Proceedings of

ASME Turbo Expo 2001

June 4-7, 2001, New Orleans, Louisiana, USA

2001-GT-0540

MATERIALS SELECTION FOR HIGH TEMPERATURE METAL RECUPERATORS

Mark A. Harper Gaylord D. Smith

Special Metals Corporation Special Metals Corporation

Philip J. Maziasz Robert W. Swindeman

Oak Ridge National Laboratory Oak Ridge National Laboratory

ABSTRACT include a favorable coefficient of thermal expansion, high

One method of increasing the efficiency of gas turbines is thermal conductivity, high temperature strength, environmental
the use of a heat exchanger to capture energy from the exhaust resistance, and good fabrication characteristics. Currently, the
gas of the system. In particular, prime-surface and plate-fin 347 stainless steel and the 625 alloy are the two most commonly
recuperators are used to simply transfer heat from the turbine used alloys for recuperator construction. This paper will
exhaust to the air leaving the compressor discharge and entering discuss the material properties of a range of Ni-containing
the combustor. In so doing, less fuel is required to heat the inlet alloys, along with a relative cost comparison, for possible use as
air to the final combustion temperature. Desirable material recuperator materials in advanced microturbines.
requirements include a low coefficient of thermal expansion,
high thermal conductivity, high temperature strength, adequate
environmental resistance and good fabrication characteristics. MATERIAL PROPERTIES
For most industrial applications the 300 and 400 series stainless General
steels are currently used for the material of construction. This Table 1 shows the nominal composition of the 347, 840,
paper discusses the properties of higher Ni-containing alloys 800H, 864, 803, 625, and 617 alloy. These alloys range in Ni
and their possible use as recuperator materials for advanced content from 12 wt% for the 347 alloy up to 61% in the 625
microturbines currently being developed. alloy. Also, the 617 alloy contains 12.5% Co and 9.5% Mo. By
using the cost of the 347 alloy as a baseline, Table 2 gives a
INTRODUCTION relative cost comparison for these materials and shows the
The use of recuperators in industrial gas turbines is expense of purchasing an alloy with greater Ni content and
increasing, with plate-fin and prime-surface recuperators the increased high temperature properties. The relative costs for
designs most often used. Plate-fin recuperators have drastically these materials ranges from an increase of about 1.5 to 2 times
decreased the size requirement for a turbine heat exchanger by the cost of the 347 alloy for the 840 material, up to 7 times the
increasing the compactness and heat transfer coefficient for the cost for the 617 alloy. It should be noted that an actual cost
unit1. In addition, prime-surface recuperators use a stacking of comparison between these alloys would be dictated by factors
corrugated sheets to form the air and exhaust gas cells. This such as the current price of nickel, product form, availability,
design eliminates furnace brazing and the need for secondary and quantity purchased. Based on Tables 1 and 2, it is apparent
surfaces such as fins, and is currently used in the AGT 1500 that a range of alloys exist between the 347 and 625 alloys, both
engine in the U.S. Army M1 tank1. Both types of units can from a chemical composition and cost viewpoint.
exhibit effectiveness levels of greater than 90% and can be The 840 alloy is typically used for heater element sheathing
manufactured with high volume production methods. and has good high temperature oxidation resistance but was not
The U.S. Department of Energy has recently awarded five designed for high strength at elevated temperatures. The 800H
new contracts for the design and development of advanced alloy possesses very good high temperature strength and
microturbines that will achieve efficiencies of 40%. To obtain oxidation resistance and is used extensively in the hydrocarbon
these higher efficiencies, hot sections will have to operate at processing and industrial heating industries where long-term
higher temperatures, thus resulting in higher temperatures at the exposure to elevated temperatures and corrosive environments
recuperator inlet. Property requirements for a recuperator alloy are required. The 864 alloy is a relatively new alloy that was

1 Copyright © 2001 by ASME

specifically developed for automotive exhaust systems2. This traditional 625 alloy. The 625LCF alloy has a lower inclusion
material exhibits excellent fatigue properties, thermal stability, content (see Table 4), finer grain size, and increased yield
and resistance to hot salt corrosion. As an upgrade to the 800H strength (see Table 5), all of which result in the improved
alloy, the 803 alloy was developed for application in severe fatigue properties. A plot showing a comparison of the low
high temperature oxidation and carburization environments. cycle fatigue strength for sheet samples (0.008 in) between the
One of the main applications for this alloy is ID-finned traditional alloy 625 and the 625LCF is shown in Figure 3.
pyrolysis tubing in ethylene furnaces. The 625 alloy has a wide Figure 4 also shows a comparison of the fatigue life for a range
range of applications and is one of the most versatile Ni-base of alloys at 1000°F.
alloys in use today. It possesses both aqueous and high
temperature corrosion resistance and exhibits excellent high Thermal Stability
temperature strength. By refining the alloying, melting, and Also important for long-term service and repairability is the
processing of the 625 alloy, the 625LCF alloy was developed thermal stability of a material. Figure 5 shows the room
for use as a fatigue-resistant, bellows-quality material, and is temperature ductility of the 800H, 864, 803, 625, and 617
currently used in the chemical process and aerospace industry. alloys after exposure at various temperatures for 1,000 hours.
Both of these alloys exhibit a significant drop in ductility after The 803 and 800H alloys exhibit a ductility drop in the 1200°F
exposure to temperatures between 1200 to 1600°F and thus are range, but still show about 25 and 30 % tensile elongation. The
not typically recommended for use above 1200°F for this 625 and 864 alloys show a ductility drop in the 1400°F range
reason. The 617 alloy was designed for use in the aerospace with the 625 alloy showing tensile elongation of less than 20%.
industry and is currently used as ducting, combustion cans, and Again, this alloy is typically not recommended for temperatures
transition liners in both air- and land-base gas turbines. above 1200°F for this reason.

Mechanical Properties Physical and Environmental Properties

Figure 1 is a plot of the yield strength, ultimate tensile A graph of the coefficient of thermal expansion for these
strength, and tensile ductility for the alloys mentioned above at alloys is shown in Figure 6. As expected, the higher Ni-
1200, 1400, 1600, and 1800°F. As shown in Figure 1(a), at containing alloys have a significantly lower thermal expansion
1200°F the 840, 800H, and 864 alloys exhibit lower yield than the 347 stainless steel. If a minimum coefficient of thermal
strength than the 347 stainless steel, whereas the 803, 625, and expansion (CTE) is required, then the 625 and/or 617 alloys
617 alloys possess higher strength. At 1400°F, again the 840 may a candidate material. However, if a matching CTE with an
and 800H alloys have less strength than the 347 material, but austenitic stainless steel is required, then the 800H, 803, and/or
the 864 alloy, along with the 803, 625, and 617 alloys are 864 alloys may be a more suitable choice.
stronger. At 1600°F, all of the alloys except the 840 material Regarding high temperature oxidation resistance, Figure 7
possess higher strength than the 347 alloy. At 1800°F, data was shows the results from an oxidation in air + 5% H2O test
not available for the 347 alloy. Similar to the yield strength of conducted at 1650°F. As shown by the large weight loss for the
these materials, the 840 alloy exhibits a lower tensile strength 300 series stainless exposed in this test, the higher Ni-
than the 347 alloy, however the same does not hold true for the containing alloys provide a marked improvement in high
tensile strength of the 800H, 864, 803, 625, and 617 alloys (see temperature oxidation resistance.
Fig. 1(b)).
Stress rupture data is shown in Figure 2, with the stress Fabrication
required to cause rupture in 1,000 hours plotted for the alloys at The fabrication characteristics of an alloy can be one of the
1200, 1400, 1600, and 1800°F. Similar to the tensile strength most critical factors in whether or not an alloy is chosen for
rankings shown in Figure 1(b), all of the alloys except the 840 recuperator service. Resistance to deformation, typically
material, possess greater creep strength than the 347 alloy at expressed in terms of hardness or yield strength, is a primary
1200 and 1400°F. Also, the 625 alloy exhibits greater creep consideration in cold forming, and although the yield strength
strength than the 617 alloy at the lower temperatures (1200 and for some of the alloys discussed above is relatively high, when
1400°F), but the reverse is true at the higher temperatures (1600 properly annealed these materials have a substantial range
and 1800°F). In addition to the materials discussed thus far, between the yield and tensile strength. This range is the plastic
new alloy development efforts have provided a substantial region of the material and all cold forming occurs within the
increase in the creep resistance of the 803 alloy. Table 3 shows limits of this region. Therefore, these high-strength alloys only
the stress rupture properties of a modified 803 alloy (i.e. the require stronger tooling and more powerful equipment for
803 alloy with specific micro-alloying additions) in which a ten- successful cold forming. The degree of strain hardening for a
fold increase in the rupture life has been demonstrated at given alloy is also an important characteristic with respect to
1500°F and 10 ksi. Efforts in this area are thus promising and fabrication. Typically, the strain-hardening rate increases with
continuing. increasing solid-solution strengthening element content. Thus
In applications and/or components where fatigue resistance the more complex an alloy, the faster it will strain harden during
is required, the 625LCF alloy has a distinct advantage over the

2 Copyright © 2001 by ASME

cold forming. And finally, the amount of springback exhibited 840 60 20 20 -- -- -- -- --
by an alloy is proportional to its modulus of elasticity. Since the 800H 46 32.5 21 -- -- 0.3 – 1.2 --
modulus of elasticity for the high-Ni alloys is relatively high, a 864 39 34 21 4.2 -- -- 0.6 --
small amount of springback may occur during cold-forming 803 37 35 25 -- -- 0.3 – 1.2 --
operations. However, compared to the 347 alloy, the 840, 625/ 2.5 61 21.5 9 -- -- -- 3.6
625LCF
800H, 864, and 803 alloys have a similar modulus of elasticity
617 1.5 52 22 9.5 12.5 1.2 -- --
(see Figure 8). Only cold forming the high-Ni alloys such as
625 and 617, would one expect more springback compared to
an austenitic stainless steel. Table 2
Relative Cost Comparison of Various Ni-Containing Alloys
SUMMARY Alloy Relative Alloy Cost
Requirements for recuperator materials are stringent, with 347 1
high temperature strength, oxidation resistance, and good 840 1.5 – 2
fabrication characteristics being necessary. Currently the 347 800H 2.5
stainless steel and the 625 alloy are used for recuperator 864 3
materials. With respect to chemical composition and cost, a 803 3
range of commercial alloys exist between the 347 and 625 625 / 625LCF 5
alloys that may have use as a recuperator material in advanced 617 6.5 – 7
microturbines.
Table 3
ACKNOWLEDGMENTS Stress Rupture Data for the 803 and 803 Modified Alloys at
Joint research between Special Metals and the Oak Ridge 1500°F and 10 ksi
National Laboratory was sponsored by the Office of Fossil Rupture %
Energy, Advanced Research Materials Program and by the Alloy Condition Life (h) Elong.
Office of Power Technology, Microturbines Materials Program, 803 S.A.* 110 35
U.S. Department of Energy, under contract DE-AC05- 803 Mod. 1 S.A. 66 56
00OR22725 with UT-Battelle, LLC. 803 Mod. 1 S.A. + Treatment 1 214 85
803 Mod. 1 S.A. + Treatment 2 725 50
803 Mod. 2 S.A. 109 60
REFERENCES 803 Mod. 2 S.A. + Treatment 2 1460 57
1. McDonald, C.F., “Gas Turbine Recuperator * S.A. = Solution Annealed
Technology Advancements” in Proceedings of
Materials Issues in Heat Exchangers and Boilers, Table 4
Total Residue and Precipitate Phases in Annealed Alloy 625
Institute of Materials, London, 1997, pp. 337- and 625LCF
369. Melt Total (Nb,Ti)(C,N TiN
2. Crum, J.R., Smith, G.D., and Flower, H.L., Paper Method Residue ) (wt%)
743, CORROSION/98, March 1998, NACE, (wt%) (wt%)
Houston, TX. 625
AOD + ESR 0.38 0.30 0.08
625LCF
VIM + ESR 0.09 0.06 0.03
AOD + ESR => Air melt with Argon-Oxygen Desulfurization +
Electroslag Remelt

Table 1 VIM + ESR => Vacuum Induction Melt + Electroslag Remelt

Nominal Composition of Various Ni-Containing Alloys
Alloy Fe Ni Cr Mo Co Al Ti Nb
347 71 12 18 -- -- -- -- 10 x
C

3 Copyright © 2001 by ASME

 150
Table 5 347
Tensile Properties at 1000°F of Annealed Alloys 625 125
840
800H
(2145°F) and 625LCF (1950°F) 864

% Elongation
803
ASTM 100 625
617
Alloy Grain 0.2% YS UTS % 75
Size # (ksi) (ksi) Elong.
625 8.0 38 104 45 50
AOD + ESR
625LCF 9.0 54 123 44 25

VIM + ESR 0
1200 1400 1600 1800
Temperature (°F)

(c) tensile elongation

Figure 1. (a) Yield strength, (b) ultimate tensile strength,
50 and (c) tensile elongation for various Ni-containing alloys at
1200, 1400, 1600, and 1800°F.
0.2% Yield Strength (ksi)

347
840
40 800H
864
803
625
30 617
50
347
20 840
40 800H
864
803
Stress (ksi)
10 625
30 617

0
1200 1400 1600 1800 20
Temperature (°F)
10

(a) yield strength 0

1200 1400 1600 1800
Temperature (°F)

Figure 2. Stress to cause rupture in 1,000 hours for various

Ultimate Tensile Strength (ksi)

125 Ni-containing alloys at 1200, 1400, 1600, and 1800°F.

347
840
100 800H
864
803
625
75 617

50

25

0
1200 1400 1600 1800
Temperature (°F)

(b) tensile strength

4 Copyright © 2001 by ASME

 70
617

Tensile Elongation (%)

60
800H
50

803
40

30
864
20
625
10
1000 1200 1400 1600
Temperature of Exposure (°F)

Figure 5. Room temperature ductility for various Ni-

containing alloys after exposure at elevated temperatures
Figure 3. Comparison of low-cycle fatigue strength for for 1,000 hours.
alloy 625 and 625LCF sheet at temperatures between 900 to
1200°F.

Thermal Expansion (10-6 in/in-°F)

1.0 12
Total Strain Range (%)

321SS INCONEL alloy 625LCF 11

0.8
347
0.6 10 864
840
800H
INCONEL alloy 601 9 803
0.4

8 625
0.2
INCOLOY alloy 800 617

7
0.0
2
10 3 4 5 6 7 800 1000 1200 1400 1600 1800 2000
10 10 10 10 10
Temperature (°F)
Cycles to Failure

Figure 4. Fatigue life of various Ni-containing alloys under

fully reversed axial strain at 1000°F. Figure 6. Plot of the coefficient of thermal expansion
for various Ni-containing alloys.

5 Copyright © 2001 by ASME

 10
Weight Change (mg/cm²) 864
800
0
840
625
-10 803

-20

-30

-40 321

-50
0 500 1000 1500 2000 2500
Time of Exposure (h)

Figure 7. Weight change for various Ni-containing

alloys exposed to air + 5% H2O at 1650°F.
Modulus of Elasticity (106 psi)

35

30

25

20
347 840 800H 864 803 625 617

Alloy

Figure 8. Plot of the modulus of elasticity for various

Ni-containing alloys at room temperature.

6 Copyright © 2001 by ASME