Powder Metallurgy Alloys For Oil Field Applications

PAPER 6F
Powder Metal Alloys for

Oil Field Applications
Biography
Maria Sawford
Research Engineer II
ATI Powder Metals
6515 Steubenville Pike
Pittsburgh, PA 15205
USA
T: 412-923-2955 x276
E: Maria.Sawford@ATImetals.com
Andrzej Wojcieszynski
Senior Technical Director,
Specialty Products and Alloys
ATI Powder Metals
T: 412-923-2955
E: A.Wojcieszynski@ATImetals.com
Roy T. Carlson
Account Manager
ATI Powder Metals
T: 412-923-2670
E: Roy.Carlson@ATImetals.com
Brian J. McTiernan
General Manager
ATI Powder Metals
T: 412-923-2670
E: Brian.McTiernan@ATImetals.com
Maria has been a Research Engineer at ATI

Powder Metals (formerly Crucible Research)
for 13 years. Currently, she is working on
Duplex Stainless Steels and Ni-based alloys
for the Oil & Gas industry and on materials
for the Nuclear industry. Previously, she has
researched and developed wear and corrosion
resistant tool steels used in food and plastics
processing, industrial tooling applications,
automotive exhaust valves and high end knives.
Maria earned her BS and MS in Materials
Science and Engineering from Penn State
University. She is a Registered Professional
Engineer in Pennsylvania.
Abstract
Various parts and components used in the oil
and gas industry are manufactured from duplex
and super duplex stainless steels and Ni-Cr
alloys due to their combination of high strength
and corrosion resistance. Manufacturing these
alloys with the HIP PM process (i.e., hot isostatic
pressing of gas atomized powder) results
in numerous advantages over conventional
products. This paper reviews the HIP PM
process and examines the microstructure,
corrosion resistance and mechanical
properties of three alloys commonly used in oil
and gas exploration and processing: the super
duplex stainless steel S32760 PM and two
Ni-Cr alloys ATI A625 PM and ATI 625M
PM. The property characteristics of the HIP
PM alloys are compared to the corresponding
alloys made by conventional ingot metallurgy.
The results show that the corrosion resistance
and mechanical properties of the HIP PM alloys
Keywords
PM powder
hot isostatic pressing (HIP)
corrosion resistance
mechanical properties
Introduction
Highly alloyed duplex and super duplex
stainless steels (SDSS) and Ni-Cr alloys
are used in the oil and gas industry when
corrosion and strength are of utmost concern.
Due to the high alloy content, these alloys can
be difficult to manufacture using conventional
methods, e.g., casting, forging and hot rolling.
The high alloy content of conventionally
produced material causes segregation during
cooling which results in these materials having
an inhomogeneous chemical composition,
anisotropic mechanical properties and a
nonuniform microstructure, all of which lead
to hot working difficulties. These issues can
be minimized through the use of the HIP PM
process (i.e., hot isostatic pressing (HIP) of gas
atomized powder) [1,2] . After a review of this HIP
PM process, the microstructure, corrosion
resistance and mechanical properties of three
alloys commonly used in oil and gas exploration
will be discussed. The alloys included in
this study are the super duplex stainless
steel S32760 PM (a HIP PM version of UNS
S32760), ATI A625 PM (argon atomized UNS
N06625) and ATI 625M PM (argon atomized
UNS N07626). The property characteristics
ZERON 100 is a registered trademark of Rolled Alloys.
ATICORROSIONCONFERENCE.COM | CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS
31596_CSC11_Proceedings_INT_120224.indd 261
are comparable to and at times better than

those of the conventionally produced alloys.
261
2/24/12 4:40 PM
PAPER 6F
Powder Metal Alloys for Oil Field Applications
Figure 1. Steps in the HIP PM process which includes a) vacuum induction melting, b) screening, c) blending, d) loading, e) outgassing and f) HIP.
a
of S32760 PM are compared to those of the

ZERON 100 alloy (UNS S32760) and the
characteristics of the ATI A625 PM and ATI
625M PM alloys are compared to those of a
conventionally produced ATI 625 bar.
The super duplex stainless steel UNS
S32760 is being used to manufacture risers,
flow lines and subsea flow meters for the oil and
gas industry. This alloy has high strength and
good corrosion resistance in various acids. The
HIP PM processing route is most advantageous
for this alloy due to the resultant fine grain
size produced during atomization. The rapid
solidification of the powder particles also results
in a fine austenite spacing, which is necessary
to minimize hydrogen induced stress corrosion
cracking (HISC). It has been noted that a fine
austenite spacing (30 m or finer) is needed to
minimize HISC in duplex stainless steels [3] .
The high strength and excellent corrosion
resistance of the Ni-Cr alloys enables these
materials to be used in various oil and gas
applications including subsea valves and
wellhead equipment. Although the conventional
625 and ATI A625 PM alloys are solid solution

strengthened, they can be age hardened
through the precipitation of gamma double
prime (g"). The ATI A625 PM alloy can be
heat treated to a maximum yield strength of 724
MPa (120 ksi) in significantly shorter heat treat
cycles as compared to conventional 625. The
ATI 625M PM alloy has an even greater ability
to age harden due to higher amounts of niobium
(Nb) and aluminum (Al) and can be heat treated
to a maximum yield strength of 1034 MPa (150
ksi). The yield strength of the ATI 625M PM
alloy is comparable to the yield strength of alloy
718; its corrosion resistance is comparable to
that of alloy 625 and better than that of alloy
718. Both ATI A625 PM and ATI 625M PM
alloys have been approved by NACE MR0175 for
use in H 2S containing environments [4] .
HIP PM Processing
Several steps are included in the HIP PM
process: melting of the raw materials, inert
gas atomization of the melt, screening of the

powder, loading of the powder into containers
and hot isostatic pressing (HIP) as depicted
in Figure 1. The raw materials are vacuum
induction melted (VIM) in a furnace to the
desired chemical composition. Once molten,
the metal is atomized with high pressure
gas, typically argon (Ar) or nitrogen (N 2 ). The
spherical powder particles that form during
atomization cool at rates up to 10 6 C/sec
(10 6 F/sec) to yield chemically homogeneous
powder. The atomized powder particles fall
to the bottom of the atomization tower where
they are collected in a cryogenic liquid for
further processing.
Once the powder is unloaded from the
atomization tower, the powder is screened to
obtain the desired particle size distribution.
The screening process takes place in a clean
room environment under a positive pressure
of filtered air to assure maximum cleanliness
and to maintain high quality standards. This
powder can be blended with screened powder
from other heats to homogenize the particle
Figure 2. Examples of HIP/clad applications: a) mill rolls and b) compounding segments and barrel for plastics processing.
262
CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS | ATICORROSIONCONFERENCE.COM
2/24/12 4:40 PM
PAPER 6F
Table 1. Chemical compositions of the alloys that were tested.

Alloy
Cr
Nb
Mo
Fe
Ni
Cu
Al
Ti
PRE1
Super Duplex Stainless Steels

S32760 PM
0.028
0.268
25.40
3.72
Bal.
7.20
0.56
0.62
43.0
Zeron 100
0.023
0.239
25.27
3.60
Bal.
7.06
0.56
0.61
42.0
ATI A625 PM
0.017
0.0079
21.26
3.83
8.83
0.43
Bal.
0.29
0.23
50.5
ATI 625M PM
0.016
0.0063
20.13
5.03
8.66
5.20
Bal.
0.47
48.8
Conv. ATI 625
0.049
0.0095
20.87
3.32
8.29
4.09
Bal.
0.25
0.28
48.2
Ni-Cr Alloys
PRE = %Cr + 3.3(%Mo + 0.5*%W) + 16*%N
size distribution. This blended powder is

loaded into a welded container, which may be
of a simple geometry or near-net-shape. The
container is continuously vibrated while the
powder is being loaded to ensure optimum
packing density. Loading of the powder can
be done inertly or in atmosphere, depending
on the alloy being loaded. Once loaded,
the container is outgassed or evacuated to
minimize entrapped gases that may interact
with the powder during consolidation. After the
outgassing process is complete, the containers
are sealed and crimped and are ready for HIP.
The high temperature and high pressure
used during HIP fully consolidate the powder
within the container. Once the material
is consolidated, additional hot working
processes, e.g., forging, extrusion, rolling,
drawing, etc., may be employed to obtain
conventional mill products. Thus, the
versatility of the HIP PM process allows for
the production of plate, sheet, bar, tube, pipe,
etc., and near-net-shapes.
The HIP PM process can also be leveraged
to produce bimetallic HIP-clad products,
typically involving a highly alloyed material
applied to a low alloy substrate, as shown
in Figure 2. In some cases, this method can
yield an economic advantage as the expensive
highly alloyed material is bonded only to
the working surfaces of the substrate and
therefore less weight of the highly alloyed
powder is required. In other HIP-clad cases,
the key property characteristics, e.g., corrosion
and/or wear resistance, of the highly alloyed
powder is necessary to enhance the service life

of the component. For example, HIP-clad ATI
A625 PM-4140 components have been used
successfully in high pressure high temperature
well environments, with the clad layer providing
corrosion resistance and the substrate providing
the necessary tensile strength.
Materials
The S32760 PM powder was nitrogen
atomized in a 23 kg (50 lbs) laboratory
atomizer at ATI Powder Metals. The ATI A625
PM and ATI 625M PM powders were argon
atomized in a 3640 kg (8,000 lbs) furnace
also at ATI Powder Metals. Laboratory sized
compacts were filled with -60 mesh powder,
outgassed and HIPed to full density. The
conventional ATI 625 alloy was supplied as
31.75 mm and 57.2 mm (1.25" and 2.25")
diameter bars from ATI Allvac in the annealed
condition. Plate material of conventional
ZERON 100 measuring 15.9 mm (0.625")
thick was obtained from ATI Allegheny Ludlum.
The chemical compositions of the alloys that
were tested are given in Table 1.
S32760 PM has a higher N and Mo content
than the ZERON 100 plate. Thus the pitting
resistance equivalent number (PRE) of S32760
PM (43.0) is higher than that for the ZERON
100 plate (42.0).
The ATI A625 PM material has a higher Cr
and Mo content than the conventional ATI 625
plate and thus has a higher PRE number (50.5
vs. 48.25). The PRE number for the ATI 625M

PM alloy (48.8) is similar to that of the ATI
625 plate (48.2), but the ATI 625 plate has
a higher C content than the two HIP PM alloys.
Experimental Procedure
Corrosion and mechanical test specimens
were prepared from HIPed compacts and the
conventional bar and plate material. The heat
treatments given to the test specimens and
their designations are given in Table 2. These
designations are used throughout this article.
The heat treatments given to ATI A625 PM
and ATI 625M PM alloys are those that are
typically used for components in the oil and
gas industry and do not necessarily result in
the maximum tensile properties.
The microstructure of S32760 PM and
the ZERON 100 plate was examined after
electrolytic etching in a 20% NaOH at 3V dc
for 45 seconds. The austenite spacing was
determined according the procedure given in
the Recommended Practice DNV-RP-F112 [3] .
The mean and standard deviation reported
herein were determined from a total of four
photomicrographs of each alloy. The Ni-Cr
alloys were etched with a waterless Kallings
etchant at 37.8C (100F) for 2 minutes.
Corrosion resistance was evaluated
according to ASTM G48 Methods A, C and D.
Prior to testing, the specimens were pickled
in a solution of 10% HCl + 3% HF at 60C
(140F) for 20 minutes and passivated in air
263
2/24/12 4:40 PM
PAPER 6F
for 24 hours. ASTM G48 Method A was used

as a screening test only on S32760 PM and the
ZERON 100 plate prior to testing in Methods
C and D. The specimens used in the Method A
testing were placed in a 150 mL test tube filled
with 6% FeCl3 at 50C (122F) for 72 hours.
ASTM G48 Method C was used to determine
the critical pitting temperature (CPT) of each
alloy. These specimens were placed in a
150 mL test tube filled with acidified ferric
chloride for 72 hours at various temperatures
up to 85C (185F). ASTM G48 Method D
was used to determine the critical crevice
corrosion temperature (CCT) for each alloy.
Teflon crevice formers and titanium nuts and

bolts were used for the crevice assembly. The
specimens were placed in individual beakers
filled with 600 mL of acidified ferric chloride
for 72 hours at various temperatures.
The V-notch impact toughness and room
temperature tensile properties of the S32760
PM, ATI A625 PM and ATI 625M PM alloys
were evaluated and compared to the respective
conventional alloy. The V-notch impact
toughness of each alloy was evaluated at 25C
(76F), -46C (-51F) and -75C (-103F). It
is widely accepted that HIP PM materials have
isotropic properties [5] . Therefore, testing of the
HIP PM alloys was conducted in one direction.

Due to the size of the conventional ATI 625
bar, only the longitudinal tensile properties
were determined.
Results
Metallography
The microstructure of S32760 PM in the asHIP condition and after solution annealing is
given in Figure 3. The as-HIP microstructure
Table 2. Heat treatments and resulting hardness results of the tested alloys.
Alloy
Heat Treatment
Designation
Hardness, HRC
S32760 PM
1141C/1hr, WQ
SA
24.0
Zeron 100
1099-1141C/1hr, WQ
22.0
Ni-Cr Alloys
ATI A625 PM
ATI 625M PM
Conv. ATI 625
as-HIP
as-HIP
21.5
996C/1hr, OQ, 649CF/8hrs, OQ
STA1
29.0
996C/1hr, OQ, 649C/16hrs, OQ
STA2
32.0
as-HIP
as-HIP
26.5
996C/1hr, OQ, 677C/16hrs, OQ
STA3
34.0
718C/8hrs, FC, 621C/4hrs, AC
DA
39.0
871C/30min, WQ
anneal
20.5
760C/8hrs, OQ
aged
21.0
OQ = oil quench, WQ = water quench, SA = SOlution anneal, STA = Solution Treat & Age, DA = Double Age
Figure 3. Photomicrographs showing the etched microstructure of S32760 PM: a) in the as-HIP condition, b) after solution annealing and c) of the
ZERON 100 plate. Note the different scale for the ZERON 100 plate.
a
sigma
ferrite
ferrite
264
2/24/12 4:40 PM
PAPER 6F
Table 3. Results from the ASTM G48 corrosion tests.

Alloy
Heat Treat
G48 Method A
G48 Method C
G48 Method D
PRE
Wt loss, g/m2
CPT, C (F)
CCT, C (F)
as-HIP
476
SA
0.09
65 (149)
35 (95)
SA
65 (149)
40 (104)
42.0
as-HIP
85 (185)
45 (113)
50.5
STA1
85 (185)
50 (122)
STA2
85 (185)
40 (104)
as-HIP
85 (185)
50 (122)
STA3
85 (185)
45 (113)
DA
85 (185)
40 (104)
anneal
85 (185)
25 (77)
aged
85 (185)
30 (86)

S32760 PM
Zeron 100
43.0
Ni-Cr Alloys
ATI A625 PM
ATI 625M PM
Conv. ATI 625
48.8
48.2
SA = SOlution anneal, STA = Solution Treat & Age, DA = Double Age
of S32760 PM contains the sigma phase,

as shown in Figure 3a. Solution annealing
dissolves the sigma phase and results in a
microstructure containing a fine and uniform
distribution of ferrite and austenite, Figure 3b.
This microstructure has a hardness of 24 HRC.
Microstructural directionality is not observed
in S32760 PM due to the PM processing.
The austenite spacing in S32760 PM was
determined to be about 10.6 m 8.3 m.
For comparison, the microstructure of the
ZERON 100 plate is elongated in the rolling
direction, as shown in Figure 3c, and has an
austenite spacing of about 22.9 m 25 m
in the longitudinal direction. The hardness of
the ZERON 100 plate is 22 HRC.
Corrosion Resistance
Results of the ASTM G48 Method A testing
on the super duplex stainless steels are given
in Table 3. As-HIP S32760 PM fails this test
due to a high weight loss of 476 g/m2. Further
testing on as-HIP S32760 PM was therefore
suspended. Solution annealed S32760 PM
passes this test, Table 3. All further references
Figure 4. Tensile properties of the SDSS.
to S32760 PM refer to the solution annealed

material, unless otherwise noted.
The results in Table 3 also show the CPT
and CCT for S32760 PM and the ZERON 100

plate. These alloys have the same resistance to
pitting corrosion as both materials have a CPT
265
2/24/12 4:40 PM
PAPER 6F
of 65C (149F). The resistance of S32760
PM to crevice corrosion, CPT = 35C (95F),
is comparable to that of the ZERON 100 alloy,
CPT = 40C (104F).
Mechanical Properties
Tensile Properties
The room temperature tensile properties
of S32760 PM, the ZERON 100 plate
(transverse) and cast S32760 [6] are given in
Figure 4. Solution annealed S32760 PM has
a yield strength (YS) of 570 MPa (82.7 ksi),
an ultimate tensile strength (UTS) of 830
MPa (120 ksi) and an elongation of about
45%. The tensile properties of solution

annealed S32760 PM are above the minimum
requirements specified in NORSOK M-630,
MDS 54 [7] : UTS = 750 MPa (109 ksi), YS =
550 MPa (80 ksi) and elongation = 25%. The
tensile properties of S32760 PM are similar
to the transverse properties of the ZERON
100 plate. Additionally, the tensile properties
of S32760 PM are better than cast S32760
which has a YS of 450 MPa (65 ksi) and a UTS
of 448 MPa (65 ksi) [6] .
The tensile properties of S32760 PM in
the as-HIP condition are also given in Figure
4. The results show that as-HIP S32760 PM
has the highest UTS and YS with values of
Figure 5. V-Notch impact toughness of the SDSS.
903 MPa (131 ksi) and 641 MPa (93 ksi),

respectively. However, the ductility is poor with
an elongation of only 2%.
V-Notch Impact Toughness
The impact toughness of S32760 PM and
the ZERON 100 plate is given in Figure 5.
The toughness of S32760 PM is about 200
J (147 ft-lbs) at -46C (-51F), which is well
above the minimum toughness requirement
of 45 J (33 ft-lbs) at -46C (-51F) required
by NORSOK M-630, MDS-54 [7] . The results
also show that the longitudinal and transverse
toughness of the ZERON 100 plate is about
350 J (257 ft-lbs) and 231 J (232 ft-lbs) at
-46C (-51F), respectively. The transverse
toughness of ZERON 100 plate is about 35%
lower than the toughness in the longitudinal
direction. The results show that the toughness
of S32760 PM is comparable to the transverse
toughness of ZERON 100 plate.
The toughness of S32760 PM at -75C
(-103F) is about 176 J (130 ft-lbs), which
is comparable to the transverse toughness
of the ZERON 100 plate, 192 J (141.5 ftlbs), at that temperature. The results show
that the toughness of S32760 PM does not
rapidly decrease with decreasing temperature
as the toughness ranges from about 241 J
(177.5 ft-lbs) at 25C (77F) to 176 J (130
ft-lbs) at -75C (-103F), a 27% decrease in
toughness. Likewise, the toughness of the
ZERON 100 plate does not rapidly decrease
with decreasing temperature with transverse
toughness ranging from 268 J (198 ft-lbs) at
25C (77F) to 193 J (142 ft-lbs) at -75C
(-103F), a 28% decrease in toughness.
Figure 6. Photomicrographs showing the etched microstructure of the a) as-HIP ATI A625 PM alloy, b) as-HIP ATI 625M PM alloy and c)
conventional ATI 625 bar.
a
266
2/24/12 4:40 PM
PAPER 6F
Ni-Cr Alloys
Figure 7. Tensile properties of the Ni-Cr alloys.
Metallography
The microstructure of the as-HIP ATI A625
PM (21.5 HRC) and ATI 625M PM (26.5
HRC) alloys and the conventional ATI 625
bar (20.5 HRC) are given in Figure 6. The
PM alloys have a fine and uniform austenitic
microstructure. Evidence of microstructural
banding and elongated grains are present in the
microstructure of the conventional ATI 625
bar, Figure 6c. The microstructure of the ATI
A625 PM, ATI 625M PM and conventional
ATI 625 alloys is unaffected by heat treatment
when viewed with an optical microscope.
However, the hardness of the ATI A625 PM
alloy increases to 29 HRC and 32 HRC with the
STA1 and STA2 heat treatments, respectively.
The hardness of the ATI 625M PM alloy
increases to 34 HRC and 39 HRC with the
STA3 and DA heat treatments, respectively.
The effect of heat treatment on the hardness of
these alloys is summarized in Table 2.
Corrosion Resistance
Results of corrosion testing on the Ni-Cr alloys
are given in Table 3. The pitting resistance of
the ATI A625 PM and ATI 625M PM alloys
is the same as the conventional ATI 625 bar
as all materials have a CPT of 85C (185F).
Additionally, Table 3 shows that the pitting
resistance of the PM materials is unaffected by
the heat treatments.
The results in Table 3 show that ATI A625
PM (STA1) and ATI 625M PM (as-HIP)
alloys have the highest resistance to crevice
corrosion as both materials have a CCT of 50C
(122F). The resistance of the ATI A625 PM
and ATI 625M PM alloys to crevice corrosion
does not vary significantly with heat treatment
as the CCT values range from 40-50C (104122F). In most cases, the crevice corrosion
resistance of the ATI A625 PM and ATI 625M
PM materials is higher than the conventional
ATI 625 bar which has a CCT of 25-30C
(77-86F), depending on heat treatment.
Mechanical Testing
Tensile Properties
The room temperature tensile properties of
the HIP PM and conventional 625 alloys are
given in Figure 7. The UTS and YS of the asHIP ATI A625 PM material are 959 MPa
(139 ksi) and 517 MPa (75 ksi), respectively.

These values increase to 1083 MPa (157 ksi)
and 676 MPa (98 ksi), respectively, when the
material is solution treated and aged (STA1).
The longer aging time of the STA2 treatment
results in a UTS and YS of 966 MPa (140
ksi) and 492 MPa (71 ksi). The strength of
the ATI A625 PM alloy is comparable to or
better than the longitudinal strength of the
conventional ATI 625 bar which has a UTS
and YS of 931 MPa (135 ksi) and 483 MPa
(70 ksi) in the annealed condition.
The tensile and yield strengths of the asHIP ATI 625M PM material are 1025 MPa
(149 ksi) and 618 MPa (90 ksi), respectively,
as shown in Figure 7. Solution treating and
aging (STA3) this alloy increases the tensile
and yield strengths to 1186 MPa (172 ksi) and
793 MPa (115 ksi), respectively. The double
aging (DA) heat treatment further increases
the tensile and yield strengths of the ATI
625M PM alloy to 1262 MPa (183 ksi) and
924 MPa (134 ksi), respectively. The strength
of the ATI 625M PM alloy is better than
that of the ATI A625 PM material and the
conventional ATI 625 bar.
The ductility of the ATI A625 PM and
ATI 625M PM alloys is lower than that of
conventional ATI 625 bar in the longitudinal
direction. This result is expected as the PM
alloys have a higher strength and hardness
than conventional ATI 625 bar.

Impact Toughness
Results of V-notch impact toughness testing
on the Ni-Cr alloys are given in Figure 8.
The toughness of the ATI A625 PM alloy
is highest when the material is in the as-HIP
condition with a toughness at -46C (-51F) of
about 91 J (67 ft-lbs). When given the STA1
and STA2 heat treatments, the toughness at
-46C (-51F) decreases to 65J (48 ft-lbs) and
54 J (40 ft-lbs), respectively. The toughness
of the as-HIP ATI A625 PM material is
similar to or better the transverse toughness
of the conventional ATI 625 bar which has a
toughness of 85 J (62 ft-lbs) at -46C (-51F).
The toughness of the ATI 625M PM alloy
is also at its highest in the as-HIP condition
with a toughness of about 81 J (60 ft-lbs)
at -46C (-51F). The toughness at -46C
(-51F) decreases to 53 J (39 ft-lbs) and 35 J
(26 ft-lbs) when the material is given the STA3
and DA heat treatments, respectively. The
toughness of the as-HIP ATI 625M PM alloy
at -46C (-51F) is similar to the transverse
toughness of the conventional ATI 625 bar.
The results in Figure 8 also show that the
toughness of the PM alloys is essentially
unchanged as the test temperature decreases
from 25C (77F) to -75C (-103F) for a given
heat treating condition.
267
2/24/12 4:40 PM
PAPER 6F
Discussion
S32760 Alloys
Microstructural evaluations on S32760 PM
showed the presence of sigma in the as-HIP
condition. This phase precipitates during the
slow cool down cycle in the HIP unit. However,
the sigma phase dissolves during solution
annealing. The test results on S32760 PM
shown herein confirm that sigma degrades
corrosion resistance and the tensile properties
as evidenced by the ASTM G48 Method A test
results in Table 3 and the ductility in Figure 4.
Thus, S32760 PM cannot be used in the asHIP condition and must be solution annealed to
produce a sigma-free microstructure.
When properly solution annealed, the
corrosion resistance of S32760 PM is similar
to that of the ZERON 100 alloy. However,
a benefit of the PM processing route is
evidenced in the austenite spacing. The
austenite spacing of S32760 PM is 10.6 m
8.3 m whereas the ZERON 100 plate has
an austenite spacing of 22.9 m 25 m in
the longitudinal direction. The fine and uniform
austenite spacing of S32760 PM is expected
to minimize the risk of HISC as compared to
conventional S32760 [3] .
In the solution annealed condition, the

toughness of S32760 PM is comparable to the
transverse toughness of the ZERON 100 plate
at all test temperatures. When properly heat
treated, the tensile properties of S32760 PM
are similar to those of the ZERON 100 plate.
It should be noted that a significant amount of
hot working was applied to the ZERON 100
plate during manufacturing. Similar amounts of
hot working would also improve the toughness
of S32760 PM.
Ni-Cr Alloys
The corrosion resistance of the ATI A625 PM
and ATI 625M PM alloys is better than that of
the conventional ATI 625 bar, especially with
respect to crevice corrosion resistance. When
properly heat treated, the ATI A625 PM and
ATI 625M PM alloys have a CCT of 50C
(122F). Although the ATI 625M PM and
conventional ATI 625 alloys have the same
PRE number, the ATI 625M PM alloy has a
better resistance to crevice corrosion. This
improved corrosion resistance is due in part to
the chemical homogeneity of the material due
to the PM process and the fact that the PM
materials have a lower carbon content than the
conventional material.
Figure 8. V-Notch impact toughness of the Ni-Cr alloys.
The ATI A625 PM and ATI 625M PM

alloys can be heat treated to a higher hardness
and strength levels than conventional ATI 625
alloy. The results show the strength of the
as-HIP ATI A625 PM and as-HIP ATI 625M
PM materials is comparable to that of the
conventional ATI 625 bar. Solution treating
and aging the ATI A625 PM alloy increases
the hardness to 29 HRC and the YS to 676 MPa
(98 ksi). The double aging treatment of the ATI
625M PM alloy increases the hardness to 39
HRC and the YS to 924 MPa (134 ksi). These
heat treatments do not significantly affect
corrosion resistance. The improvements in
hardness and strength imparted by the heat
treatments cause the ductility and toughness
of the PM alloys to decrease. When choosing
the most appropriate heat treating condition
for these alloys, the toughness, strength and
corrosion requirements must be considered
simultaneously. Thorough testing should
be conducted prior to placing a component
manufactured from any alloy in use.
Conclusion
The HIP PM process can be used to
manufacture conventional mill products,
near net shapes and HIP/clad components.
The results herein show that the corrosion
resistance and mechanical properties of the
HIP PM materials are comparable to and at
times exceeds those of the conventionally
produced counterparts. Specifically:
The corrosion resistance of S32760 PM is
similar to that of the ZERON 100 plate.
The uniform and fine austenite spacing
of S32760 PM should minimize the risk
of HISC as compared to conventionally
produced S32760.
The toughness of S32760 PM is comparable
to the transverse toughness of the ZERON
100 plate with a toughness of 199 J (147
ft-lbs) at -46C(-51F)
The tensile properties of S32760 PM
are similar to those of the ZERON 100
plate with YS of 585 MPa (85 ksi) and an
elongation of 45%.
The crevice corrosion resistance of the
ATI A625 PM and ATI 625M PM alloys
268
2/24/12 4:40 PM
PAPER 6F
is higher than that of the conventional ATI

625 bar with CCT values of about 50C
(122F) for the PM alloys.
The strength of the as-HIP ATI A625
PM and as-HIP ATI 625M PM alloys
is comparable to that of the conventional
ATI 625 bar. Solution treating and aging
of the ATI A625 PM material increases
the YS to 676 MPa (98 ksi). The double
aging treatment of the ATI 625M PM alloy
increases the YS to 924 MPa (134 ksi).
The toughness of the as-HIP ATI A625
PM and ATI 625M PM alloy is similar
to that of conventional ATI 625 bar. The
toughness of the PM alloys decreases with
heat treatment as the hardness increases
with aging, as expected.
References
1. John H. Moll, John J. Conway and Brian
J. McTiernan, As-HIP P/M Superalloys:
A Technical and Commercial Success,
Advances in Powder Metallurgy &
Particulate Materials, Vancouver, 1999.
2. John H. Moll, Brian J. McTiernan,
Powder Metallurgy Superalloys,
ASM Handbook. 10th, Vol. 7, ASM
International, 1998.
3. Design of Duplex Stainless Steel
Subsea Equipment Exposed to Cathodic
Protection, Recommended Practice
DNV-RP-F112, Det Norske Veritas,
October 2008.
4. Petroleum and Natural Gas Industries:
Materials for Use in H 2 S-containing

Environments in Oil and Gas Production,
ANSI/NACE MR0175/ISO 15156-3,
NACE International, 2009.
5. William Stasko, et.al., Advances in the
Development of Particle Metallurgy Hot
Work Tool Steels, 15th International
Die Casting Congress & Exposition, St.
Louis, Mo, 1989.
6. Rolled Alloys, http://www.rolledalloys.
com/products/duplex-stainless-steels/
ZERON-100.
7. Material Data Sheets and Element Data
Sheets for Piping, M-630, NORSOK,
September 2010.
n
269
2/24/12 4:40 PM

Powder Metallurgy Alloys For Oil Field Applications

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Powder Metallurgy Alloys For Oil Field Applications

Uploaded by

Copyright:

Available Formats

PAPER 6F

Powder Metal Alloys for

Maria has been a Research Engineer at ATI

ZERON 100 is a registered trademark of Rolled Alloys.

ATICORROSIONCONFERENCE.COM | CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS

are comparable to and at times better than

Powder Metal Alloys for Oil Field Applications

of S32760 PM are compared to those of the

625 and ATI A625 PM alloys are solid solution

gas atomization of the melt, screening of the

CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS | ATICORROSIONCONFERENCE.COM

Powder Metal Alloys for Oil Field Applications

Table 1. Chemical compositions of the alloys that were tested.

Super Duplex Stainless Steels

Conv. ATI 625

PRE = %Cr + 3.3(%Mo + 0.5*%W) + 16*%N

size distribution. This blended powder is

powder is necessary to enhance the service life

vs. 48.25). The PRE number for the ATI 625M

ZERON 100 is a registered trademark of Rolled Alloys.

ATICORROSIONCONFERENCE.COM | CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS

Powder Metal Alloys for Oil Field Applications

for 24 hours. ASTM G48 Method A was used

Teflon crevice formers and titanium nuts and

HIP PM alloys was conducted in one direction.

Super Duplex Stainless Steels

Conv. ATI 625

996C/1hr, OQ, 649CF/8hrs, OQ

996C/1hr, OQ, 649C/16hrs, OQ

996C/1hr, OQ, 677C/16hrs, OQ

718C/8hrs, FC, 621C/4hrs, AC

ZERON 100 is a registered trademark of Rolled Alloys.

CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS | ATICORROSIONCONFERENCE.COM

Powder Metal Alloys for Oil Field Applications

Table 3. Results from the ASTM G48 corrosion tests.

Super Duplex Stainless Steels

Conv. ATI 625

SA = SOlution anneal, STA = Solution Treat & Age, DA = Double Age

of S32760 PM contains the sigma phase,

Figure 4. Tensile properties of the SDSS.

to S32760 PM refer to the solution annealed

and CCT for S32760 PM and the ZERON 100

ZERON 100 is a registered trademark of Rolled Alloys.

ATICORROSIONCONFERENCE.COM | CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS

Powder Metal Alloys for Oil Field Applications

45%. The tensile properties of solution

Figure 5. V-Notch impact toughness of the SDSS.

903 MPa (131 ksi) and 641 MPa (93 ksi),

ZERON 100 is a registered trademark of Rolled Alloys.

CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS | ATICORROSIONCONFERENCE.COM

Powder Metal Alloys for Oil Field Applications

Figure 7. Tensile properties of the Ni-Cr alloys.

(139 ksi) and 517 MPa (75 ksi), respectively.

ATICORROSIONCONFERENCE.COM | CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS

than conventional ATI 625 bar.

Powder Metal Alloys for Oil Field Applications

In the solution annealed condition, the

Figure 8. V-Notch impact toughness of the Ni-Cr alloys.

The ATI A625 PM and ATI 625M PM

ZERON 100 is a registered trademark of Rolled Alloys.

CORROSION SOLUTIONS CONFERENCE 2011 PROCEEDINGS | ATICORROSIONCONFERENCE.COM

Powder Metal Alloys for Oil Field Applications

is higher than that of the conventional ATI

PRE = %Cr + 3.3(%Mo + 0.5%W) + 16%N