High Performance Alloys

In its quest to propel flight missions to new heights, the aerospace sector is advancing toward superior products. This demands high performance and toughness at ultrahigh temperatures that standard alloys can’t endure.

Superalloys, like the family of alloys called Nitronic, are the ideal workhorse materials for these applications, known for their high resistance to wear, galling, heat, oxidation and corrosion. However, severe supply chain issues have put manufacturers on a nearly two-year waitlist to acquire these advanced materials.

High Performance Alloys (HPA) steals the spotlight by delivering tailored material solutions in the shortest time possible. A one-stop shop for Nitronic, Monel and other nickel and cobalt based superalloys, it leverages four decades of material supply expertise and advanced manufacturing capabilities to fulfill the critical demand for these robust materials.

“We are in the business of finding quick manufacturing solutions for superalloy products. As our small nature makes us agile, we can turn 90-week lead times into just 30 weeks,” says Russell Kirchner, CFO of HPA.

Full-Service Manufacturer

Shifting from a sole focus on distribution, HPA has expanded its capabilities to become a steadfast partner for all superalloy product requirements.

Since its inception, it has played pivotal roles in providing high-strength materials for critical applications. In the 1990s, it was approached by NASA for the acquisition of specialized materials for space applications. Over time, it has evolved to meet the demands of space missions, earning a place in NASA’s approved materials catalog.

HPA eventually branched off into the military sector, supplying materials like high-strength Nitronic 60 that can safely replace beryllium copper (CuBe) in bushings. Nitronic 60, an anti-galling material, is a safer alternative for bushings than CuBe, which is prone to wear and can generate hazardous dust particles in the machining process.

Nitronic and other superalloys are now highly desired for diverse applications across industries like aerospace, military and nuclear. HPA is at the forefront of fulfilling their demands despite supply chain challenges. Leveraging its extensive supply network and in-house production capabilities, it consistently delivers products to producers and distributors seeking specific diameter materials.

It stocks materials in advance, with a focus on grain structures, melt quality and other characteristics required for aerospace use. Proactively stocking inventory expedites production processes and reduces lead times.

When the U.S. Army urgently required materials for a high priority project, HPA took the initiative to produce to their requirements, ensuring timely delivery within two months.

In another instance, a client required type 304 stainless steel for nuclear applications. The initial batch, obtained through a different supplier, contained cobalt, necessitating a project restart. Troubled with lead times exceeding a year, the client consulted with HPA and came to an ideal solution. They arranged for a special melt to create cobalt-free ingots from the 304 stainless steel. HPA took the client’s ingots and processed them into two-inch round bars, meeting their requirements within four weeks.

HPA’s comprehensive range of products, including bars, sheets and fasteners, are manufactured using an expansive range of tools and machinery across two facilities.

Tipton, Indiana, serves as the primary facility. It has complete hot and cold-working capabilities, including wire drawing, straightening cut to length and grinding. Bar processing is one of HPA’s biggest strengths. Its 750-ton Lake Erie Forge Press can swiftly process small- to medium-sized batches of materials into round, square and rectangular bars of required dimensions.

HPA has made significant investments in its cold-forging capabilities to innovate a new approach that relies on precise die ratios to produce bars that balance inner hardness strength and outer uniformity. This is crucial in products like fasteners, where the center of the bar needs to exhibit maximum strength.

Unlike textbook-level cold working, which results in low ductility and malleability, its proprietary method harnesses the benefits of cold working without the negatives. Using a GFM 412 Rotary Forger, it brings four dies to the center, creating bars with a harder center and softer outer edge. For some projects, HPA can then run the bar through a draw bench to strengthen the outside, helping ensure better uniformity of hardness throughout the product.

“Our robust machines are well-equipped to handle the harsh and heavy processes cold working demands to produce highstrength products,” says David Kirchner, COO of HPA. Its Windfall, Indiana facility has water jet machines and HD plasma cutting equipment for precise custom plate and sheet cutting services.

The Hoover Dam previously required arcs of a stronger material to replace type 304 stainless steel. HPA’s Windfall facility furnished the client’s requirements by cutting and supplying eight segmented arcs from base plates made of Nitronic 60, offering a seamless transition to a higher-strength material.

Forging Ahead in the Metal Revolution

HPA’s culture entails a strong customer focus and engagement throughout the manufacturing process. It primarily interacts with manufacturers and machining companies in the aerospace, military and nuclear industries.

During customer consultations, it engages in discussions about their desired mechanical properties, including different grades of alloys, allowing them to estimate final product delivery lead times and prices before finalizing an order. An ISO-9001- certified organization, all of its products are meticulously tested at independent labs to ensure their reliability.

Beyond manufacturing client-approved designs, HPA embraces a creative side, producing custom stainless-steel plates featuring distinct designs for smaller clients in its locality. The process involves collaboration with its waterjet cutting specialists, who provide guidance on challenging cuts and material considerations. It also works with local artists to produce metal and materials like stained glass depictions for personal projects and advertising initiatives.

In response to the market demands for these difficult-toobtain superalloy products, HPA is doubling its production capacity. It recently added equipment to handle HPA’s level five materials and beyond, which have 200 Ksi (1379+ MPa) minimum ultimate tensile strength, for materials up to two inches in diameter and no lower limit for smaller sizes.

It works closely with clients’ R&D Engineering teams to help reach their goals and new heights for product design and new product development.

HPA continues to walk the path of innovation and assure clients with consistent, superior-quality superalloy products, serving as a one-stop solution for high-performance alloy supply and manufacturing requirements across the aerospace market.