What Is Monel?
Initially developed for commercial use in 1905, Monel® is a group of copper and nickel alloys valued for their excellent temperature and corrosion resistance. In recent years, this versatile material has become increasingly important to the aerospace and defense industries. This blog will further discuss the benefits and common applications of Monel® so you can decide whether it’s the right choice for your project.
What Is Monel® Metal?
Monel® is a trademarked type of nickel alloy that contains copper as the main alloying element. In addition to these two metals, Monel® also contains small amounts of aluminum, carbon, iron, manganese, silicon, sulfur, and titanium. The specific alloy’s composition varies depending on its intended application.
Monel® alloys feature high strength and corrosion resistance in both saltwater and freshwater. They are also resistant to high and low temperatures, making them suitable for use in challenging environments. For these reasons, Monel® is known as a superalloy.
Some additional noteworthy characteristics of Monel® alloys include:
- Malleability
- High resistance to corrosion
- Stronger than steel
- Maintains strength in subzero temperatures
- Low coefficient of thermal expansion
- High resistance to alkalis
- Can be brazed, welded, and soldered
Monel® materials are available in three commercial grades, each with its own distinct features:
- Monel 400: Used in aerospace, marine engineering, and chemical processing, Monel 400 is a tough grade that is especially good at resisting attacks from strong acids and seawater.
- Monel R-405: This grade is nearly identical in composition to Monel 400, but R-405 has a higher sulfur content that makes it more machinable.
- Monel K-500: Monel K-500 has enhanced strength and hardness due to a slightly higher titanium and aluminum content.
Benefits of Monel®
Monel® has many characteristics that make it well-suited to highly demanding environments, such as aerospace applications. For example, it can easily withstand the high pressure and heat of combustion chambers. Certain Monel® alloys, such as Monel 400, are even able to retain their strength and shape in temperatures up to 1300 °C.
Key benefits of Monel® metals include:
- Corrosion resistant: Monels are highly resistant to corrosion from acids and alkalis, outperforming many other popular corrosion-resistant alloys like stainless steel.
- Weldability: Easily welded with standard welding techniques.
- Formability: Formable into a wide range of shapes, including pipes and rods.
- Temperature resistance: Monel® maintains its strength over a wide range of temperatures, from sub-zero to 480 °C or more.
Applications of Monel®
Monel® is used in a wide range of applications, particularly those that require a high degree of corrosion resistance and toughness. Thus, it is often used in chemical processing, hydrocarbon processing, marine engineering, and aerospace equipment, such as:
- Carburetors
- Exhaust assemblies and manifolds
- Heat exchangers
- Pipes
- Tubes
- Holding engine parts in place
- Frame structures
- Propeller shafts
- Gears and chains for landing gear
- Rivets
- Wires
Since Monel® alloys are able to withstand the heat created by high-speed flight, it is regularly used to manufacture aircraft frame structures, rocket components, and rivets. Monel® rivets hold engines, exhaust assemblies, and other aircraft systems in place and are a more durable replacement for corrosion-resistant steel in these applications.
Monel® Components From Helander
Monel® alloys are a group of high-performance metal materials uniquely suited to demanding environments. Throughout the aerospace and defense industries, in particular, there are numerous applications that benefit from this material. At Helander, we create custom-fabricated Monel® components developed to ISO 9001 and AS9100 standards.
Beyond just parts, we deliver confidence. Helander Metal Spinning company has a history of successful collaborations with leading aerospace and defense companies. Learn more about how we serve the aerospace and defense industries or request a quote to start your project.
Hydroforming (Sheet Hydroforming) is a specialized deep draw process that uses high-pressure rubber to shape and form metal workpieces. In sheet hydroforming, a metal sheet is placed over a die before highly pressurized water forces it down and makes it conform to the shape of the mold. In tube hydroforming, a preexisting tube is set between two dies, and water pushes the interior of the tube to expand and conform to the new shape. Both processes allow for the seamless forming of new shapes and parts in common metal alloys without welds. Additionally, the hydroforming process is an excellent choice for developing complicated, 
Also known as spin forming, metal spinning is a process manufacturers use to craft axially symmetric metal parts without cutting the material. This process is efficient and highly versatile. At Helander, we have spent over 80 years providing superior quality metal spinning services to our customers in the aerospace, commercial, medical, and defense industries.
Metal spinning, sometimes referred to as spin forming, is a machining technique that creates axially symmetrical parts from metal tubes or discs. This process works by rotating the metal workpiece, forming it to a mandrel. Once clamped to a vertical or horizontal lathe, the force and rotation will shape the workpiece into a cone, tube, toroid, or other rounded shape.