Alloy 105,Nimonic 105 Other/Similar Specs,

Alloy 105,Nimonic 105 Wire,

Alloy 105 (Nimonic 105 Wire) - Introduction with Composition, Properties, Applications and Product Forms

Alloy 105, commercially known as Nimonic 105 and a high-strength member of the Nimonic superalloy family, is a nickel-chromium-cobalt-aluminum-titanium alloy celebrated for its exceptional ultra-high-temperature strength, creep resistance, and long-term oxidation stability. This alloy is specifically engineered to perform in extreme thermal environments—including prolonged exposure to temperatures above 900°C, cyclic mechanical stress, and harsh atmospheres like combustion gases—making it a critical material in aerospace, energy, and advanced industrial sectors where components must withstand extreme heat and heavy operational loads. It is available in a comprehensive range of forms to meet diverse industrial needs, including Bar (Round bar, Flat bar), Ribbon, Wire, Rods, Tube, Pipe, Foil, Plate, Sheet, Strip, and Forging Stock. Nimonic 105 Wire, in particular, stands out for its uniform high-temperature properties, flexibility, and precision, making it ideal for welding, thermal spray coatings, and intricate components in gas turbine hot sections and high-heat industrial systems. Below is a detailed overview of its chemical composition, key properties, practical applications, and available product forms.

Chemical Composition

The precisely balanced chemical composition of Alloy 105 (Nimonic 105 Wire) is the foundation of its exceptional ultra-high-temperature performance and corrosion resistance. The typical composition (by weight) is as follows:

Nickel (Ni): 58-62% (the primary matrix element, delivering structural stability at ultra-high temperatures and serving as the base for strength-enhancing gamma-prime (γ’) precipitates)

Chromium (Cr): 14-16% (forms a dense, adherent chromium oxide layer, ensuring superior oxidation and sulfidation resistance at temperatures up to 1100°C)

Cobalt (Co): 14-16% (enhances high-temperature strength, creep resistance, and thermal fatigue performance by stabilizing the alloy matrix and reducing precipitate coarsening)

Aluminum (Al): 4.5-5.1% (works with titanium to form high-volume fractions of gamma-prime (γ’) intermetallic precipitates, the core contributor to the alloy’s ultra-high-temperature strength)

Titanium (Ti): 2.2-2.8% (combines with aluminum to form gamma-prime precipitates, significantly boosting creep rupture strength and maintaining mechanical integrity at elevated temperatures)

Carbon (C): 0.06-0.12% (forms fine carbides with chromium and titanium, reinforcing grain boundaries and improving creep resistance without compromising ductility)

Iron (Fe): ≤ 1.0% (minimized to preserve ultra-high-temperature properties and prevent degradation of oxidation resistance)

Silicon (Si): ≤ 0.4% (aids in deoxidation during manufacturing and supports the formation of a stable oxide layer for enhanced long-term oxidation resistance)

Manganese (Mn): ≤ 0.5% (enhances hot workability, enabling fabrication into diverse product forms like wire, foil, and strip)

Boron (B): 0.004-0.010% (strengthens grain boundaries, reducing creep rupture susceptibility and improving ductility at ultra-high temperatures)

Zirconium (Zr): 0.06-0.16% (stabilizes carbides, refines microstructure, and further enhances creep resistance and thermal fatigue performance)

Phosphorus (P): ≤ 0.02% (strictly limited to avoid grain boundary embrittlement under high stress or thermal cycling)

Sulfur (S): ≤ 0.01% (minimized to ensure good ductility and resistance to stress corrosion cracking in harsh environments)

This engineered blend—focused on nickel, chromium, cobalt, and precipitate-forming elements—delivers Alloy 105’s signature balance of ultra-high-temperature strength, creep resistance, and oxidation stability, critical for the most demanding thermal applications.

Key Properties

Alloy 105 (Nimonic 105 Wire) and its various forms exhibit exceptional properties that make them indispensable in ultra-high-temperature, corrosive, and cyclic-stress environments:

Mechanical Properties (solution-annealed and aged condition):

Tensile strength: 1200-1350 MPa (174,000-195,800 psi) at room temperature; retains ~520 MPa (75,400 psi) at 950°C (1742°F)

Yield strength (0.2% offset): 800-900 MPa (116,000-130,500 psi) at room temperature; retains ~450 MPa (65,300 psi) at 950°C (1742°F)

Elongation (in 50 mm): 16-26% at room temperature; 11-19% at 950°C (1742°F) (excellent ductility for forming complex components like turbine blades and combustion liners)

Reduction of area: 32-42% (superior toughness, resisting fracture under ultra-high-temperature cyclic stress and mechanical impact)

Hardness: 37-42 HRC (Rockwell hardness) at room temperature; maintains ~27 HRC at 950°C (1742°F)

High-Temperature Properties:

Continuous service temperature: Up to 1020°C (1868°F) (a top performer for precipitation-strengthened nickel alloys, with long-term stability in air and industrial combustion atmospheres)

Creep resistance: Exceptional resistance to creep deformation—1000-hour creep rupture strength of ~260 MPa (37,700 psi) at 950°C (1742°F) and ~130 MPa (18,850 psi) at 1020°C (1868°F)

Thermal fatigue resistance: Withstands repeated thermal cycling (e.g., 180°C to 980°C) without cracking, critical for components like gas turbine combustion liners and turbine vanes

Oxidation resistance: Superior resistance to oxidation and scaling in air at temperatures up to 1120°C (2048°F), with minimal weight gain (≤ 7 mg/cm²) even after 5000 hours at 1020°C (1868°F)

Corrosion Resistance:

General corrosion: Excellent resistance to high-temperature combustion gases (including jet fuel and natural gas byproducts), industrial steam, and aggressive organic/inorganic chemicals

Sulfidation resistance: Resists sulfidation in sulfur-containing environments (e.g., coal-fired power plants, waste incinerators) up to 920°C (1688°F)

Pitting/crevice corrosion: Good resistance to pitting in moderate chloride environments (e.g., aerospace components exposed to marine atmospheres and humidity)

Carburization resistance: Maintains integrity in mild-to-moderate carburizing atmospheres (e.g., industrial heat-treating furnaces) by limiting carbon absorption and preventing excessive carbide growth

Physical Properties:

Density: 8.1-8.3 g/cm³ (0.293-0.300 lb/in³)

Thermal conductivity: 10.8-12.8 W/(m·K) at 20°C (68°F); increases to 23-26 W/(m·K) at 1000°C (1832°F) (efficient heat dissipation at ultra-high temperatures, reducing thermal stress in components)

Coefficient of thermal expansion: 12.8-14.8 μm/(m·K) (20-1000°C) (controlled expansion to minimize thermal stress in assembled systems like turbine casings)

Modulus of elasticity: 200-210 GPa (29,000-30,500 ksi) at room temperature; decreases to ~138 GPa (20,000 ksi) at 1000°C (1832°F)

Melting point: 1350-1400°C (2462-2552°F)

Product Forms

Alloy 105 (Nimonic 105 Wire) is manufactured in a diverse range of forms to accommodate specialized ultra-high-temperature and corrosion-resistant applications:

Bar: Available as Round bar (diameters from 10 mm to 190 mm) and Flat bar (thickness 5 mm to 95 mm, width 20 mm to 480 mm), ideal for machining into turbine components, valve stems, and high-temperature fasteners.

Ribbon: Thin, flat strips (thickness 0.1 mm to 1 mm, width 5 mm to 95 mm) used in thermal spray coatings, high-temperature electrical heating elements, and flexible seals for industrial furnaces.

Wire: Nimonic 105 Wire (diameters 0.5 mm to 6 mm) offers uniform ultra-high-temperature properties, suitable for welding (TIG/MIG), thermal spray applications, and precision heating coils in high-heat industrial systems.

Rods: Solid cylindrical rods (diameters 3 mm to 48 mm) used for gas tungsten arc welding (GTAW) filler metal and manufacturing small ultra-high-temperature components (e.g., sensor supports, turbine blade pins).

Tube and Pipe: Hollow forms (outer diameter 6 mm to 95 mm, wall thickness 0.5 mm to 9.5 mm) for high-temperature fluid transport (e.g., gas turbine fuel lines, heat exchanger tubes in power plants).

Foil: Ultra-thin sheets (thickness 0.02 mm to 0.1 mm) used in high-temperature gaskets, heat shields for aerospace electronics, and thin-film thermal barriers.

Plate and Sheet: Flat forms (plate: thickness 3 mm to 48 mm; sheet: 0.3 mm to 3 mm) for fabricating combustion liners, furnace walls, and aerospace heat exchangers.

Strip: Narrow, flat strips (thickness 0.1 mm to 2 mm, width 3 mm to 48 mm) for precision components like turbine seals, heat exchanger fins, and electrical contacts in ultra-high-temperature environments.

Forging Stock: Billets and ingots for hot forging into complex shapes (e.g., gas turbine disks, turbine blades, industrial furnace doors) requiring exceptional ultra-high-temperature strength.

Applications

The exceptional ultra-high-temperature strength, creep resistance, and oxidation stability of Alloy 105 (Nimonic 105 Wire) across its various forms make it a critical material in industries requiring performance under the most extreme thermal conditions:

Aerospace and Aviation:

Gas turbine engines: High-pressure turbine blades, vanes, combustion liners, and afterburner components (from plate, forging stock, and sheet) withstanding temperatures up to 1020°C (1868°F).

Aerospace fasteners: Ultra-high-temperature bolts, studs, and rivets (from bar and rod) securing engine hot-section components exposed to cyclic thermal stress and vibration.

Rocket propulsion systems: Combustion chamber liners and nozzle components (from forging stock, tube, and sheet) resisting extreme heat from rocket fuel combustion.

Energy and Power Generation:

Gas/steam turbines: Hot-section components (from plate, forging stock, and bar) for industrial power turbines, enduring ultra-high temperatures and cyclic loading.

Waste-to-energy plants: High-temperature combustion chamber liners and heat recovery components (from sheet and plate) withstanding corrosive flue gases and temperatures above 920°C.

Nuclear power: Advanced heat exchanger tubes and structural components (from tube and plate) resisting radiation and high-temperature coolants in next-generation reactors.

Industrial and High-Temperature Processing:

High-temperature furnaces: Furnace walls, heating elements, thermocouple sheaths, and hearth plates (from wire, plate, and tube) operating in air or inert atmospheres up to 1120°C (2048°F).

Chemical processing: Reactor liners, catalyst support grids, and heat exchangers (from plate, tube, and bar) withstanding aggressive chemicals (e.g., strong acids, molten salts) at elevated temperatures.

Metallurgical processing: High-temperature heat treatment fixtures, molten metal handling parts, and annealing furnace components (from bar, forging stock, and plate) resisting wear and ultra-high heat.

Defense and Specialized Engineering:

Military aircraft engines: Critical hot-section components (from forging stock and plate) requiring ultra-high-temperature durability in combat environments.

Hypersonic vehicles: Heat shields and structural components (from plate and forging stock) enduring aerodynamic heating up to 1020°C (1868°F).

Naval systems: Advanced marine gas turbine components (from plate, tube, and bar) resisting seawater corrosion and high temperatures.

Specialized Applications by Form:

Wire: Welding filler metal for joining ultra-high-temperature components, thermal spray coatings for wear and corrosion protection, and precision heating coils.

Plate/Sheet: Combustion liners, furnace walls, and aerospace heat exchangers requiring large, flat ultra-high-temperature surfaces.

Tube/Pipe: High-temperature fluid transport (fuel lines, heat exchanger tubes) and thermocouple protection sheaths in corrosive environments.

Forging Stock: Complex turbine disks, turbine blades, and heavy-duty industrial furnace components requiring custom shapes and exceptional ultra-high-temperature strength.

In summary, Alloy 105 (Nimonic 105 Wire) — available in forms from Bar and Wire to Plate and Forging Stock — delivers exceptional ultra-high-temperature strength, creep resistance, and oxidation stability. Its diverse product forms enable tailored solutions across aerospace, energy, industrial, and defense sectors, establishing it as a critical material in applications requiring reliable performance under the most extreme thermal conditions.

Packing of Standard Packing: 

Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and steel drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 1172 gallon liquid totes Special package is available on request.