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Product Overview

Primary Heading: High-Integrity Corrosion Resistant Incoloy 825 Round Bar for Sour Gas Extraction

In severe downhole drilling and high-pressure subsea exploration, material degradation leads to catastrophic operational failure. Our Corrosion Resistant Incoloy 825 Round Bar is refined through proprietary vacuum induction melting (VIM) followed by electroslag remelting (ESR). This advanced dual-melt metallurgical pathway guarantees ultra-low residual gas levels, tight chemical homogenization, and superior center-to-surface grain refinement across heavy-cross-section bars up to 250mm in diameter.

By balancing high nickel content ( $38.0 % - 46.0 %$ ) with chromium, molybdenum, and copper, this alloy provides unmatched defense against both general oxidation and localized pitting in chloride-saturated sour gas wells.

Corrosion resistant Incoloy 825 round bar for oil and gas wellhead equipment

Technical Specifications & Dimensional Matrix

Product Form: Hot-rolled, hot-forged, precision peeled, cold-drawn, or centerless ground round bars
Diameter Range: 12.0 mm to 250.0 mm (Custom OD forgings available upon review)
Length: Random lengths (3m–6m) or precision cut-to-length billets (tolerance down to $\pm 0.5 mm)$
Dimensional Tolerance: Strict adherence to ISO h8–h11 or tighter custom machining tolerances
Surface Quality: Black forged, bright peeled, polished, or centerless ground ( $? ? \leq 0.8 ? m)$
Delivery Condition: Solution annealed, stabilized, and water quenched; ultrasonic tested to internal zero-defect defect criteria

Chemical Composition Baseline (%)

Element	Content (%)	Metallurgical Function
Nickel (Ni)	$38.0 - 46.0$	Exceptional resistance to chloride stress-corrosion cracking
Chromium (Cr)	$19.5 - 23.5$	Resistance to oxidizing media, nitrates, and organic acids
Iron (Fe)	Balance	Structural matrix and mechanical economy
Molybdenum (Mo)	$2.5 - 3.5$	High resistance to localized pitting and crevice corrosion
Copper (Cu)	$1.5 - 3.0$	Superior resistance to sulfuric acid and reducing environments
Titanium (Ti)	$0.6 - 1.2$	Stabilization against intergranular sensitization and precipitation
Carbon (C)	$\leq 0.05$	Prevents carbide precipitation during thermal cycles
Manganese (Mn)	$\leq 1.0$	Deoxidation and matrix strengthening
Silicon (Si)	$\leq 0.5$	Deoxidation efficiency
Sulfur / Phosphorus	$\leq 0.015 / \leq 0.020$	Ultra-pure melt control for maximum impact toughness

Mechanical & Physical Properties

Metric	Value / Range
Tensile Strength ( $R_{m}$ )	$\geq 585 MPa$ ( $85 ksi$ )
Yield Strength ( $R_{p 0.2}$ )	$\geq 240 MPa$ ( $35 ksi$ )
Elongation ( $A_{5}$ )	$\geq 30 %$
Hardness (Annealed)	$\leq 90 HRB$ / $\leq 185 HBW$
Density	$8.14 {g/cm}^{3}$
Melting Range	$1370^{\circ} C - 1400^{\circ} C$
Charpy V-Notch Impact ( $- 46^{\circ} C$ )	$\geq 80 J$ (Proven sub-zero toughness)

High precision Incoloy 825 solid round bar diameter 12mm to 250mm cross section

Key Performance Features of Corrosion Resistant Incoloy 825 Round Bar

Pitting & Crevice Corrosion Immunity: With an engineered Pitting Resistance Equivalent Number (), the Corrosion Resistant Incoloy 825 Round Bar suppresses halide breakdown in sour brine mixtures, seawater injection systems, and stagnant wellhead crevices.
Superior Sour Service ( $H_{2} S + C O_{2}$ ) Resistance: Full stabilization via optimal titanium-to-carbon balancing prevents chromium carbide formation at grain boundaries, eliminating intergranular corrosion and sulfide stress cracking (SSC) under extreme downhole partial pressures.
High-Pressure Mechanical Stability: Maintains high tensile integrity, elastic modulus, and fracture toughness under cyclic internal pressures exceeding $15, 000 PSI($ 103.4 MPa) in subsea Christmas trees and surface manifolds
Precision Machinability for High-Tolerance Components: Uniform micro-carbide dispersion and optimized grain structures allow deep hole drilling, smooth threading, and intricate turning for high-pressure sealing interfaces with reduced tool wear.

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Wellhead and Extraction Applications for Corrosion Resistant Incoloy 825 Round Bar

Surface & Subsea Christmas Tree Components: Valve blocks, master valve stems, choke bodies, and high-pressure casing heads operating under continuous sour fluid flow.
Downhole Tool Mandrels & Packers: Heavy-wall hollow carriers, safety valves, polished bore receptacles (PBR), and expandable casing packers subjected to sour brines and extreme geothermal temperatures.
Valves, Flanges & Sealing Trims: High-durability ball valves, gate valve seats, and high-pressure fluid control manifolds requiring micro-inch surface finishes and zero chloride stress cracking.
Sour Gas Flowlines & Manifold Fasteners: High-integrity solid studs, tie-rods, and pressure-retaining structural pins in offshore marine riser assemblies.

Corrosion resistant Incoloy 825 round bar applied in oil and gas wellhead valve equipment

Why Specify DLX for Your Corrosion Resistant Incoloy 825 Round Bar Needs

1,200 Tons Monthly Smelting & Forging Capacity: Our integrated processing facility delivers high-volume production scalability with single-heat consistency and shortened project lead times.
100% Volumetric Ultrasonic & Hydrostatic Verification: Every forged and peeled bar undergoes dual-direction ultrasonic inspection ( critical flaws) and comprehensive positive material identification (PMI) prior to dispatch.
Zero-Oxygen Vacuum Melting Infrastructure: Utilizing ultra-clean VIM + ESR furnaces, we eliminate non-metallic inclusions, ensuring consistent dynamic fatigue limits and cryogenic impact toughness.
Flexible B2B Order Sizing: Project-specific minimum order quantities designed around specific bar diameters and cut-to-length billet programs, matching custom OEM forging and CNC machining schedules.
Complete Metallurgical Traceability: Comprehensive Mill Test Certificates covering mechanical testing, chemical spectrometry, micrographic grain size analysis, and intergranular corrosion testing with every shipment.

Clean vacuum induction melting and forging process of Incoloy 825 alloy bar at DLX fdaaa1a2a2b1244ee143083244a7fba3(6907ed47ab).png

Frequently Asked Questions on Corrosion Resistant Incoloy 825 Round Bar

Q1: How does your Incoloy 825 round bar prevent intergranular corrosion after field welding or high-temperature exposure?
A: Our Corrosion Resistant Incoloy 825 Round Bar incorporates a precision titanium addition ( $0.6 % – 1.2 %$ ) relative to its ultra-low carbon level. During stabilizing thermal treatment, titanium carbides form preferentially, preventing the depletion of chromium at grain boundaries. This keeps the material fully resistant to intergranular corrosion even in as-welded or thermally stressed wellhead service.

Q2: What diameter range is available, and what are the standard lead times for custom forgings?
A: We supply solid bars from 12mm to 250mm. Standard sizes ( $20 mm - 160 mm$ ) are maintained in routine production cycles. Custom forging heats up to 250mm are scheduled with rapid processing times supported by our 1,200-ton monthly capacity.

Q3: Can DLX provide custom pre-machined and rough-turned billets?
A: Yes. In addition to full-length round bars (up to 6 meters), we provide precision band-saw cutting, deep hole trepanning, and rough CNC turning with tight concentricity tolerances, allowing immediate feed into your finish-machining lines.

Q4: What quality documentation is delivered with each production heat?
A: Every batch is accompanied by comprehensive certified test reports detailing chemical spectrometry, room and elevated temperature tensile values, Brinell/Rockwell hardness, Charpy impact toughness at sub-zero temperatures, microstructural grain sizing, and $100 %$ ultrasonic testing confirmation.

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