White paper

Exotic alloys
The answer for demanding
spring applications

By John King, Manager of Engineering, Atlantic Spring

Keith Thomas, Vice President & General Manager, MW Industries
Exotic alloys: the answer for demanding spring applications White paper

If you have a demanding application that is used in high-temperature, corrosive or other harsh environments,
manufacturing your spring or fastener out of an “exotic” alloy may provide the performance-driven solution
you require. Exotic alloy solutions have been around for decades and continue to find their way into a variety
of applications where durability, reliability and longevity are the main goals.
However, the key is to understand performance attributes, cost and trade-offs when embarking down the
decision-making path.
For example, some exotic alloys are capable of sustaining temperatures in the 650 to 1,400 degree Fahrenheit
range. Others are resistant to chlorine, sulfuric, phosphoric and nitric acids. Each exotic alloy has its own
attributes which has to align with the application objectives in order for the execution to be successful.
We’ve prepared a list below of the most commonly-used exotic alloys for springs, accompanied by attributes
and considerations, to help narrow down choices for your next challenge.

A286
Description. A-286 (also known as A-286 stainless steel) is an iron/nickel/chromium super alloy appropriate
for applications that require high tensile strength, oxidation and corrosion resistance.
Economics. Developed in the late 1960s as an alternative for Inconel® X-750which had become expensive.
Because it has one-third the nickel content of Inconel® X-750, it is an attractive alternative. However, it is not as
readily available for spring wire applications.
Applications: Most frequently used for springs used in valves subjected to high temperatures.
Alternative material for: Inconel X-750. However, if higher corrosion resistance is desired, Inconel X-750 is a
better choice.

Where can you turn for exotic alloy assistance?

Design engineers are being challenged like never before to create next generation products in a
compressed timeline. Designs are becoming more complex, while at the same time, development cycles
are shrinking. Additionally, companies are losing specializing knowledge, faster than they are building it.
Simply said, professionals being asked to do more with less.
In the pursuit of specifying the right type of spring for your application, you may run into a knowledge
stumbling block. For example, you may have a basic knowledge of exotic alloys, but your experience may
not be deep enough to give you confidence that you are making the right decision.
That’s where MW Industries comes into the picture.
With our far-ranging expertise in metallurgy and hundreds of “experience years” in spring manufacturing,
we help design engineers all day long to pick the right metal or alloy for specific applications—some of
which are extremely challenging.
In addition to manufacturing springs using exotic alloys, we continuously expand our knowledge base
by interacting frequently with alloy suppliers. We learn from their experts so that we are continuously up
to date on technology, availability, pricing and other key attributes that impact our ability to provide you
with the right solution.
That’s why MW Industries is your ideal partner for spring solutions made from exotic alloys.

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Exotic alloys: the answer for demanding spring applications White paper

Beryllium copper
Description: Beryllium copper is a copper alloy with up to 3% beryllium and sometimes includes other
elements. It combines high strength with non-magnetic and non-sparking qualities. It has excellent
metalworking, forming and machining properties.
Beryllium copper is known for its ability to withstand corrosion. Additionally, it has a low torsion modulus
which enables it to deliver more force compared to steel in a restrained area. Because it is formed soft and
then becomes hard after heat treating, the material is very effective in spring applications.
Beryllium copper also has great electrical connectivity which might be desired in certain applications.
Alloy type used in springs: Beryllium copper 172
Economics: It costs approximately 2.5 times that of stainless steel, but is two-thirds the cost of Inconel.
Applications: Anything that needs long-life corrosion-resistance to salt water. Examples include springs used
in nuclear submarine hatch covers and in valves for off shore oil rigs.
Alternative material for: Selected for its unique performance properties.
Cons: Low strength in compression applications.

Elgiloy
Definition: Elgiloy® is considered a “super-alloy” consisting of cobalt, chromium, nickel, iron, molybdenum and
manganese. It’s used to make springs that are corrosion resistant as well as provide high strength, ductility
and good fatigue life. Elgiloy is highly resistant to sulfide stress corrosion cracking and pitting, and can operate
at temperatures up to 850°F.
MW Industries uses: Wire or strip.
Applications: Oil and gas in a wellbore environment is probably one of the largest applications for Elgiloy
springs because the alloy is highly resistant to corrosion cracking in seawater. It is also used in aerospace
applications where high strength and temperature resistance is required. Other applications include springs
for medical and dental products.
Alternative material for: Inconel X-750, if upgraded
performance is required. Elgiloy will provide more strength in a Rene 41
small space than Inconel X-750.
Heat Resistant Inconel
Cons: Cost can be prohibitive if the performance requirements
do not merit its use.
Exotic Alloys Elgiloy
Limitations: Three-quarters of an inch is the maximum wire Titanium
size. In strip form, you are limited to 1/16th of an inch thickness
and 12 to 14 inches wide.

Hastelloy
Definition: Hastelloy® alloys provide excellent resistance to chlorides and acids.
MW Industries uses: Hastelloy C276 is most commonly used to manufacture springs.
Applications: Food processing, petrochemical, marine applications and water treatment valves.
Alternative material for: Improved performance compared to 300 series stainless steel. Less expensive than
Elgiloy.
Cons: Narrow range of product forms used for spring applications. Limited tensile strength.

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Exotic alloys: the answer for demanding spring applications White paper

How MW Industries solved a spring problem with Hastelloy

A food processing plant was using equipment to peel and chop fruits and vegetables. During peak season,
the stainless steel springs on that equipment were being replaced weekly. This was causing a significant
amount of downtime and related labor to replace.
MW Industries examined the production process and discovered the problem. Bleach was being used
at the end of the shift to clean the equipment as part of its sanitation compliance procedure. The food
processing facility was unaware of the adverse effect of the bleach on the springs.
The recommendation was made to change all of the springs from stainless steel to Hastelloy. Now the
food processor can run all season without replacing parts.
The changeover was simple to execute because a stainless steel spring can easily be “copied” into
Hastelloy. The result is a spring that’s have similar mechanical properties and functions in a nearly
identical way.
Hastelloy is a great alternative for those applications using stainless steel springs which are subjected to a
higher level of chlorine and acids. Hastelloy will help eliminate corrosion, cracking and other part failures.

Inconel
Definition: Inconel is a group of alloys containing chromium and iron, resistant to corrosion and high
temperatures. Higher temperature and corrosion resistance compared to many other alloys. It is less expensive
than the cobalt alloys.
MW Industries uses: Inconel X-750 is most common for spring and wire because this grade offers the best
combination of high temperature and corrosion resistance. Inconel 718 and 600 are also used for coiled
springs as well as spring washers like Belleville washers.
Applications: Valves that are used with high temperature fluid or steam. An example is the springs used in
vacuum furnaces for semiconductor manufacturing. It is also National Association of Corrosion Engineers
(NACE) approved for “down hole” gas exposure. Other uses include lower-tier tools, which will not be
subjected to severe service or have a short lifespan, where term corrosion exposure is not an issue.
Alternative material for: MP35N and Elgiloy, at less than half the cost. However, it is not as resistant to certain
chemicals as compared to MP35N and Elgiloy.
Cons: Moderate resistance to chlorides, saltwater and acids. If your application requires more strength and
corrosion resistance, upgrade to MP35N, Elgiloy or titanium.

How MW Industries solved a spring problem using Inconel

A company that manufactures valves for high pressure steam applications was having a problem with the
supplier of their Inconel springs. The springs were not properly performing in the intended application.
MW Industries knew from its signficiant experience with the material that it needed to take into account
performance at room temperature, as well as in elevated steam conditions.
MW Industries redesigned the spring and adjusted the heat-treatment process. The spring was then able
to function perfectly in the application.

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Exotic alloys: the answer for demanding spring applications White paper

Maraging steel
Material: Maraging steel was originally developed for liquefied natural gas tankers. Its inherent material
lattice structure prevents propagation of cracking when subjected to a stress. It is the strongest steel available
and is good for both low and high temperature applications.
MW Industries uses: For high stress applications, four different alloys 200, 250, 300 and 350 are used. The
numbers reference the material’s yield strength, which is superior to other alloys.
Applications: Torsion and recoil springs.
Alternative material for: Provides higher strength than stainless 17-7 PH.
Cons: Not as corrosion resistant as a high nickel alloy.

MP35N
Material: MP35N is a cobalt/nickel base alloy which is corrosion resistant and exhibits high strength, good
fatigue life.
MW Industries uses: Machined parts, spring washers, and products formed from bar stock are produced from
MP35N.
Applications: Corrosion resistant applications involving oil and gas exploration or chemical and marine
equipment. It is also used in aerospace applications where high strength and hardness levels are required and
also for springs used in medical and dental products.
Alternative material for: MP35N comes in a wider array of forms than Elgiloy, which is only available in wire
or strip. MP35N is available in bars, sheets and wire, offering manufacturing flexibility. It is interchangeable
with Elgiloy in environments below 400°F
Cons: For temperature requirements above 400°F, Elgiloy is a preferred choice—particularly in oil and gas
applications.

How MW Industries solved a spring problem using MP35N

A customer was using a custom wave spring that another manufacturer was producing for a “down hole”
oil and gas application. It was an expensive solution because they were stacking two wave springs end-
to-end. In addition to the economics, the performance was less than desirable and the spring needed to
be replaced often.
MW Industries designed a stack of Belleville washers that are machined out of MP35N sheet. Although
the Belleville washers were more expensive, they did not have to be replaced as frequently, bringing
down the overall cost.
The solution meet temperature cycle demands as well as were able to perform in a corrosive environment.
The customer was so pleased it asked MW Industries to review some of its other spring applications and
make recommendations for improved performance.

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Exotic alloys: the answer for demanding spring applications White paper

Ni-Span-C
Material: Ni-Span-C is a nickel/chrome alloy. It can handle broad swings in temperature (between -75°F to
140°F), while maintaining the same force.
Applications: Springs for thermostats and watches.
Alternative material for: No other alloy delivers a constant torsion modulus through a broad temperature
range for applications that require both.
Cons: Cost and availability.

Rene 41
Material: Rene 41 is an alloy of steel, nickel, cobalt and chromium, developed for super high temperatures up
to 1,500°F.
Applications: It frequently is the only spring wire that is suitable for a ceramic application requiring force.
Also valves located in, or next to, a furnace. Any application that is exposed to super high temperatures such
as refractories
Alternative material for: Superior performing compared to Inconel alloys.
Cons: High cost and not good for applications requiring high strength.

Tantalum
Definition: Tantalum is an element and is the only material that withstands chlorine acid directly.
MW Industries uses: Tantalum 61
Applications: Tantalum springs are used in municipal processing plants valves for water and sewer lines
because they can withstand hydrochloric acid. The valves sit at the bottom of the tanks and the springs are
used to open and close them. Also used in the electronic industry for contacts.
Alternative material for: Superior properties when compared to Hastelloy C. Chlorine concentration levels
will determine if Hastelloy is suitable for sewage treatment applications or if an upgrade to Tantalum is
required.
Cons: It is extremely expensive, ranging from $800 to $1,500 per pound. It is also not very strong, so unless
you have continual exposure to high concentrations of chlorine, you are likely to consider alternatives.

How MW Industries solved a spring problem using tantalum

A well-known, global engineering company was experiencing performance issues with its Hastelloy C
valves located at the bottom of a sewage tank. MW Industries showed them how springs made from
tantalum could provide the desired lifespan and improve performance. Converting to the tantalum
solution meant they were no longer faced with the unpleasant task of replacing springs at the bottom of
a sewage tank.

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Exotic alloys: the answer for demanding spring applications White paper

Titanium
Definition: Titanium offers very high strength at low weight. It provides maximum force in a small space. It is
both hot and cold “workable.” Titanium has a low torsion modulus and is heat treatable after forming. Its ability
to be hot formed, enables the fabrication of larger springs.
MW Industries uses: Grade 5 and Beta C, which was developed by the aerospace industry.
Applications: Primarily aerospace including springs for airplane turbines, landing gear and pedals. Also used
for military and automotive applications. Other uses include implantable medical devices and compensator
springs for oil and gas applications.
Alternative material for: Stainless steel or Inconel. Stainless steel is heavier, but much less expensive.
Weight/cost attributes needs to be considered.
Cons: Temperature attributes not as good as Inconel, but superior to stainless steel.

Exotic alloys: capabilities at-a-glance

High tensile Corrosion Low torsion Electrical Non- Spring Alternative
Temperature
strength resistance modulus connectivity magnetic applications for

Valves subjected to
A286 X X Up to 800°F Inconel X-750
high temperatures
Long-life corrosion
Beryllium Stainless steel,
X X X X X resistence to sea
copper Inconel
water
Oil/gas wellbore
Elgiloy X X Inconel
environment
Food processing, 300 series
Hastelloy X Up to ~400°F petrochemical, stainless steel
marine, etc.
Temperature +LJKWHPSÀXLG
Inconel X use varies by MP35N, Elgiloy
or steam
grade
Torsion springs
Maraging Wide temp
X for valves, recoil Stainless 17-7 PH
steel uses springs
Oil/gas wellbore
MP35N X X Up to 400 F Elgiloy
environment
Thermostats,
Ni-Span-C -75F° to 140F° Unique material
watches

RENE 41 Up to 1,500°F Refractories Inconel

Valves for water,
sewer lines.
Tantalum X Hastaloy C
High chlorine
applications
Aerospace, Stainless steel,
Titanium X X X medical, oil Inconel
& gas

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Exotic alloys: the answer for demanding spring applications White paper

MW Industries: your resource for exotic alloy expertise

Our MW Industries’ professionals located across all manufacturing locations have decades of experience in
knowing what material will work best for a given application. Understanding metallurgy is the foundation of
spring making, followed by a thorough knowledge about mechanical aspects.
More than 900 engineers located at the company’s various operating manufacturing locations spend
thousands of hours per year making sure they are up on material and processing knowledge, as well as
partnering with customers to make sure that a recommendation is given that will best suit the application.
MW Industries also partners with alloy manufacturers to gain knowledge from those responsible for
developing exotic alloys. With close ties to these manufacturers, MW Industries has a direct pipeline to supply
and data that is used to produce successful results.
The company is proud to partner with many of the world’s best known brands to provide spring and fastener
solutions that help insure product success.
MW Industries has licensed engineers available to review any product challenge and assist with component
design. It’s likely we have already solved a similar problem and can draw from our vast experience.
The company is known for fast quotes, rapid turnaround, precision, consistent quality and superb customer
service, no matter how common or rugged the application demands are.
Please contact us if you need assistance finding the right spring solution for your product.
MW Industries
Phone: 1-847-349-5769
Email: sales@mw-ind.com
www.mw-ind.com

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