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How often has your race ending catastrophe been the result of a measly piece of loose hardware or similar failure? All too often we hear of disasters caused by some two-bit piece of hardware or simple preventable prep error. At the root of many of these issues is a procedural misstep or forgotten bolt.
Among the best racers and engine builder are perfect prep practices that promote performance, provided you pay attention in class. So enough alliterative humor let’s get to it! You have probably heard of safety wire or “lockwire” and have most definitely seen it while wandering in the pits. Locking fasteners like nylocs, split washers, wavy washers, thread locking compound etc. all have their place in automotive or aviation usage but safety wire trumps them all.
Even if you consider yourself an A and P-trained safety wire guru, take a seat and brush up, our Canadian jet mechanic friend AgentJayZ takes a perfectionist approach to showing us how it’s done — and done right.
Before we talk about the technique lets examine the concept and sense of insurance safety wire offers. While it is common place to “witness mark” hardware after it receives a final torque it is easy to miss, forget, or accidentally mark an un-torqued bolt after looking away due to a distraction. Safety wire is visible re-assurance that the fastener has been checked, and verified, and cannot escape unless the wire fails.
Added benefits of safety wire come into their own when heat is applied — while standard wire is generally 304 stainless and adept to standing up to most harsh environments, Inconel wire can be used for the most extreme high temperature applications. While nyloc hardware melts at the first site of exhaust heat or flame, safety wire stands up to the strain.
A few things worth remembering — cut a piece longer than you think you need, eight to ten twists per inch, use the right tools if you have access to them, wire hardware the correct direction whether it’s right of left hand threads, and not mentioned by Jay but if drilling your own six-point bolt heads for wire, a jig is necessary to do it properly.
It is common to find fasteners drilled through the flats, but ideally the bored hole should run corner to corner — a challenging operation without the right jig. Many aviation hardware sources may offer pre-drilled bolts to save you time.
Safety wire makes for power in numbers — as more bolts are connected the safety net grows, one bolt prevents the loosening of the next and so on. Of course this effect is not without considerable time and effort but what is at stake? Your prized vehicle, engine, and potentially life?
Let’s not dismiss the aesthetic merit of safety wire. In the circles of those in the know — safety wire is mark of pride of craftsmanship, care, and attention to detail. This gearhead bling is purely utilitarian but carries with it a cultural association, one of performance and precision. Learn to safety wire, impress you peers and tech inspectors, raise your standards of prep — you’ll thank yourself in the future.
When you need a metal with outstanding physical properties that can withstand extreme conditions, Inconel alloys are often the best choice.
Ulbrich offers a variety of nickel superalloys that will stand up to just about any high-temperature or oxidation element you throw at it.
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Alloys are created by combining two or more substances to create a product with more desirable properties than any of its parts. Alone, pure metal is often soft and prone to corrosion.
Inconel superalloys are one alloy class that has proven valuable in applications like jet engines, offshore marine platforms, and automotive parts.
So, what exactly are Inconel superalloys?
Basically, these compounds are nickel-based alloys that contain chromium and iron. Together, the elements form supermetals with traits that are highly sought after and difficult to find. These characteristics include high corrosion resistance and great performance in extreme temperatures, which are ideal for heat treatment.
It’s important to note that Inconel is a registered trademark of Special Metals Corporation. So, if you’re purchasing Inconel 625, you are buying their product. When this alloy is produced and sold generically, it is often called Nickel Alloy 625. This naming convention follows for the entire family of Inconel alloys and their generic counterparts.
Inconel material is known for oxidation resistance, creep resistance, corrosion resistance, and high strength in extreme temperatures in real-world applications — and when tested in simulations run by supercomputers.
Additionally, Inconel alloy can be produced in a small grain size, which increases its yield strength and physical properties. When milled properly, an alloy like Inconel x 750 can withstand over 1,300° Fahrenheit (704° Celsius).
You’re already aware of the high strength and corrosion resistance that Inconel superalloys possess in elevated temperatures. Here’s a look at some additional properties that make them special.
Superalloys earn their name by being more versatile than their parent metals, and thus more valuable to their users. In general, superalloys have incredible high-temperature strength and resist the extreme environments they’re exposed to. They also have a smaller grain boundary than regular alloys, which prevents them from becoming brittle.
In other words, when more typically used metals aren’t durable enough, superalloys can get the job done.
Inconel material is known for performing well, even as it reaches its melting point. Its microstructure and physical properties allow an Inconel alloy to have excellent corrosion resistance and oxidation resistance compared to other metals.
These special properties are why Inconel Strip & Shaped Wire are widely used by stampers, and manufacturers producing parts for a wide range of industries. It's also one of the most common powdered metals used in additive manufacturing.
Many industries requiring extremely strong material tend to gravitate toward metals like a titanium or stainless steel alloy. However, thanks to their versatility, Inconel material and other superalloys are gaining traction and are often the best choice for certain applications.
Inconel alloys are commonly used in applications where thermal expansion occurs due to high temperatures. Thanks to their extreme temperature resistance, Inconel material is a core component of automotive parts, the aerospace industry, marine applications, and the oil and gas industry.
Each Inconel alloy has its own strengths and characteristics, so it’s important to understand the differences in order to choose the right one for your application.
Although a nickel-based superalloy like Inconel has all sorts of applications, there are different types of Inconel alloys—and each has its own unique properties. Here are a few of the Inconel superalloys that Ulbrich works with:
Learning the various applications helps you understand the advantages of Inconel superalloys. So, are there any disadvantages?
Like any material, Inconel superalloys have a wide range of advantages—but also a few disadvantages. If you’re not sure which material is best, just rely on the Ulbrich Team to help you through!
The elements mixed to produce superalloys create an alloy with premium physical and mechanical properties. They become stronger. They’re more resistant to corrosion, oxidation, and high temperatures. Thus, they’re invaluable to industries like power generation.
Inconel alloys tend to be more expensive than basic steel or iron. However, their physical properties far outweigh cheaper alternatives. For example, you can build a bridge with steel, but you wouldn’t trust it to hold up to the extreme environment of a gas turbine. That’s a much more intense, specialized application better suited for Inconel material!
Cost can be one disadvantage of Inconel superalloys.
Another potential downside of a nickel alloy is how challenging it can be to work with. Inconel's high strength and excellent corrosion resistance properties make it an ideal material for use in extreme environments. However, these same properties also make it challenging to stamp and deep draw, as it can be prone to cracking, wrinkling, or tearing during manufacturing processes.
In addition, Inconel's high hardness can cause excessive wear on stamping or deep drawing tools, leading to shorter tool life and increased manufacturing costs. Therefore, special care must be taken when stamping or deep drawing Inconel to ensure that the final product meets your desired specifications.
As durable as Inconel material is under pressure, if you’re working with gas turbines or internal combustion engines, you might also consider a Nimonic alloy.
Like Inconel, Nimonic is a nickel superalloy discovered through materials science that resists heat and corrosion. Both compounds are popular across many industries that require great performance under extreme conditions. However, there are some key differences, including:
Choosing the right superalloy for your unique application is vitally important, so let the precision metal experts help!
As the leader in precision metals since 1924, Ulbrich Stainless Steel has the expertise you need to choose the right Inconel superalloy for your unique application. We offer a variety of nickel-based alloys in a range of shapes and sizes, and we’re here to guide and educate you on each of them.
Contact us to learn more about the products we offer—and the cutting-edge technology that we’ll use to customize your material's properties.
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