Anti-Galling Alloys
Anti-galling alloys are highly preferred in most industry applications due to their inability to seize or unintentionally adhere to another metal they are in contact with. The adhesion in galling alloys makes them easily wear, freeze, or separate from the component they were originally attached to. Therefore, compared to galling alloys, anti-galling alloys tend to have reduced wear and tear, improved performance, lower maintenance costs, and versatility, especially in industries like food processing, where anti-seize liquid lubricants are restricted. Waukesha Foundry is the #1 trusted and reliable manufacturer of anti-galling alloys. We utilize advanced technology and 100 years of metallurgical experience to manufacture anti-galling alloys with intricate designs to meet our customer’s unique casting specifications and quality requirements. Want to know how our anti-galling alloys are ideal for the food processing industry and other applications that require reliable, high-performance alloys? Let’s dive in!
What are Anti-Galling Alloys
Galling or seizing of steel hardware occurs when two metal surfaces in sliding contact start sticking to each other mainly due to friction, cohesion attraction, and ductility. This phenomenon is common in hydraulic cylinders, metal forming, engine pistons, and fasteners made of metal castings that generate an oxide surface film for corrosion protection. Surface contact is a critical factor in galling, as it often leads to various forms of wear when lubrication is inadequate. Some metals highly susceptible to galling include aluminum, stainless steel, and titanium.
Typically, when these metals rub against each other under poor lubrication and pressure, they generate heat and friction. The heat and friction cause stress at the contact area, leading to the formation of lumps that break and penetrate the protective oxides. The breaking of the protective oxides and the increased adhesion ultimately result in cold welding or galling. The detrimental impacts of galling include increased wear, reduced efficiency, operational failures, and cost implications due to frequent maintenance and downtime. In the food industry, another major concern is that bacteria may develop in the pits or folds caused by galling, leading to increased cleaning requirements and further downtime.
One popular method adopted to prevent wear or add protection from galling is lubrication/coating. Liquid lubricants such as anti-freeze or anti-galling lubricants add another protective layer over sliding metallic surfaces, reducing friction and contact temperature, which in turn reduces galling. However, the use of anti-galling lubricants is prohibited in numerous industries, such as food processing industries.
Anti-galling alloys serve as a good alternative to galling alloys as they do not require lubrication to operate efficiently. They are manufactured to resist friction-induced wear and seizing, translating to an extended lifespan and reliable performance in demanding industrial environments. This ultimately results in smooth operations, enhanced safety and efficiency, and reduced downtime across a wide range of applications.
Anti-Galling Alloys at Waukesha Foundry
At Waukesha Foundry, we have various anti-galling alloys manufactured with the tightest tolerances and the best surface finish. These alloys include:
Waukesha Metal 88 (WM88)
WM88, also known as “Alloy 88” or “Waukesha 88”, UNS N26055, and ASTM A494 CY5SnBiM, is well known for its high strength and exceptional corrosion resistance. The FDA (and 3-A sanitary standards) have approved it as the hardware is safe and can withstand repeated cleaning and sterilization cycles.
WM88 is an excellent choice for applications requiring close clearance with moving parts. Its high-temperature tolerance allows the alloy to be cut or shaped on a machine with or without coolant. Finally, the alloy has low thermal conductivity, meaning it does not dissipate heat well during machining. This requires careful selection of cutting tools to prevent overheating or tool damage.
Waukesha Metal 126 (WM126)
WM126 is a copper-based anti-galling material highly utilized in the meat processing industry and applications that require strength and resistance to galling and corrosion. This includes gears, bushings, and bearings. Just like WM88, WM126 has high heat resistance, meaning that it can also be used at extreme temperatures.
WM126 is a copper-based anti-galling material highly utilized in the meat processing industry and applications that require strength and resistance to galling and corrosion. This includes gears, bushings, and bearings. Just like WM88, WM126 has high heat resistance, meaning that it can also be used at extreme temperatures. The alloy content of WM126 makes it particularly effective in resisting wear under high load conditions, reducing the risk of catastrophic failure in critical applications.
Waukesha Metal 23Bi (WM23Bi)
The anti-galling alloy WM23Bi has a reputation for superior yield strength and hardness compared to WM88. This alloy’s high performance makes it an ideal choice for maintaining a sharper edge on blades or other cutting tools that require long-lasting precision. In addition to its excellent corrosion resistance and high-temperature resistance, WM23Bi is also well-suited for non-galling applications at lower temperatures. It is commonly used in ice cream processing due to its reliability in colder environments.
NITRONIC 60 VS WM88
Nitronic 60 is a standard non-galling alloy that can be compared to our WM88. Typically, the galling resistance in WM88 is significantly better than that in non-galling alloys like Nitronic 60 and standard stainless steels. WM88 experiences galling at a rate five times less than that of 316 stainless steel.
The low galling rate results in less wear and longer component life. Therefore, utilizing non-galling alloys like WM88 instead of stainless steel can help minimize operation costs, as non-galling alloys require less maintenance and low downtime. These benefits make WM88 and the above non-galling alloys a cost-effective type for applications where galling is a concern, especially in environments involving reactive metals.
WM54C
The anti-galling alloy WM54C has properties similar to those of WM88 but offers greater temperature resistance. This makes WM54C ideal for applications needing higher thermal stability.
Waukesha Foundry’s Expertise
For the last 10 decades, Waukesha Foundry has gained a reputation for its innovative manufacturing of intricately shaped anti-galling cast components for numerous industries, including food processing equipment. By integrating cutting-edge technology with the art and science of extracting metals from their ores, we are able to produce anti-galling metal castings of complex geometries that also meet unique quality requirements.
As ISO 9001:2015 by TÜV Rheinland, you can expect us to provide unmatched quality assurance, ensuring each metal casting meets the highest standards. Finally, our advanced manufacturing capabilities allow us to produce castings in more than 200 alloys weighing 1 to 6000 pounds.
Applications of Anti-Galling Alloys
Anti-galling alloys are ideal for numerous industries, including:
Food Processing
As mentioned above, non-galling alloys like our standard WM88 are highly utilized in various food processing industries. This alloy is FDA-approved for food contact and is safe for regular cleaning and sterilization processes. Most food processing industries prohibit the use of non-galling alloys, as most of them use lubricants to work efficiently or minimize galling.
Energy
The energy sector utilizes anti-galling in various applications, such as pumps and turbines in geothermal energy plants, fuel handling equipment in nuclear power, and valves and fittings used in pipelines and power plants. Anti-galling alloys are highly preferred in this sector due to their high heat resistance, reliability, and high performance, as well as their extended lifespan.
Aerospace
Anti-galling alloys’ reliability and durability, especially when under high stress and temperature variations, make them ideal for aerospace applications. Our 54C Alloy has excellent self-lubricating qualities, making it a good option for valve guides in aircraft engines that perform in very high temperatures.
Industrial Applications
Ant-galling alloys’ ability to resist wear and seizing when exposed to high loads and continuous operations makes them ideal for numerous industrial applications, such as in automotive engine parts, heavy machinery that operates under heavy loads, metal forming tools, and drilling components.
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Get Anti-Galling Alloys at Waukesha Foundry
Anti-galling alloys are ideal for numerous industries mainly due to their reliability, high performance, and low maintenance costs. At Waukesha Foundry, we have the expertise and extensive experience to manufacture unique anti-galling alloys for numerous applications. Get in touch today to learn more about our anti-galling alloys and other metal castings.