Monel 400/K500 Pipes & Tubes: Manufacturing, Testing, Applications & Advantages

• Excellent corrosion resistance
• Ideal for seawater systems, chemical plants, and heat exchangers

• Age-hardened for high mechanical strength
• Used in oilfield tools, pump shafts, subsea and marine components

Moksh Tubes supplies both grades in seamless, welded, heat exchanger, condenser tube, and U-tube forms.

The manufacturing process begins with selecting ultra-pure raw materials:

• High Nickel (Ni) ingots
• Copper (Cu) cathodes
• Alloying elements (Al, Ti for K500)

Raw materials are melted in VIM or ESR furnaces to ensure:

• Purity
• High corrosion resistance
• Consistent chemical composition

Once melted, the alloy is cast into billets used for seamless pipe manufacturing.

Billets are heated at 1100–1200°C in rotary furnaces to prepare for piercing.

Using Mannesmann piercing mills, billets are converted into hollow shells. Benefits:

• Seamless structure
• No weld seam
• Superior strength

Elongates the hollow shell to required diameter while maintaining:

• Wall thickness uniformity
• Grain structure control
• Strength and ductility

For precision sizing, pipes are cold drawn using carbide dies and mandrels.

• Improved dimensional accuracy
• Better surface finish
• Increased mechanical strength

• Restores ductility
• Improves toughness
• Releases internal stresses

Monel K500: Undergoes additional age-hardening for higher strength.

Pipes are straightened using multi-roll straightening machines.

Pipe ends are beveled or machined for welding, threading, or custom connections.

• Hydrostatic test
• Eddy current test
• Ultrasonic testing
• PMI (Positive Material Identification)
• Dimensional inspection

Pipes are polished and packed in:

• Wooden boxes
• Hexagonal bundles
• Seaworthy packing

Full documentation (MTC, test reports) is provided.

Monel plates and coils are procured in grades 400 and K500.

Edges are trimmed and beveled for proper weld penetration.

Plates are rolled into cylindrical shapes using bending rolls or hydraulic presses.

Two types of welding are used:

• ERW: Small diameters, economical and fast
• TIG/MIG/SAW: Large diameters, clean welds, ideal for corrosive environments

• Stress-relief annealing
• Solution annealing

Restores corrosion resistance and mechanical properties.

• Hydrotest
• Radiography (X-ray)
• PMI test
• Dimensional checks

• Cold pilgering
• Multi-stage drawing
• Bright annealing
• Finishing & coiling
• Hydro & eddy current testing

Applications:

• Desalination plants
• Marine coolers
• Chemical heat exchangers
• Power plant condensers

• Cutting straight tubes
• Solution annealing
• Cold bending (controlled radius)
• Post-bending heat treatment
• Hydrotesting
• PMI testing

• PMI Test
• Hydrostatic Test
• Ultrasonic Test
• Eddy Current Test
• Radiography (for welded pipes)
• IGC Test
• Mechanical Testing
• Hardness Test
• Micro & Macro Examination

• Seawater systems
• Heat exchanger tubes
• Pump shafts
• Ballast water systems

• Acid handling lines
• HF alkylation units
• Brine heaters

• Downhole tools
• Refinery piping
• Sour gas lines

• Condensers
• Boilers
• Reboilers

• Distillers
• Evaporators
• Brine pipelines

• Excellent seawater corrosion resistance
• Long service life (10–25 years)
• Superior mechanical strength (especially K500)
• High resistance to acids & alkalis
• Withstand high-velocity fluids
• Temperature stability from cryogenic to 600°C
• Non-magnetic properties
• Easy to fabricate & weld