
Austenitic cast alloys 6
Martensitic & ferritic cast alloys 10
Duplex cast alloys 11
Steel & low alloy steels, special cast 12
alloys
C CENTRIFUGALLY CAST ALLOYS & 13
PRODUCTS
D IRON BASE ALLOYS
Tungsten Street Plant 17
General information on iron 18
base alloys
Flake graphite irons 19
Spheroidal graphite irons 20
Austenitic & ni-hard martensitic cast 21
irons
Carbon & carbon manganese steels 22
Low alloy steels 23
E CASTINGS FOR THE 24
PETROCHEMICAL INDUSTRY

INDEX
Typical creep rupture strength table 29
Typical creep limiting strength table 31

1
F THE CASTING PROCESS 33
2 INTRODUCTION

Founded in 1984, Steloy Castings today ranks as the most advanced specialist foundry group in South Africa – a
position achieved through a dedication to quality, customer service and delivery.

The Steloy Castings headquarters and two of the company’s operational divisions are located in Ekandustria,
Bronkhorstspruit, 100km northeast of Johannesburg, with a third satellite division in Chamdor, Krugersdorp,
30km west of Johannesburg. From its three foundry complexes, Steloy supplies a full range of stainless steel,
super alloyed and carbon steel components to markets as diverse as pump and valve manufacturers and the
petrochemical, heat treatment, cement, chemical, glass, paper, steel, ferro-alloy, aluminium, rolling stock and
power generation industries. Spun tube is produced at South Africa’s only stainless steel centrifugal casting
plant, which forms part of the Chamdor plant.

The acquisition of this third foundry has enabled the group to expand its services to the petrochemical sector from
static castings such as tube sheets, brackets and fittings (supplied for many years) to the supply of fully fabricated
coils assembled from static castings and spun cast tubes for reformer, ethylene cracking and direct reduction furnaces.

Steloy Castings operates in accordance with well-established quality assurance systems. Both the Cobalt and Tungsten
Street plants are SABS ISO 9001:2000 listed, underwritten by SANAS and RvA, while the Chamdor plant has TÜV (Rheinland)
ISO 9001:2000 certification.
 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 cold box machines 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 9001:2000.

3 C O B A LT S T R E E T P L A N T
4 CHAMDOR PLANT

Steloy Castings’ Chamdor facility produces high integrity, high performance stainless steel and
alloy castings – both static and centrifugally cast.

Equipment enables the production of static castings ranging from 1kg to 3200kg. Moulding for
static castings is carried out on cold box machines for castings up to 30kg fettled mass, or by means
of the no-bake process for castings up to 3200kg fettled mass. A shell moulding facility is used to produce
castings to high tolerances.

Current ranges of the centrifugally cast products are up to 830mm in diameter and up to 5000mm long. The smaller
diameter tubes can be the longer, i.e. 5000mm long with an outer diameter (OD) ranging from 80mm to 200mm and
an inner diameter (ID) as small as 32mm. Centrifugally cast tubes can be supplied in as-cast, partially machined and
fully machined conditions. Machining on ODs involve turning while IDs are pull bored (1.6-3.2µm) finish.

Two Shimadzu optical emission spectrometers are utilised to ensure compliance to specified compositions.

A fully automatic LP gas fired heat treatment furnace – in conjunction with a

water quench facility – enables the heat treatment of all grades in-house. In
addition, a fully equipped pattern shop ensures independence from outside
services.

The Chamdor Plant has TÜV (Rheinland) ISO 9001:2000 certification.

 MATERIAL GROUP
AUSTENITIC CAST ALLOYS
MARTENSITIC & FERRITIC CAST ALLOYS
DUPLEX CAST ALLOYS
STEEL & LOW ALLOY STEELS
SPECIAL CAST ALLOYS
5 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
METALLOGRAPHIC STRUCTURE TYPICAL APPLICATIONS
Corrosion Austenitic Impellers, pumps, casings
resistant valve bodies
Heat resistant Austenitic Furnace components, hangers,
brackets, tube sheets, tube bends
Martensitic and/or Ferritic Impellers, valve bodies, casings
Austenitic/Ferritic Impellers, pumps, casings
Ferritic/Pearlitic/Martensitic Pumps, valves, structural
components, pressure
containing parts
Austenitic/Ferritic/Martensitic Special requirements for
strength, corrosion, wear and heat
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
 6 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) MECHANICAL PROPERTIES

Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others
BRITISH GERMAN Yield Tensile Elongation
CODE USA ASTM
STANDARDS Max Max Max Max Max Point Strength %
STANDARDS
BS 3100 STD No DIN MPa Min MPa Min Min

AUSTENITIC CAST ALLOYS: CORROSION RESISTANT

Steloy - CF 8 ASTM A743 CF-8 304C 15 1.4308 G-X6CrNi18 9 0,08 1,50 2,00 0,04 0,04 18,0-21,0 8,0-11,0 – 205 485 35

Steloy - CF-8M ASTM A743 CF-8M 316C 16 1.4408 G-X6CrNiMo18 10 0,08 1,50 2,00 0,04 0,04 18,0-21,0 9,0-12,0 2,0-3,0 205 485 30

Steloy - CF-3 ASTM A743 CF-3 304C 12 1.4306 G-X2CrNi18 9 0,03 1,50 2,00 0,04 0,04 17,0-21,0 8,0-12,0 – 205 485 35

Steloy - CF-3M ASTM A743 CF-3M 316C 12 1.4404 G-X2CrNiMo18 10 0,03 1,50 1,50 0,04 0,04 17,0-21,0 9,0-13,00 2,0-3,0 205 485 30

Steloy - CG-8M ASTM A743 CG-8M 317C 16 1.4448 G-X6CrNiMo17-13 0,08 1,50 1,50 0,04 0,04 18,0-21,0 9,0-13,0 3,0-4,0 240 520 25

Steloy - CH20 ASTM A743 CH20 – – – 0,20 1,50 2,00 0,04 0,04 22,0-26,0 12,0-15,0 – 205 485 30

Steloy - CF-8C ASTM A351 CF8C 1.4552 G-X5CrNiNb19-11 0,08 1,50 2,00 0,04 0,04 18,0-21,0 9,0-12,0 0,50 Nb 1,00 max, 8x%C 205 485 30

Steloy - CN-7M* ASTM A743 CN-7M – 1.4500 G-X7NiCrMoCuNb25-20 0,07 1,50 1,50 0,04 0,04 19,0-22,0 27,5-30,5 2,0-3,0 3,0-4,0Cu 170 425 35

Steloy - 90* – – – – 0,07 1,00-1,25 0,7-1,0 0,04 0,04 20,25-23,0 27,7-29,0 4,25-5,0 Cu2,75-3,25Nb0,5 200 450 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.
Alloys marked * are regarded as Super Austenitic Stainless Steels – developed for superior resistance in severe corrosion environments.
 CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES
Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others
BRITISH GERMAN Yield Tensile Elongation
CODE USA ASTM
STANDARDS Max Max Max Max Max Point Strength %
STANDARDS
BS 3100 STD No DIN MPa Min MPa Min Min

AUSTENITIC CAST ALLOYS: CORROSION RESISTANT (continued)

Steloy - 28/31* – – 1.4563 XlNiCrMoCu31-27-4 0,03 2,00 1,50 0,02 0,015 27,0 31,0 3,5 Cu1,0 215 450 30

Steloy 1.4547* ASTM A351 CK3MCuN – 1.4547 – 0,025 1,20 1,00 0,045 0,01 19,5-20,5 17,5-19,5 6-7 N 0,18-0,24
260 550 35
Cu 0,5-1,0

Steloy 1.4652* – – 1.4652 – 0,020 2-4 0,50 0,030 0,005 24-25 21-23 7-8 N 0,45-0,55
Cu 0,30-0,60 – – –

AUSTENITIC CAST ALLOYS: HEAT RESISTANT

Steloy - HT ASTM A297 HT 330C 12 – 0,35-0,75 2,00 2,50 0,04 0,04 15,0-19,0 33,0-37,0 0,5 max – – 450 4

Steloy - HU ASTM A297 HU 331C 40 1.4865 G-X40NiCrSi38-18 0,35-0,75 2,00 2,50 0,04 0,04 17,0-21,0 37,0-41,0 0,5 max – – 450 4

Steloy - HX ASTM A297 HX 334C 11 – – 0,35-0,75 2,00 2,50 0,04 0,04 15,0-19,0 64,0-68,0 0,5 max – – 415 –

Steloy - HC ASTM A297 HC 452C 11 – 0,5 1,00 2,00 0,04 0,04 26,0-30,0 4,0 max 0,5 max – – 380 –

NOTE: Alloys marked * are regarded as Super Austenitic Stainless Steels – developed for superior resistance in severe corrosion environments.

7 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)

 8 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) MECHANICAL PROPERTIES

Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others Yield Tensile Elongation
BRITISH GERMAN
CODE USA ASTM Max Max Max Max Max Point Strength %
STANDARDS
STANDARDS
BS 3100 STD No DIN MPa Min MPa Min Min

AUSTENITIC CAST ALLOYS: HEAT RESISTANT (continued)

Steloy - HF ASTM A297 HF 309C 30 1.4826 G-X40CrNiSi22-9 0,2-0,40 2,00 2,00 0,04 0,04 18,0-23,0 8,0-12,0 0,5 max – 240 485 25

Steloy - HD ASTM A297 HD – 1.4823 G-X40CrNiSi27-4 0,5 1,50 2,00 0,04 0,04 26,0-30,0 4,0-7,0 0,5 max – 240 515 8

Steloy - HE ASTM A297 HE 309C 40 – – 0,2-0,50 2,00 2,00 0,04 0,04 26,0-30,0 8,0-11,0 0,5 max – 275 585 9

Steloy 2.4879 – – 2.4879 G-NiCr28W 0,35-0,55 2,00 1,50 0,045 0,030 27,0-30,0 47,0-50,0 – W4,0-5,5 240 440 4

Steloy - HK40 ASTM A351 HK40 – 1.4848 G-X40CrNiSi25-20 0,35-0,45 1,50 1,75 0,04 0,04 23,0-27,0 19,0-22,0 0,5 max – 240 425 10

Steloy - HH ASTM A297 HH 309C 32 1.4837 G-X40CrNiSi25-12 0,2-0,5 2,00 2,00 0,04 0,04 24,0-28,0 11,0-14,0 0,5 max 240 515 10

Steloy - HK ASTM A297 HK 310C 40 1.4848 G-X40NiCrSi25-20 0,2-0,6 2,00 2,00 0,04 0,04 24,0-28,0 18,0-22,0 0,5 max 240 450 10

Steloy W 2,5-4,0
– 2.4608 NiCr26MoW 0,10 2,00 1,50 0,03 0,03 24,0-27,0 44,0-48,0 2,5-4,0 240 550 30
2.4608 Co 2,5-4,0

Steloy HH mod ASTM A447 – – – 0,20-0,45 2,50 1,75 0,05 0,05 23,0-28,0 10,0-14,0 – N 0,2 max – 550 4

Steloy 1.4849 – – 1.4849 G-X40NiCrSiNb38-18 0,30-0,50 1,5 1,0-2,5 0,035 0,030 17,0-19,0 36,0-39,0 – Nb 1,20-1,80 220 400 5
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) MECHANICAL PROPERTIES
Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others Yield Tensile Elongation
BRITISH GERMAN
CODE USA ASTM Max Max Max Max Max Point Strength %
STANDARDS
STANDARDS
BS 3100 STD No DIN MPa
Mpa Min MPa
Mpa Min Min

AUSTENITIC CAST ALLOYS: HEAT RESISTANT (continued)

Nb 1,4-1,7
Steloy 2.4680 ASTM A560 – 2.4680 G-NiCr50Nb 0,10 0,30 0,50 0,02 0,02 47,0-52,0 BAL – Fe 1,0 max 345 550 5
N 0,16 max
Steloy 1.4859 ASTM A351 CT15C – 1.4859 G-X10NiCrNb32-20 0,05-0,15 0,15-1,50 0,50-1,50 0,03 0,03 19,0-21,0 31,0-34,0 – Nb 0,50-1,50 170 435 20
Steloy HP45 ~ASTM A297 HP mod – 1.4857 G-X40NiCrSi35 25 0,44-0,49 0,5-1,50 1,0-2,50 0,045 0,030 24,0-28,0 33,0-37,0 0,5 max 235 430 4,5
Steloy 1.4852 ~ASTM A297 HP45Nb – 1.4852 G-X40NiCrSiNb35-25 0,4-0,5 1,50 1,2-1,8 0,025 0,015 23-27 32-36 0,5 Nb 0,8-1,2 250 450 6
Nb 0,8-1,2
1.4852 G-X40NiCrSiNb35-25
Steloy 1.4852MA HP45Nb micro – 0,4-0,5 1,50 1,2-1,8 0,025 0,015 23-27 32-36 0,5 Ti 0,1-0,3 250 450 6
micro micro Zr 0,1-0,3
Nb 1,5-2,0
1.4889 G-X40NiCrNb45-35
Steloy 1.4889MA 35Cr45NiNb – 0,35-0,45 1,0-1,5 1,50-2,00 0,04 0,03 32,5-37,5 42-46 – Ti 0,1-0,3 240 440 3
micro micro Zr 0,1-0,3
2.4879 Co 2,60-3,40
Steloy 2.4879 mod – – 3Co G-NiCr28W mod 0,35-0,45 0,50-2,00 0,50-1,50 0,04 0,03 27-30 47-50 – W 4,0-5,5 240 440 3
GX50NiCrCoW Co 14-16
Steloy 1.4869 – – 1.4869 0,45-0,55 1,00 1,00-2,00 0,04 0,03 24-26 33-37 – 270 480 5
35-25-15-5 W 4-6

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.

9 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)

 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 Martensitic and Ferritic Cast Alloys

CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES

Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others
BRITISH GERMAN Yield Tensile Elongation
CODE USA ASTM
STANDARDS Max Max Max Max Ma Point Strength %
STANDARDS
BS 3100 STD No DIN MPa Min MPa Min Min

MARTENSITIC AND FERRITIC CAST ALLOYS

Steloy - CA-15 ASTM A743 CA-15 410C 21 1.4006 G-X12Cr13 0,15 1,00 1,50 0,04 0,04 11,5-14,0 1,0 max 0,5 max 450 620 18

Steloy - 13 – 420C24/C29 1.4027 G-X20Cr14 0,16-0,23 1,00 1,00 0,045 0,030 12,5-14,5 1,0 max – 465 690 11

Steloy - CA-40 ASTM A743 CA-40 – 1.4028 G-X30Cr13 0,2-0,4 1,00 1,50 0,04 0,04 11,5-14,0 1,0 max 0,5 max 485 690 15

Steloy - CB-30 ASTM A743 CB-30 – 1.4059 G-X22CrNi17 0,30 1,00 1,50 0,04 0,04 18,0-21,0 2,0 max – 205 450 –

Steloy - CB-7Cu ASTM A747 CB-7Cu1 – 1.4542 X5CrNiCuNb17-4 0,07 0,70 0,5-1,0 0,035 0,030 15,5-17,7 3,6-4,6 – Cu2,5-3,2Nb0,15-0,35 1000 1170 5

Steloy - CA-6NM ASTM A743 CA-6NM 425C 11 1.4313 G-X5CrNi13-4 0,06 1,00 1,00 0,04 0,03 11,5-14,0 3,5-4,5 0,4-1,0 550 755 15

Steloy - CC-50 ASTM A743 CC-50 – 1.4340 G-X40CrNi27-4 0,50 1,00 1,50 0,04 0,04 26,0-30,0 4,00 – – 380 –

Steloy - 2802 – – 1.4138 G-X120CrMo29-2 0,9-1,30 1,00 2,00 0,045 0,030 27,0-29,0 – 2,00-2,50 880-1080 – –

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.
 CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES
Related International Codes AT ROOM TEMPERATURES
STELOY C Mn Si P S Cr Ni Mo Others
BRITISH GERMAN Yield Tensile Elongation
CODE USA ASTM
STANDARDS Max Max Max Max Max Point Strength %
STANDARDS
BS 3100 STD No DIN MPa Min MPa Min Min

DUPLEX CAST ALLOYS

Steloy CD-4MCu ASTM A890gr 1A 322C 13 0,040 1,00 1,00 0,040 0,040 24,5-26,5 4,75-6,00 1,75-2,25 Cu2,75-3,25 485 690 16

Steloy - 225 ASTM A890gr 4A 1.4462 0,030 1,50 1,00 0,040 0,020 21,0-23,5 4,50-6,50 2,50-3,50 Cu1,00 max N0,10-0,30 415 620 25
Cu0,5-1,0 W0,5-1,0
Steloy - 2507 ASTM A890gr 6A 0,030 1,00 1,00 0,030 0,025 24,0-26,0 6,5-8,5 3,0-4,0 N0,20-0,30 450 690 25

Steloy - CD-3MCuN ASTM A890gr 1C 0,030 1,20 1,10 0,030 0,030 24,0-26,7 5,60-6,70 2,90-3,80 Cu1,40-1,90 N0,22-0,33 450 690 25

Steloy - CD-4MCuN ASTM A890gr 1B 0,040 1,00 1,00 0,040 0,040 24,5-26,5 4,7-6,0 1,7-2,3 Cu2,7-3,3 N0,10-0,25 485 690 16

Steloy - CD-6MN ASTM A890gr 3A 0,060 1,00 1,00 0,040 0,040 24,0-27,0 4,0-6,0 1,75-2,50 N0,15-0,25 450 655 25

Steloy - CE-8MN ASTM A890gr 2A 0,080 1,00 1,50 0,040 0,040 22,5-25,5 8,0-11,0 3,0-4,5 N0,10-0,30 450 655 25

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.

11 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

 12 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

CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES

Related International Codes AT ROOM TEMPERATURES
STELOY Yield Tensile Elongation
BRITISH GERMAN
CODE USA ASTM C Mn Si P S Cr Ni Mo Others Point Strength %
STANDARDS
STANDARDS Max Max Max Max Max
BS 3100 STD No DIN MPa Min MPa Min Min
STEEL AND LOW ALLOY STEELS
Steloy - WCB ASTM A216 WCB A1 1.0619 GS-C25 0,30 1,00 0,60 0,040 0,045 0,50 0,50 0,20 Cu 0,30 max V0,03 max 250 485-655 22

Steloy - LCC ASTM A352 LCC – – – 0,25 1,20 0,60 0,040 0,045 0,50 0,50 0,20 Cu 0,30 max 275 485-655 22
20J AT - 46˚C Impact
Steloy - LC2 ASTM A352 LC2 – – – 0,25 0,50-0,80 0,60 0,040 0,045 – 2,0-3,0 – – 275 485-655 24
20J AT - 73˚C Impact
Steloy - LCB ASTM A352 LCB – 1.1156 GS-Ck24 0,30 1,00 0,60 0,040 0,045 0,50 0,50 0,20 240
Cu 0,30 max V0,03 max 18J AT 450-620 24
- 46˚C Impact
Steloy - LCA ASTM A352 LCA – – – 0,25 0,70 0,60 0,040 0,045 0,50 0,50 0,20 205
Cu 0,30 max V0,03 max 18J AT 415-485 24
- 32˚C Impact
Steloy - C5 ASTM A217 C5 B5 1.7363 G-X12CrMo5 0,20 0,40-0,70 0,75 0,040 0,045 4,0-6,5 0,50 0,45-0,65 Cu 0,50 max W0,10 max 415 620-795 18

SPECIAL CAST ALLOYS

Steloy - N-12MV ASTM A494 N-12MV 64%Ni, 29%Mo Steloy - CW-12MW ASTM A494 CW-12MW 17,5%Cr, 54%Ni, 17%Mo Steloy - CZ-100 ASTM A494 CZ100 95%Ni min

Steloy - M-35-1 ASTM A494 M-35-1 66%Ni, 30%Cu Steloy - IN657 2,4680 50%Cr, 48%Ni, 1%Nb Steloy - 600 2,4816 15%Cr, 76%Ni, 8%Fe

Steloy - 825 2.4858 21%Cr, 42%Ni Steloy - CrCo40 40Co, 30Cr, 20Ni, 1,5Mo
3%Mo, 2%Cu, 1%Ti
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.
 This method of tube manufacturing has a distinct advantage over static casting due to the extreme gravitational forces present
during solidification in conjunction with relatively fast solidification rates. These produce an extraordinary level of metal
soundness and minimised segregation, both major contributing factors in achieving exceptional metallurgical integrity.

Some discarded (lower density) material can be contained in a thin layer on the inner bore surface of the tube, but is easily
removed via machining, pull boring in particular.

Steloy Castings’ (horizontal) centrifugally cast range consists of the following:

1. Tubes for high temperature and high pressure applications (typically those found in the petrochemical industry)
2. Pipes for high-temperature and high-pressure applications
3. Pipes for corrosion resistant applications
4. Hollow bar and tube for general engineering applications.

1. TUBES FOR HIGH TEMPERATURE AND HIGH PRESSURE APPLICATIONS (REFORMING & CRACKING)
These tubes – particularly reformer, cracking and catalyst tubes – are primarily produced for the petrochemical
industry and manufactured in accordance with the general requirements of ASTM A608. Three major properties
required are creep, scaling and corrosion resistance.

This range is discussed in more detail in the section referring to the petrochemical industry.

13 C E N T R I F U G A L LY C A S T A L L O Y S & P R O D U C T S
 14 C E N T R I F U G A L LY C A S T A L L O Y S & P R O D U C T S (continued)

2. PIPES FOR HIGH TEMPERATURE AND HIGH PRESSURE APPLICATIONS

(NB. The “high temperatures” referred to here are far lower than those associated with applications requiring tubes
manufactured to A608.)

• ASTM A660 is the standard specification for centrifugally cast carbon steel pipe for high temperature service.
Steel pipe manufactured to A660 is suitable for fusion welding, bending and other forming operations. The
various chemistries of the grades listed are closely related to those of ASTM A216 materials used for
static castings.

• ASTM A426 is the standard specification for centrifugally cast ferritic alloy steel pipe for high
temperature service. This specification contains several grades of ferritic steel. The chemistries of the
grades listed in this specification are closely related to those of the ASTM A217 materials (static castings).

• ASTM A451 is the standard specification for centrifugally cast austenitic steel pipe for high temperature
service. This specification covers austenitic alloy steel pipe for use in high temperature, corrosive or nuclear
service and involves a number of austenitic steels. The chemistries of grades listed in this specification are closely
related to a number of those in ASTM A351 (static castings). Of specific importance is the fact that none of the alloys
listed in this specification has a carbon content in excess of 0.20%. The carbon content is thus much lower than that of the
grades listed in either ASTM A608 or A297.
 3. FERRITIC/AUSTENITIC STAINLESS STEEL PIPE FOR CORROSIVE ENVIRONMENTS
ASTM A872 is the standard specification for centrifugally cast ferritic/austenitic stainless steel pipe for corrosive
environments.

This specification covers a number of duplex stainless steels. It should be noted that the intended application is for
corrosive environments. Prolonged periods at elevated temperatures will lead to embrittlement.

The chemistries of the grades listed in the specification are closely related to a number of those in ASTM A890
(static castings).

4. ALTERNATIVE TO PRODUCTS USUALLY PRODUCED AS (WROUGHT) HOLLOW BAR

Economy of scale, standardised dimensions and material compositions and minimum order quantities are
often a cause for concern when hollow bar is considered in engineering applications.

Due to the exceptional metallurgical integrity and flexibility in terms of chemistry and dimensions that can
be achieved with spun casting as well as the fact that there are fewer limitations with regard to minimum
order quantities, there are few cases where spun cast tubes cannot be considered a suitable alternate to
hollow bar.

15 C E N T R I F U G A L LY C A S T A L L O Y S & P R O D U C T S (continued)
16 C E N T R I F U G A L LY C A S T A L L O Y S & P R O D U C T S (continued)

Steloy Castings produces a number of products for both direct use as thick-walled
tubes (hollow bar) and indirect use, where tube is cut into smaller sections for use
as cylinders or even rings and bushes.

Although it is a policy of Steloy Castings to produce only in accordance with acknowledged cast
specifications, special provision has been made to accommodate specific customer requirements.
This involves the following:

- The customer provides a mutually acceptable specification, including acceptance criteria.

- Spun tube is produced in accordance with the chemistry of other acknowledged cast specifications but
mechanical properties (implicitly excluded) are subject to mutual agreement. A typical example will be
ASTM A915. Specification ASTM A958, on the other hand, makes provision for tensile properties but
impact properties are excluded.

- Tubes can be supplied in as-cast condition, machined or cut and machined, and with or without heat
treatment.

- Machining can include pull boring of the inner diameter and turning of the outer diameter.
 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 cold box machines 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.

17 TUNGSTEN STREET PLANT

 18 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

MATERIAL GROUP METALLOGRAPHIC STRUCTURE TYPICAL APPLICATIONS ENVIRONMENT

FLAKE GRAPHITE IRONS Various size flake graphite in a mainly Pump casings, impellers, brackets, support General engineering
pearlitic structure bends, valve bodies, pulleys non-corrosive environment

SPHEROIDAL GRAPHITE IRONS Ferritic matrix for lower grade. Pump casings, impellers, brackets, supports, High strength casting
Ferritic/pearlitic matrixes for intermediate bends, valve bodies, shafts, gear pulleys, applications
grades. Pearlitic/tempered martensitic chains, sprockets
structure higher grades

AUSTENITIC CAST IRONS Flake graphite austenitic Pumps, valves, furnace, piston ring carriers Corrosion resistant to alkalis, diluted acids,
for light components, bushing, alloy metal sea water, salt solution
parts, non magnetized castings

Ni-HARD MARTENSITIC CAST IRON Martensitic Pumps, mill liners, slurry pumps, pipe bends Corrosion resistant to alkalis, diluted acids

CARBON AND CARBON Ferritic/Pearlitic Pumps, valves, impellers, pipe bends, Pressure containing parts, high strength
MANGANESE STEELS brackets, supports, flanges but ductile components

LOW ALLOY STEELS Pearlitic/Martensitic Valves, brackets, shafts, furnace components For use at elevated temperatures and
higher tensile strengths
 RELATED INTERNATIONAL CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES
STELOY Yield Point Tensile Elongation Hardness Charpy
CODE RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Mo %Cu Others MPa Min Strength %Min Brinell V-Notch
0,2%Proof MPa Min Min

FLAKE GRAPHITE IRONS

SABS 1034-1975 ASTM A48-03 BS 1452-1990 DIN 1691-1985
000PB10 Grade 150 Class 20 Grade 150 GG15 3,00- 0,30- 2,00- 0,25 0,12 – – – – – 150 – 150- –
0.6015 3,60 0,70 2,70 max max 190
000PB12 Grade 200 Class 25 Grade 180 GG20 3,10- 0,40- 2,00- 0,25 0,12 – – – – – 180 – 160- –
0.6020 3,60 0,75 2,50 max max 200
000PB14 Grade 200 Class 30 Grade 220 GG20 3,10- 0,40- 1,90- 0,25 0,12 – – – – – 220 – 170- –
0.6020 3,50 0,80 2,40 max max 210
000PB17 Grade 250 Class 35 Grade 250 GG25 2,90- 0,50- 1,80- 0,20 0,12 – – 0,30 – – 250 – 180- –
0.6025 3,40 0,90 2,30 max max max 220
000PB20 Grade 300 Class 45 Grade 300 GG30 2,80- 0,60- 1,60- 0,20 0,12 – – 0,30- – – 300 – 190- –
0.6030 3,30 1,00 2,00 max max 0,80 250
000PB23 Grade 350 Class 50 Grade 350 GG35 2,70- 0,70- 1,50,- 0,20 0,10 0,20 – 0,50- %Ni – 350 – 200- –
0.6035 3,20 1,10 1,90 max max max 1,00 0,50- 260
0,70

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 ø test bar. Tensile strength of cast on test bar will vary with casting section thickness. Hardness values will vary with casting section thickness.

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

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

RELATED INTERNATIONAL CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES

STELOY Yield Point Tensile Elongation Hardness Charpy
CODE RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Mo %Cu %Mg MPa Min Strength %Min Brinell V-Notch
0,2%Proof MPa Min Min

SPHEROIDAL GRAPHITE IRONS

SABS 936-1969 ASTM A536-03 BS 2789-1985 DIN 1693-1977
350/22
– 60-40-18 370/17 – 3,00- 0,10- 2,20- 0,04 0,02 – – – 0,02- 220 350 22 <160 17J
PNG2417 SNG 24/17 3,80 0,20 2,70 max max 0,05 at 20˚C
SG38 – GGG40.3 3,00- 0,10- 2,20- 0,04 0,02 – – – 0,02- 250 400 18 <179 14J
400/18 0.7043 3,80 0,20 2,70 max max 0,05 at 20˚C
SG42 65-45-12 420/12 GGG40 3,10- 0,15- 2,20- 0,04 0,02 – – – 0,02- 270 420 12 <212 –
PNG2712 SNG 27/12 0.7040 3,80 0,30 2,70 max max 0,05
– – 450/10 GGG50 3,10- 0,15- 2,20- 0,04 0,02 – – – 0,02- 320 450 10 160- –
0.7050 3,80 0,30 2,70 max max 0,05 221
PNG3207 SG50 80-55-06 500/7 GGG50 3,20- 0,20- 2,20- 0,04 0,02 – – 0,35- 0,02- 320 500 7 170- –
SNG 32/7 0.7050 3,80 0,50 2,80 max max 0,60 0,05 241
PNG3903 SG60 – 600/3 GGG60 3,20- 0,35- 2,30- 0,04 0,02 – – 0,70- 0,02- 370 600 3 192- –
SNG 37/2 0.7060 3,90 0,60 2,90 max max 0,95 0,05 269
700/2
PNG4502 SG70 100-70-03 SNG 42/2 GGG70 3,30- 0,50- 2,30- 0,04 0,02 – – 0,80- 0,02- 420 700 2 229- –
SNG 47/2 0.7070 3,90 0,90 2,90 max max 1,20 0,05 302
PNG5202 SG80 – 800/2 GGG80 3,40- 0,40- 4,00- 0,04 0,02 – – 0,90- 0,02- 480 800 2 248- –
4,00 0,70 5,00 max max 1,20 0,05 352
PNG5802 – 120-90-02 900/2 – 3,20- 0,40- 2,30- 0,04 0,02 – 0,30- 0,90- 0,02- 600 900 2 302- –
4,00 0,50 2,90 max max 0,50 1,20 0,05 359
ASTM A897-
PNG6807 – 90 A.D.I. – – 3,20- 0,40- 2,20- 0,04 0,02 – 0,30 0,70- 0,02- 700 1050 7 302- 80J
1050-700-7 3,80 0,70 2,70 max max max 1,20 0,05 363 at 22˚C
ASTM A897-
PNG7804 – 90 A.D.I. – – 3,20- 0,40- 2,20- 0,04 0,02 – 0,40 0,80- 0,02- 850 1200 4 341- 60J
1200-850-4 3,80 0,70 2,70 max max max 1,30 0,05 444 at 22˚C
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 ø test bar. Hardness values applicable to the end area of the parallel portion of a 14 mm ø test bar.
 RELATED INTERNATIONAL CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES
STELOY Yield Point Tensile Elongation Hardness Charpy
CODE RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Cu %Ni Others MPa Min Strength %Min Brinell V-Notch
0,2%Proof MPa Min Min

AUSTENITIC CAST IRONS

– ASTM A436-03 BS 3468-1974 DIN 1694-1981
OPL1562 – Type 1 LNiCuCr GGL.NiCuCr 3,00 0,50- 1,00- A.L.A.P. A.L.A.P. 1,00- 5,50- 13,50- – – 170 – 140- –
1562 1562 max 1,50 2,80 2,50 7,50 17,50 200
OPL1563 – Type 1B LNiCuCr GGL.NiCuCr 3,00 0,50- 1,00- A.L.A.P. A.L.A.P. 2,50- 5,50- 13,50- – – 190 – 150- –
1563 1563 max 1,50 2,80 3,50 7,50 17,50 250
Castings will be supplied in the as-cast condition. Tensile strength on 25 mm ø test bar.

STELOY Yield Point Tensile Elongation Hardness Charpy

RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Mo %Cu Others MPa Min Strength %Min Brinell V-Notch
CODE 0,2%Proof MPa Min Min

Ni-HARD MARTENSITIC CAST IRON

SABS 1338-1991 ASTM 532 BS 4844-1986 %Ni
NiHARD1 Grade 2B Class 1 2B – 3,20- 0,20- 0,80 0,10 0,30 1,50- – – 2,00- – – – 550 –
Type A 3,80 0,70 max max max 2,50 4,00 min
NiHARD2 Grade 2A Class 1 2A – 2,80- 0,30- 0,80 0,10 0,30 1,50- – – 2,00 – – – 500 –
Type B 3,40 0,70 max max max 4,00 4,00 min
NiHARD4 Grade 2E Class 1 2E – 2,80- 0,40- 1,50- 0,10 0,30 7,50- – – 4,50 – – – 600 –
Type D 3,60 0,60 2,00 max max 9,00 6,00 min
Castings will be supplied in the heat treated condition. Hardness values after heat treatment.

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

 22 I R O N B A S E A L L O Y S Carbon & Carbon Manganese Steels

RELATED INTERNATIONAL CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES

STELOY Yield Point Tensile Elongation Hardness Charpy
CODE RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Mo %Cu Others MPa Min Strength %Min Brinell V-Notch
0,2%Proof MPa Min Min

CARBON & CARBON MANGANESE STEELS

SABS 1465-1988 ASTM A216-03 BS 3100-1991 DIN 1621 %Ni
00PDSA1 C2 WCA A1 GS-45 0,25 0,90 0,60 0,05 0,05 0,30 0,15 0,30 0,40 230 430 22 130- 27J
1.0446 max max max max max max max max max 163 at 20˚C
00PDSA2 C3 WCB A2 GS-52 0,35 1,00 0,60 0,05 0,05 – – – 260 490 18 140- 20J
1.0552 max max max max max 179 at 20˚C
00PDSA3 C4 – A3 GS-60 0,45 1,00 0,60 0,05 0,05 – – – – 295 540 14 170- 18J
1.0558 max max max max max 192 at 20˚C
00PDSA4 C5 WCC A4 – 0,18- 1,20- 0,60 0,05 0,05 – – – – 320 540- 16 152- 30J
0,25 1,60 max max max 690 207 at 20˚C
00PDSA5 C6 – A5 DIN17205
GS-30Mn5 0,25- 1,20- 0,60 0,05 0,05 – – – – 370 620- 13 179- 25J
1.1165 0,33 1,60 max max max 770 229 at 20˚C
00PDSA6 C7 – A6 DIN17205
GS-30Mn5 0,25- 1,20- 0,60 0,05 0,05 – – – – 495 690- 13 201- 25J
1.1165 0,33 1,60 max max max 850 255 at 20˚C
00PAW2 – – AW2 – 0,40- 1,00 0,60 0,05 0,05 0,30 0,15 0,30 0,40 325 620 12 – –
0,50 max max max max max max max max
00PAW3 – – AW3 – 0,50- 1,00 0,60 0,05 0,05 0,30 0,15 0,30 0,40 370 690 8 – –
0,60 max max max max max max max max
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.
 RELATED INTERNATIONAL CODES CHEMICAL COMPOSITION (% BY WEIGHT) MECHANICAL PROPERTIES
STELOY Yield Point Tensile Elongation Hardness Charpy
CODE RSA USA BRITISH GERMAN %C %Mn %Si %P %S %Cr %Mo %Cu Others MPa Min Strength %Min Brinell V-Notch
0,2%Proof MPa Min Min

LOW ALLOY STEELS

SABS 1465-1988 ASTM A217-03 BS 3100-1991 DIN 17245 %Ni
00000B1 – WC1 B1 GS-22Mo5 0,20 0,40- 0,20- 0,04 0,04 0,30 0,45- 0,30 0,40 260 460 18 130- 20J
1.5419 max 1,00 0,60 max max max 0,65 max max 192 at 20˚C
00000B2 E1 WC6 B2 GS-17CrMo55 0,20 0,50- 0,60 0,04 0,04 1,00- 0,45- 0,30 0,40 280 480 17 140- 30J
1.7357 max 0,80 max max max 1,50 0,65 max max 212 at 20˚C
00000B3 E2 WC9 B3 GS-12CrMo9-10 0,18 0,40- 0,60 0,04 0,04 2,00- 0,90- 0,30 0,40 325 540 17 156- 25J
1.7380 max 0,70 max max max 2,75 1,20 max max 235 at 20˚C
00000B4 – – B4 – 0,25 0,30- 0,75 0,04 0,04 2,50- 0,35- 0,30 0,40 370 620 13 179- 25J
max 0,70 max max max 3,50 0,60 max max 255 at 20˚C
00000B5 – C5 B5 GS-12CrMo19-5 0,20 0,40- 0,75 0,04 0,04 4,00- 0,45- 0,30 0,40 420 620 13 179- 25J
1.7353 max 0,70 max max max 6,00 0,65 max max 255 at 20˚C
0000BT1 – – BT1 – 0,23- 0,70- 0,30- 0,04 0,04 0,60- 0,35- – 0,80- 495 690 11 201- 35J
0,28 1,00 0,60 max max 0,80 0,55 1,20 279 at 20˚C
0000BT2 – – BT2 – 0,23- 0,70- 0,60- 0,04 0,04 0,60- 0,35- – 0,90- 585 850 8 248- 25J
0,28 1,00 0,60 max max 0,80 0,55 1,30 327 at 20˚C
0000BT3 – – BT3 – 0,27- 0,70- 0,30- 0,03 0,03 0,65- 0,35- – 1,50- 695 1000 6 293- 20J
0,32 1,00 0,60 max max 0,85 0,55 1,80 362 at 20˚C
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.

23 I R O N B A S E A L L O Y S Low Alloy Steels

 24 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

When alloys are cast for the petrochemical industry, two requirements are of paramount importance:

• Corrosion resistance
• Heat resistance

Corrosion resistant alloys are covered under Austenitic Cast Alloys: Corrosion Resistant on page 6.
Distinction is made between static and centrifugally cast product. Heat resistant alloys are cast for
both heat treatment and petrochemical applications. Due to the more expansive application of
these alloys in the petrochemical industry, this will be the main focus of further discussion.

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 650°C and higher. Of
paramount interest 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
The role of the various alloying elements can be summarised as follows:
Chromium is primarily responsible for resistance to oxidisation (scaling) and uniform corrosion. This is related to the extremely stable oxide
layer formed by this element.
Nickel promotes an austenitic microstructure, thereby promoting thermal shock resistance and prevention of sigma phase formation.
Micro-alloying elements such as Nb, Ti and Zr are added to enhance creep strength through carbide formation.
It should be noted that creep resistant alloys also contain a significant quantity of carbon, required for solid solution strengthening as well as
carbide formation. Of further importance is the aspect of secondary carbide formation, where carbides precipitate during operation at high
temperatures. Precipitation takes place at operating temperature, within the austenite grains, contributing to strength and creep resistance.
Other alloying elements used, for either solid solution or precipitation strengthening, are Mo, Si, W, Co and R.E.Metals.

Steloy Castings produces a wide range of heat resistant alloys in both static castings and centrifugally cast tubes and pipes.
The current range of heat resistant alloys is the culmination of the application-driven alloy evolution that has taken place in
the petrochemical industry.
ASTM A297 provides – apart from indicating the (application-related) variance in Cr and Ni contents – a reference point for
the structured discussion of alloy development.

25 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)
 26 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)

STATIC CASTINGS
The ASTM A297 specification is intended for general applications (implicitly for static castings). Further development
and modification had to take place, using this ASTM A297 as basis, in order to meet the stringent requirements 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, designers and producers have realised the limitations of the standard ASTM
A297 gr HH specification. This specification contains a number of appropriate mandatory and supplementary requirements,
all aimed at ensuring sufficient casting integrity and material properties as would be required by the intended application of
(amongst others) petroleum still tube supports and similar applications up to 1095°C.

ASTM A297 gr HK has also been modified to Grade HK 40 (currently listed in ASTM A351). In this case more stringent requirements have been
placed on the % carbon range, while inclusion into A 351 will imply increased assurance of casting integrity.

ASTM A297 gr HP has been modified to Grade HP 45 and although it is not formally listed as such in any of the current ASTM
specifications, it must be regarded as one of the most significant alloy developments for the petrochemical industry. Apart from
forming the basis of the alloy to which all recent micro-alloying additions have been made in order to produce static castings for
supports, bends, hangers, brackets and tube sheets, it also overlaps with the current status quo regarding the majority of
centrifugally cast (spun tube) alloys.
 CENTRIFUGALLY CAST PIPES AND TUBES
The production of and specifications for centrifugally cast tubes are discussed in detail under Centrifugal Casting on pages 13
to 15. Some of the specifications, e.g. ASTM A 660, ASTM A426 also refer to pipes for high temperature applications and
could have been included in this section.

The application-driven evolution of spun cast alloys for high temperature applications can be discussed in a way similar
to that of static casting specifications.

The original BS 4534 specification for weldable Cr – Ni centrifugally cast steel tubes and ASTM A608 specification for
centrifugally cast iron-nickel-chromium high-alloy tubing for pressure application at high temperatures can be regarded as the basis
of further application-driven alloy development in centrifugally cast alloys.

The alloys listed in both these specifications reveal the same tendencies as A 297, where application-related variances in the Cr and Ni
contents can clearly be observed. Of specific importance, though, is the fact that grade HK40 is already indicated as such in the
ASTM A608 specification. The whole range of alloys listed in this specification have already – when compared to the A 297
specification – been subjected to intentional limitations of the % carbon range.

Grade HP45 does not yet feature in any of the current ASTM (spun tube) specifications. The tendency regarding further
development, particularly the introduction of micro-alloying elements, is, however, identical to that observed for static castings.

27 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)
 28 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)

Various international companies are currently producing micro-alloyed HP45. This type of alloy is available under a number of in-house specifications,
all subject to the patent rights/trade marks/privileged information of the various producers. The basic composition, however, remains the same. The
distinguishing aspects lie in the nature and extent of the micro-alloying additions and the
APPLICATION-DRIVEN ALLOY DEVELOPMENT CHART subsequent effect on claimed creep properties.
25Cr 20Ni
A297 HK
C 25Cr 20Ni 0,4C
ASTM A351 HK 40
High
Si
GX40CrNiSi 25 20
HK 40+Si (1.4848) The major applications for these alloys are reformer and catalyst tubes. Being in a position to
25Cr 12Ni N 25Cr 12Ni N produce certified creep properties is a distinct advantage when design in accordance with API
A297 HH QA ASTM A447
G-X40NiCrSi 35 25
HP mod HiSi
560 and – more importantly for spun tubes – thickness calculations according to API 530 are
applied.

Lo Si
G-X10NiCrSi 35 25

C
w
HP Nb Low Carbon
25Cr 35Ni C 25Cr 35Ni 0,45C Nb 25Cr 35Ni Nb
ASTM A297 HP HP 45 HP mod Nb Ti, Zr
1.4852 RE
1.4852 MA
HP45 micro
Steloy Castings is continually testing creep rupture properties of its major creep resistant alloys
Al 28Cr 38Ni Al micro to confirm and certify its materials by acknowledged independent laboratories. Of particular
RE Proprietary

C+W importance is 25Cr35NiNb Micro (Steloy 1.4852 MA) and 35Cr45NiNb Micro (Steloy 1.4889 MA).
Al 25Cr 38Ni 3W 1,5 Al
Proprietary
W
Typical creep rupture properties are indicated in the tables that follow.
25Cr 35Ni 4W
HP 40 + W
Co+W
Co+W
Alhough the discussed above centred on the development of the HP45 micro-alloyed range of
G-NiCr28W Co 28Cr 48Ni 3Co 5W Co 25Cr 35Ni 15Co 5W
2.4879 Proprietary G-X50NiCrCoW 35-25-15-5
1.4869
materials, a number of other generic groups also exist and can be applicable to both static and
35Cr 45Ni
ET 45
Co
35Cr 45Ni Nb
G-X40NiCrNb 45 35
M/A
Ti, Zr RE
35Cr 45Ni Nb MA
1.4889 micro
centrifugal castings. A concise indication of these groups can be obtained by referring to the
1.4889

application-driven alloy development chart.

 TYPICAL CREEP RUPTURE STRENGTH (Rm 100 000 in N/mm2)
TYPICAL MECHANICAL
STELOY ALLOY RELATED SPECIFICATION STRESS TO RUPTURE (in MPa) IN 100 000 HOURS AT TEMPERATURE INDICATED IN °C
PROPERTIES AT ROOM TEMP.
UTS YS Elong. % 600° 650° 700° 750° 800° 850° 900° 950° 1000° 1050° 1100°
Steloy WCB ASTM A216gr WCB 500 250 22
Steloy WC9 ASTM A217gr WC9 550 275 20
Steloy C5 ASTM A217gr C5 650 415 18 15 4
Steloy CF8C ASTM A743 CF8C 485 205 30 75 60 45 30 20 13 – – – – –
Steloy HF ASTM A297gr HF 485 240 25 65 50 35 25 18 12 7,5 – – – –
Steloy HH mod ASTM A447 550 – 4 – – 35 25 19 13 8 5 3 1,2 –
Steloy HK40 ASTM A351gr HK40 425 240 10 – – 57 40 30 21 15 10 6 3 1,4
Steloy 1.4859 ASTM A351gr CT15C 435 170 20 92 75 60 45 32 22 15 9 5 2 –
Steloy HP45 ASTM A297 HP45 430 235 4,5 – – 60 46 33 23 16 11 6,5 3,5 1,5
Steloy 2.4879 2.4879 440 240 4 – – 70 55 42 31 22 15,5 10 6,4 3,4

Indicated values are typical values only. The results of continuous creep testing are periodically revised and then updated in the applicable material data sheets.

29 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 Typical Creep Rupture Strength Table

 30 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 Typical Creep Rupture Strength Table (continued)

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

TYPICAL MECHANICAL
STELOY ALLOY RELATED SPECIFICATION STRESS TO RUPTURE (in MPa) IN 100 000 HOURS AT TEMPERATURE INDICATED IN °C
PROPERTIES AT ROOM TEMP.
UTS YS Elong. % 600° 650° 700° 750° 800° 850° 900° 950° 1000° 1050° 1100°
Steloy 2.4680 ASTM A560 550 345 5 – – 62 45 30 20 13 7,5 3,5 1,5 –
Steloy 2.4608 2.4608 550 240 30 120 75 60 38 30 17 9 6 3,5 – –
Steloy 1.4852 ASTM A297 HP45Nb 450 250 6 – – 68 55 42 32 23 16 10 5,5 2,5
Steloy 1.4852MA HP45 Nb micro 450 250 6 – – – – 48 36 26 18 12 6,8 4
Steloy 1.4889MA 35Cr 45Ni Nb micro 440 240 3 – – – – 39 28 20 14 9 5 2,6
Steloy 2.4879 mod 2.4879 mod 440 240 3 – – 70 56 43 32 23 16 11 6,6 3,8
Steloy 1.4869 1.4869 480 270 5 – – – – – 42 28 19 11,5 7,4 4,3

Indicated values are typical values only. The results of continuous creep testing are periodically revised and then updated in the applicable material data sheets.
 TYPICAL CREEP LIMITING STRENGTH (Rp1/10 000 in N/mm2)

MAXIMUM
TEMPERATURE OF LIMITING STRESS (in MPa) FOR 1% CREEP IN 10 000HRS AT TEMPERATURE INDICATED IN °C
STELOY ALLOY RELATED SPECIFICATION OXIDISATION
RESISTANCE IN AIR
°C 600° 650° 700° 750° 800° 850° 900° 950° 1000° 1050° 1100°
Steloy WCB ASTM A216gr WCB 450
Steloy WC9 ASTM A217gr WC9 450
Steloy C5 ASTM A217gr C5 620 26 15 – – – – – – – – –
Steloy CF8C ASTM A743 CF8C 850 83 65 49 36 25 17 – – – – –
Steloy HF ASTM A297gr HF 900 74 58 44 33 23 15 10 – – – –
Steloy HH mod ASTM A447 1000 – – 50 36 26 18 12 9 6 4 –
Steloy HK40 ASTM A351gr HK40 1100 – – 71 53 40 28 20 13 8 5 2,2
Steloy 1.4859 ASTM A351gr CT15C 1050 98 82 62 45 33 23 16 10 6 3,1 –
Steloy HP45 ASTM A297 HP45 1100 – – 69 53 40 30 20 14 9 6 2,8
Steloy 2.4879 2.4879 1150 – – 85 68 51 39 28 19 13 8 5

Indicated values are typical values only. The results of continuous creep testing are periodically revised and then updated in the applicable material data sheets.

31 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 Typical Creep Limiting Strength Table

 32 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 Typical Creep Limiting Strength Table (continued)

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

MAXIMUM
TEMPERATURE OF LIMITING STRESS (in MPa) FOR 1% CREEP IN 10 000HRS AT TEMPERATURE INDICATED IN °C
STELOY ALLOY RELATED SPECIFICATION OXIDISATION
RESISTANCE IN AIR
°C 600° 650° 700° 750° 800° 850° 900° 950° 1000° 1050° 1100°
Steloy 2.4680 ASTM A560 950 – – 70 54 38 27 17 11 6,5 3,4 –
Steloy 2.4608 2.4608 1150 95 80 60 45 35 20 15 8 5 2 –
Steloy 1.4852 ASTM A297 HP45Nb 1090 – – 72 57 43 30 22 15 9 5,5 2,9
Steloy 1.4852MA HP45Nb micro 1090 – – 76 61 49 37 26 19 12,3 7,5 3,4
Steloy 1.4889MA 35Cr45NiNb micro 1125 – – – – 47 35 26 18 11,9 7,2 3,8
Steloy 2.4879 mod 2.4879 mod 1150 – – 81 65 50 37 26 19 12,4 7,7 4,5
Steloy 1.4869 1.4869 1190 – – – – – 43 30 21 14 8,3 5

Indicated values are typical values only. The results of continuous creep testing are periodically revised and then updated in the applicable material data sheets.
 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.

33 THE CASTING PROCESS

 34 T H E C A S T I N G P R O C E S S (continued)

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 three-
dimensional 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 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.

6. 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 self-
set moulding and core-making. Any combination of these processes can be used to adhere to customer requirements.
7. 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.

35 T H E C A S T I N G P R O C E S S (continued)
 36 T H E C A S T I N G P R O C E S S (continued)

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.