In this paper a novel nickel-base, alumina forming alloy, Nikrothal PM 58 is introduced. Similar to the previously developed, ferritic, iron-base alloy Kanthal APMT, the alloy bases its corrosion resistance on the formation of an adherent surface alumina layer. They both have high creep strength, due to a dispersion strengthened microstructure from the powder metallurgical processing route. This unique combination of properties enables application temperatures ranging from 1472 F (800°C) to 2372 F (1300°C) and new possibilities to design high temperature components like mesh belts, furnace rollers and muffles. Mechanical and corrosion properties for Nikrothal PM 58 at 2012 F (1100°C) and 2192 F (1200°C) are presented and compared with other commercial high temperature alloys.

Extension of the service life for high temperature structural alloy RA602CA is the goal for the project described in this paper. The performance of alloy RA602CA and aluminized RA602CA in a gas carburization furnaces were studied for periods up to two years. Aluminizing treatments (widely used in aerospace industry, especially in turbine blade applications) were also studied in this project. Carbon has very low solubility in alumina, so aluminizing could be a good method for protecting RA602CA alloys. Microstructural development during the carburizing process is presented, and the degradation of chromium oxide as well as alumina oxides is identified. The weight gain of RA602CA compared to similar alloys is discussed.

In today’s competitive world of globalization and low cost manufacturing, it is essential that when engineering a job, to get it right the first time. This is especially true for capital equipment with a high cost and long expected lifetimes. It is even more critical, when the equipment must operate at high temperatures, and different potential for failure exists. In order to do it right the first time, engineers must understand high temperature properties, and incorporate these principles into the decision making process for materials. Some of these properties are intrinsic, some are affected by environment, and some are governed by thermodynamic and kinetic changes to the material at the operating temperatures. All must be considered.