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57-424: Black Swan Nickel Mine is an inactive surface and underground nickel mine near Kanowna, Western Australia . The mine operated from 1997 to 2008, at which point it was placed into care and maintenance . It is owned by Poseidon Nickel, who aims to restart production at Black Swan. The nickel deposit at Black Swan was discovered in the 1960s but was not developed at the time. The mine, owned by MPI Mines Limited at

114-708: A martensitic stainless steel alloy, today known as AISI type 420. The discovery was announced two years later in a January 1915 newspaper article in The New York Times . The metal was later marketed under the "Staybrite" brand by Firth Vickers in England and was used for the new entrance canopy for the Savoy Hotel in London in 1929. Brearley applied for a US patent during 1915 only to find that Haynes had already registered one. Brearley and Haynes pooled their funding and, with

171-575: A body-centered tetragonal crystal structure, and offer a wide range of properties and are used as stainless engineering steels, stainless tool steels, and creep -resistant steels. They are magnetic, and not as corrosion-resistant as ferritic and austenitic stainless steels due to their low chromium content. They fall into four categories (with some overlap): Martensitic stainless steels can be heat treated to provide better mechanical properties. The heat treatment typically involves three steps: Replacing some carbon in martensitic stainless steels by nitrogen

228-604: A group of investors, formed the American Stainless Steel Corporation, with headquarters in Pittsburgh , Pennsylvania. Brearley initially called his new alloy "rustless steel". The alloy was sold in the US under different brand names like "Allegheny metal" and "Nirosta steel". Even within the metallurgy industry, the name remained unsettled; in 1921, one trade journal called it "unstainable steel". Brearley worked with

285-511: A local cutlery manufacturer, who gave it the name "stainless steel". As late as 1932, Ford Motor Company continued calling the alloy "rustless steel" in automobile promotional materials. In 1929, before the Great Depression, over 25,000 tons of stainless steel were manufactured and sold in the US annually. Major technological advances in the 1950s and 1960s allowed the production of large tonnages at an affordable cost: Stainless steel

342-451: A lower design criteria and corrosion resistance is required, for example in high temperatures and oxidizing environments. Martensitic , duplex and ferritic stainless steels are magnetic , while austenitic stainless steel is usually non-magnetic. Ferritic steel owes its magnetism to its body-centered cubic crystal structure , in which iron atoms are arranged in cubes (with one iron atom at each corner) and an additional iron atom in

399-579: A potential carcinogen in mammalian cells. In the 2000s, a nickel boom began centered around Claver, Surigao del Norte in the Philippines ; in 2017, the government of the Philippines (then the world's largest exporter of nickel ore) engaged in a crackdown against mine operators accused of violating environmental laws; the government closed the operations of 28 of the Philippine's 41 mining companies. In 2020,

456-469: A protective oxide surface film, such as aluminum and titanium, are also susceptible. Under high contact-force sliding, this oxide can be deformed, broken, and removed from parts of the component, exposing the bare reactive metal. When the two surfaces are of the same material, these exposed surfaces can easily fuse. Separation of the two surfaces can result in surface tearing and even complete seizure of metal components or fasteners. Galling can be mitigated by

513-406: A useful interchange table. Although stainless steel does rust, this only affects the outer few layers of atoms, its chromium content shielding deeper layers from oxidation. The addition of nitrogen also improves resistance to pitting corrosion and increases mechanical strength. Thus, there are numerous grades of stainless steel with varying chromium and molybdenum contents to suit the environment

570-436: Is pentlandite (Ni 9 S 8 ) although many other nickel sulfides are known. Furthermore, nickel is often a constituent of iron sulfides such as pyrrhotite . The principal (i.e. economically most important) nickel oxides are nickeliferous limonite ((Fe 1−x Ni x )O(OH)·nH 2 O). Pentlandite supplies an estimated 65% of the world's nickel but nickel laterites constitute the largest reserves. Nickel content of its ores

627-547: Is a long history of toxic emission problems at such operations around the world. Exploratory drilling near Tamarack occurred in 2022. Stainless steel Stainless steel , also known as inox , corrosion-resistant steel ( CRES ), and rustless steel , is an alloy of iron that is resistant to rusting and corrosion . It contains iron with chromium and other elements such as molybdenum , carbon , nickel and nitrogen depending on its specific use and cost. Stainless steel's resistance to corrosion results from

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684-406: Is a recent development. The limited solubility of nitrogen is increased by the pressure electroslag refining (PESR) process, in which melting is carried out under high nitrogen pressure. Steel containing up to 0.4% nitrogen has been achieved, leading to higher hardness and strength and higher corrosion resistance. As PESR is expensive, lower but significant nitrogen contents have been achieved using

741-532: Is an extension of the heating- quenching - tempering cycle, where the final temperature of the material before full-load use is taken down to a cryogenic temperature range. This can remove residual stresses and improve wear resistance. Austenitic stainless steel sub-groups, 200 series and 300 series: Ferritic stainless steels possess a ferrite microstructure like carbon steel, which is a body-centered cubic crystal structure, and contain between 10.5% and 27% chromium with very little or no nickel. This microstructure

798-426: Is bent or cut, magnetism occurs along the edge of the stainless steel because the crystal structure rearranges itself. Galling , sometimes called cold welding, is a form of severe adhesive wear, which can occur when two metal surfaces are in relative motion to each other and under heavy pressure. Austenitic stainless steel fasteners are particularly susceptible to thread galling, though other alloys that self-generate

855-510: Is classified into five main families that are primarily differentiated by their crystalline structure : Austenitic stainless steel is the largest family of stainless steels, making up about two-thirds of all stainless steel production. They possess an austenitic microstructure, which is a face-centered cubic crystal structure. This microstructure is achieved by alloying steel with sufficient nickel, manganese, or nitrogen to maintain an austenitic microstructure at all temperatures, ranging from

912-409: Is near that of ordinary steel, and much higher than the melting points of aluminium or copper. As with most alloys, the melting point of stainless steel is expressed in the form of a range of temperatures, and not a single temperature. This temperature range goes from 1,400 to 1,530 °C (2,550 to 2,790 °F; 1,670 to 1,800 K; 3,010 to 3,250 °R) depending on the specific consistency of

969-455: Is often only a few percent by weight. Sulfide ores are subjected to comminution followed by froth flotation . Pentlandite and related minerals separate with sulfides of copper, cobalt, and iron. Two hydrometallurgical methods have been developed to extract nickel and cobalt from nickel laterites, these processes are called sulphuric acid leaching and reduction roast-ammonia leaching. For high-magnesium silicates in lower profiles laterites

1026-1421: Is one of the most-produced industrial chemicals. At room temperature, type 304 stainless steel is only resistant to 3% acid, while type 316 is resistant to 3% acid up to 50 °C (120 °F) and 20% acid at room temperature. Thus type 304 SS is rarely used in contact with sulfuric acid. Type 904L and Alloy 20 are resistant to sulfuric acid at even higher concentrations above room temperature. Concentrated sulfuric acid possesses oxidizing characteristics like nitric acid, and thus silicon-bearing stainless steels are also useful. Hydrochloric acid damages any kind of stainless steel and should be avoided. All types of stainless steel resist attack from phosphoric acid and nitric acid at room temperature. At high concentrations and elevated temperatures, attack will occur, and higher-alloy stainless steels are required. In general, organic acids are less corrosive than mineral acids such as hydrochloric and sulfuric acid. Type 304 and type 316 stainless steels are unaffected by weak bases such as ammonium hydroxide , even in high concentrations and at high temperatures. The same grades exposed to stronger bases such as sodium hydroxide at high concentrations and high temperatures will likely experience some etching and cracking. Increasing chromium and nickel contents provide increased resistance. All grades resist damage from aldehydes and amines , though in

1083-402: Is porous and fragile. In addition, as iron oxide occupies a larger volume than the original steel, this layer expands and tends to flake and fall away, exposing the underlying steel to further attack. In comparison, stainless steels contain sufficient chromium to undergo passivation , spontaneously forming a microscopically thin inert surface film of chromium oxide by reaction with the oxygen in

1140-498: Is present at all temperatures due to the chromium addition, so they are not capable of being hardened by heat treatment. They cannot be strengthened by cold work to the same degree as austenitic stainless steels. They are magnetic. Additions of niobium (Nb), titanium (Ti), and zirconium (Zr) to type 430 allow good weldability. Due to the near-absence of nickel, they are less expensive than austenitic steels and are present in many products, which include: Martensitic stainless steels have

1197-452: Is superior to both aluminium and copper, and comparable to glass. Its cleanability, strength, and corrosion resistance have prompted the use of stainless steel in pharmaceutical and food processing plants. Different types of stainless steel are labeled with an AISI three-digit number. The ISO 15510 standard lists the chemical compositions of stainless steels of the specifications in existing ISO, ASTM , EN , JIS , and GB standards in

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1254-562: The Essen firm Friedrich Krupp Germaniawerft built the 366-ton sailing yacht Germania featuring a chrome-nickel steel hull, in Germany. In 1911, Philip Monnartz reported on the relationship between chromium content and corrosion resistance. On 17 October 1912, Krupp engineers Benno Strauss and Eduard Maurer patented as Nirosta the austenitic stainless steel known today as 18/8 or AISI type 304. Similar developments were taking place in

1311-638: The cryogenic region to the melting point. Thus, austenitic stainless steels are not hardenable by heat treatment since they possess the same microstructure at all temperatures. However, "forming temperature is an essential factor for metastable austenitic stainless steel (M-ASS) products to accommodate microstructures and cryogenic mechanical performance. ... Metastable austenitic stainless steels (M-ASSs) are widely used in manufacturing cryogenic pressure vessels (CPVs), owing to their high cryogenic toughness, ductility, strength, corrosion-resistance, and economy." Cryogenic cold-forming of austenitic stainless steel

1368-528: The water industry . Precipitation hardening stainless steels have corrosion resistance comparable to austenitic varieties, but can be precipitation hardened to even higher strengths than other martensitic grades. There are three types of precipitation hardening stainless steels: Solution treatment at about 1,040 °C (1,900 °F) followed by quenching results in a relatively ductile martensitic structure. Subsequent aging treatment at 475 °C (887 °F) precipitates Nb and Cu-rich phases that increase

1425-719: The 10.5%, or more, chromium content which forms a passive film that can protect the material and self-heal in the presence of oxygen. The alloy's properties, such as luster and resistance to corrosion, are useful in many applications. Stainless steel can be rolled into sheets , plates, bars, wire, and tubing. These can be used in cookware , cutlery , surgical instruments , major appliances , vehicles, construction material in large buildings, industrial equipment (e.g., in paper mills , chemical plants , water treatment ), and storage tanks and tankers for chemicals and food products. Some grades are also suitable for forging and casting . The biological cleanability of stainless steel

1482-536: The 1840s, both Britain's Sheffield steelmakers and then Krupp of Germany were producing chromium steel with the latter employing it for cannons in the 1850s. In 1861, Robert Forester Mushet took out a patent on chromium steel in Britain. These events led to the first American production of chromium-containing steel by J. Baur of the Chrome Steel Works of Brooklyn for the construction of bridges. A US patent for

1539-549: The 19th century didn't pay attention to the amount of carbon in the alloyed steels they were testing until in 1898 Adolphe Carnot and E. Goutal noted that chromium steels better resist to oxidation with acids the less carbon they contain. Also in the late 1890s, German chemist Hans Goldschmidt developed an aluminothermic ( thermite ) process for producing carbon-free chromium. Between 1904 and 1911, several researchers, particularly Leon Guillet of France, prepared alloys that would be considered stainless steel today. In 1908,

1596-459: The Philippines became the world's largest producer of nickel ore, after Indonesia halted nickel ore exports; both countries had extensively supplied China, the world's largest purchaser of nickel ore. The two largest Philippine nickel companies are Nickel Asia Corp. and Global Ferronickel Holdings Inc.; both operate in the Surigao del Norte region. Nickel mines in the Philippines, while beneficial to

1653-588: The Silver Swan underground operation. Grades for the nickel ore during this time were 0.7 percent for the open pit operation and 5.1 percent for the underground. Poseidon Nickel eventually acquired the mine in 2014–15, having purchased the also inactive Emily Ann and Maggie Hays nickel mines the previous year. The company announced in late 2022 that it was aiming to restart production at the mine in 2024. Nickel mine Nickel occurs in two general types of ores, sulfides and oxides. The most important sulfide ore

1710-649: The United States, where Christian Dantsizen of General Electric and Frederick Becket (1875–1942) at Union Carbide were industrializing ferritic stainless steel. In 1912, Elwood Haynes applied for a US patent on a martensitic stainless steel alloy, which was not granted until 1919. While seeking a corrosion-resistant alloy for gun barrels in 1913, Harry Brearley of the Brown-Firth research laboratory in Sheffield, England, discovered and subsequently industrialized

1767-441: The air and even the small amount of dissolved oxygen in the water. This passive film prevents further corrosion by blocking oxygen diffusion to the steel surface and thus prevents corrosion from spreading into the bulk of the metal. This film is self-repairing, even when scratched or temporarily disturbed by conditions that exceed the inherent corrosion resistance of that grade. The resistance of this film to corrosion depends upon

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1824-587: The alloy in question. Like steel , stainless steels are relatively poor conductors of electricity, with significantly lower electrical conductivities than copper. In particular, the non-electrical contact resistance (ECR) of stainless steel arises as a result of the dense protective oxide layer and limits its functionality in applications as electrical connectors. Copper alloys and nickel-coated connectors tend to exhibit lower ECR values and are preferred materials for such applications. Nevertheless, stainless steel connectors are employed in situations where ECR poses

1881-610: The alloy must endure. Corrosion resistance can be increased further by the following means: The most common type of stainless steel, 304, has a tensile yield strength around 210 MPa (30,000 psi) in the annealed condition. It can be strengthened by cold working to a strength of 1,050 MPa (153,000 psi) in the full-hard condition. The strongest commonly available stainless steels are precipitation hardening alloys such as 17-4 PH and Custom 465. These can be heat treated to have tensile yield strengths up to 1,730 MPa (251,000 psi). Melting point of stainless steel

1938-699: The alloy. The invention of stainless steel followed a series of scientific developments, starting in 1798 when chromium was first shown to the French Academy by Louis Vauquelin . In the early 1800s, British scientists James Stoddart, Michael Faraday , and Robert Mallet observed the resistance of chromium-iron alloys ("chromium steels") to oxidizing agents . Robert Bunsen discovered chromium's resistance to strong acids. The corrosion resistance of iron-chromium alloys may have been first recognized in 1821 by Pierre Berthier , who noted their resistance against attack by some acids and suggested their use in cutlery. In

1995-576: The battery industry; and the remainder went to other applications. By 2023, approximately 65% of primary nickel usage went to stainless steel and 15% to the battery industry . A study was conducted by scientists Dan et al on the effects of Nickel smelting fumes, to do this they did the study on NIH/3T3 cells and in the lung tissue of rats. They found that the fumes that the NIH/3T3 cells were transforming into malignant cells meaning that high exposure to Ni-smelting fumes may be harmful as Ni-smelting fumes may be

2052-580: The center. This central iron atom is responsible for ferritic steel's magnetic properties. This arrangement also limits the amount of carbon the steel can absorb to around 0.025%. Grades with low coercive field have been developed for electro-valves used in household appliances and for injection systems in internal combustion engines. Some applications require non-magnetic materials, such as magnetic resonance imaging . Austenitic stainless steels, which are usually non-magnetic , can be made slightly magnetic through work hardening . Sometimes, if austenitic steel

2109-544: The chemical composition of the stainless steel, chiefly the chromium content. It is customary to distinguish between four forms of corrosion: uniform, localized (pitting), galvanic, and SCC (stress corrosion cracking). Any of these forms of corrosion can occur when the grade of stainless steel is not suited for the working environment. The designation "CRES" refers to corrosion-resistant (stainless) steel. Uniform corrosion takes place in very aggressive environments, typically where chemicals are produced or heavily used, such as in

2166-623: The economy, have been harmful to both human health and well-being as well as to the environment. One example of this is in the Mindoro Oriental region , where nickel mines have left behind toxic mine tailings. This has polluted the water, which is necessary for both humans to drink as well as for them to use for agricultural practices. The nickel mines have also destroyed lands that indigenous tribes have lived on for generations. From 1953 to 1958 Nickel Rim mines operating around Sudbury, Ontario deposited their mine tailings in an impoundment near

2223-611: The exploitation method used is smelting. According to the intergovernmental International Nickel Study Group, in 2017 the countries with the largest volume of nickel ore reserves are Australia (19.5 million metric tons), Brazil (10.5 million metric tons), Russia (7.5 million metric tons), New Caledonia (6.5 million metric tons), Cuba (5.5 million metric tons), and the Philippines (just under 5 million metric tons). As of 2017, 33 countries produced nickel ore. Nickel production increased from 2000 to 2013 (when it peaked), decreased from 2014 to 2016, and recovered from 2017 to 2018. As of 2017,

2280-634: The impoundment is going to discharge water with high concentrations of iron and sulphate for at least the next 50 years. A study found that the Mount Keith Nickel Mine which is an open pit mine in Western Australia is sequestering and storing large amounts of carbon dioxide through enhanced weathering of mineral waste, this means that this mine is offsetting approximately 11% of the annual greenhouse gas emissions released by this mine. Nickel , copper as well as cobalt deposits became

2337-523: The increased domestic demand for electric vehicles . In 2020, highly valuable nickel, copper and cobalt occurrences were discovered near Tamarack , Minnesota . Environmental groups have expressed concerns over the potential pollution of the Kettle River headwaters, and the Mississippi watershed . The Environmental Protection Agency considers hardrock mining the top polluting industry in the US, and there

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2394-593: The largest nickel mine operators are (in descending order of kilotonnes mined): Other large nickel producers include Jinchuan Group Ltd., the largest nickel producer in China, and Sherritt , a Canadian company from Canada that refines nickel from lateritic ores and has operations in Canada, Cuba, Indonesia and Madagascar. According to the intergovernmental International Nickel Study Group, as of 2017, an estimated 75% of primary nickel usage went to stainless steel ; 3.7% went to

2451-477: The mine through a takeover of Lionore, but soon after, in late 2008 and early 2009, low nickel prices forced a number of mines in Western Australia to close, including Black Swan. The mine, which had employed over 500 people during operations, was placed in care and maintenance . During its eleven year operation, the mine produced 41,000 tonnes of nickel from the Black Swan open pit and 138,000 tonnes of nickel from

2508-405: The mine. The water in the impoundment was later tested and found to have low pH and high concentrations of iron , sulphur and dissolved metals such as aluminum and nickel. This is due to the oxidation of the tailings (usually sulfide minerals like pyrrhotite ). The limited oxygen diffusing into the layers causes the tailings to oxidize over a longer period of time, for this reason the water at

2565-448: The most sought-after mineral exploration sites worldwide by private companies and national governments, when nickel prices more than doubled from 2017 to 2021. In the US, the only lucrative nickel mine in Riddle, Oregon ceased operation in 1987 due to pollution concerns, but some sites are now actively re-explored as the federal government considers these deposits of strategic importance due to

2622-502: The most widely used. Many grading systems are in use, including US SAE steel grades . The Unified Numbering System for Metals and Alloys (UNS) was developed by the ASTM in 1970. Europe has adopted EN 10088 . Unlike carbon steel , stainless steels do not suffer uniform corrosion when exposed to wet environments. Unprotected carbon steel rusts readily when exposed to a combination of air and moisture. The resulting iron oxide surface layer

2679-469: The process plant from there to Black Swan. Additionally, the existing process plant at Black Swan was upgraded at a cost of A$ 13 million with the aim of increasing annual nickel production to 18,000 tonnes. In the 2000s, the mine saw frequent changes of ownership, including Finnish company Outokumpu until 2002, followed by MPI Mines Limited, which had already been involved in the project earlier, Lionore from 2004 and Norilsk Nickel from 2007. Norilsk acquired

2736-414: The product was issued in 1869. This was followed with recognition of the corrosion resistance of chromium alloys by Englishmen John T. Woods and John Clark, who noted ranges of chromium from 5–30%, with added tungsten and "medium carbon". They pursued the commercial value of the innovation via a British patent for "Weather-Resistant Alloys". Scientists researching steel corrosion in the second half of

2793-429: The pulp and paper industries. The entire surface of the steel is attacked, and the corrosion is expressed as corrosion rate in mm/year (usually less than 0.1 mm/year is acceptable for such cases). Corrosion tables provide guidelines. This is typically the case when stainless steels are exposed to acidic or basic solutions. Whether stainless steel corrodes depends on the kind and concentration of acid or base and

2850-574: The solution temperature. Uniform corrosion is typically easy to avoid because of extensive published corrosion data or easily performed laboratory corrosion testing. Acidic solutions can be put into two general categories: reducing acids, such as hydrochloric acid and dilute sulfuric acid , and oxidizing acids , such as nitric acid and concentrated sulfuric acid. Increasing chromium and molybdenum content provides increased resistance to reducing acids while increasing chromium and silicon content provides increased resistance to oxidizing acids. Sulfuric acid

2907-949: The standard AOD process. Duplex stainless steels have a mixed microstructure of austenite and ferrite, the ideal ratio being a 50:50 mix, though commercial alloys may have ratios of 40:60. They are characterized by higher chromium (19–32%) and molybdenum (up to 5%) and lower nickel contents than austenitic stainless steels. Duplex stainless steels have roughly twice the yield strength of austenitic stainless steel. Their mixed microstructure provides improved resistance to chloride stress corrosion cracking in comparison to austenitic stainless steel types 304 and 316. Duplex grades are usually divided into three sub-groups based on their corrosion resistance: lean duplex, standard duplex, and super duplex. The properties of duplex stainless steels are achieved with an overall lower alloy content than similar-performing super-austenitic grades, making their use cost-effective for many applications. The pulp and paper industry

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2964-536: The strength up to above 1,000 MPa (150,000 psi) yield strength. This outstanding strength level is used in high-tech applications such as aerospace (usually after remelting to eliminate non-metallic inclusions, which increases fatigue life). Another major advantage of this steel is that aging, unlike tempering treatments, is carried out at a temperature that can be applied to (nearly) finished parts without distortion and discoloration. Typical heat treatment involves solution treatment and quenching . At this point,

3021-695: The structure remains austenitic. Martensitic transformation is then obtained either by a cryogenic treatment at −75 °C (−103 °F) or by severe cold work (over 70% deformation, usually by cold rolling or wire drawing). Aging at 510 °C (950 °F) — which precipitates the Ni 3 Al intermetallic phase—is carried out as above on nearly finished parts. Yield stress levels above 1400   MPa are then reached. The structure remains austenitic at all temperatures. Typical heat treatment involves solution treatment and quenching, followed by aging at 715 °C (1,319 °F). Aging forms Ni 3 Ti precipitates and increases

3078-644: The time, began production in 1997, first as an underground operation, named Silver Swan, later as an open pit mine as well. The development of the Silver Swan Mine cost A$ 46 million and first ore to Outokumpu 's smelter in Finland was delivered in May 1997. The mine was estimated at the time to produce 10,000 tonnes of nickel annually. With the completion of mining at the Flying Fox Mine in 1998, Outokumpu transferred

3135-487: The use of dissimilar materials (bronze against stainless steel) or using different stainless steels (martensitic against austenitic). Additionally, threaded joints may be lubricated to provide a film between the two parts and prevent galling. Nitronic 60, made by selective alloying with manganese, silicon, and nitrogen, has demonstrated a reduced tendency to gall. The density of stainless steel ranges from 7.5 to 8.0 g/cm (0.27 to 0.29 lb/cu in) depending on

3192-415: The yield strength to about 650 MPa (94,000 psi) at room temperature. Unlike the above grades, the mechanical properties and creep resistance of this steel remain very good at temperatures up to 700 °C (1,300 °F). As a result, A286 is classified as an Fe-based superalloy , used in jet engines, gas turbines, and turbo parts. Over 150 grades of stainless steel are recognized, of which 15 are

3249-476: Was one of the first to extensively use duplex stainless steel. Today, the oil and gas industry is the largest user and has pushed for more corrosion resistant grades, leading to the development of super duplex and hyper duplex grades. More recently, the less expensive (and slightly less corrosion-resistant) lean duplex has been developed, chiefly for structural applications in building and construction (concrete reinforcing bars, plates for bridges, coastal works) and in

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