How to Cut and Fabricate Incoloy 800 Tube for Custom Applications

Incoloy 800 is a popular nickel-iron-chromium alloy with high strength and excellent resistance to oxidation, carburization, and nitridation at high temperatures. This makes it an ideal material for custom applications in industries such as aerospace, chemical processing, and power generation.

However, cutting and fabricating Incoloy 800 tube can be challenging due to its high strength and toughness. Precision and attention to detail are critical to ensure accurate and clean cuts that meet the desired specifications. This guide provides expert advice and practical tips on how to cut and fabricate Incoloy 800 tubes for custom applications.

Selecting the Right Cutting Method

Cutting Incoloy 800 tubes for custom applications can be a challenging task. The type of cutting method used is essential to ensure that it meets the desired requirements and produces accurate results. Consider using laser cutting technology to effectively cut an Incoloy 800 tube. Its advantages include:

  • Faster processing speeds.
  • Greater precision.
  • No heat-affected zone (HAZ).
  • Minimal waste material generated.

It also offers flexibility in terms of customization since the design can be adjusted depending on the application’s needs. Additionally, lasers are cost-effective compared to other methods due to their accuracy and efficiency in providing high-quality results with minimal wastage.

Abrasive Cutting

Abrasive cutting is a machining process that separates materials by cutting them with an abrasive tool. It uses highly abrasive particles, such as diamond or cubic boron nitride, to remove material from the workpiece. Abrasive cutting often involves high-pressure water jets and other techniques to create various intricate shapes and sizes. It features materials that are difficult or impossible to cut with traditional methods. The process produces clean cuts in a short time without causing any damage to the workpiece. Depending on the type of material being cut, it can provide superior surface finishes compared to conventional methods such as sawing or milling.

Cold Sawing

In this method, a circular saw blade with carbide teeth cuts the metal tube with a low-speed, high-torque motion. Cold sawing offers precise cuts and minimal material distortion.

Laser Cutting

Laser cutting uses a high-powered laser beam to melt and vaporize the material, producing clean, precise cuts with minimal material damage. Laser cutting is best suited for thin and delicate tubes.

Preparing the Tube for Cutting

Before cutting Incoloy 800 tube, it is important to prepare the material to minimize the risk of material damage. Below are some tips for preparing your tube for cutting:

Ensure the tube is straight and free from deformations or warps that could affect the cutting process.

Clean the tube thoroughly to remove any contaminants such as oil, debris, or rust that could undermine the precision of the cut.

Measure and mark the tube accurately to ensure the correct length and dimensions are achieved.

Cutting the Tube Precisely

When cutting Incoloy 800 tube, precision is critical to obtain a clean and accurate cut. Below are some tips to ensure that your cuts are precise and meet the desired specifications:

  • Maintain consistent and steady blade pressure throughout cutting to prevent blade chatter or wobbling.
  • Use the appropriate cutting speed and feed rate for your chosen cutting method and tube dimensions.
  • Ensure that both ends of the tube are perfectly square and deburred to avoid any damage to the equipment or safety hazards.

Fabricating Incoloy 800 Tube

Once you have cut your Incoloy 800 tube to the desired length, you can fabricate it to fit specific customer applications. Below are some common methods of fabricating Incoloy 800 tubes:


Incoloy 800 tubes can be easily welded using TIG or MIG welding techniques. However, it is essential to ensure proper joint preparation, a clean welding environment, and the use of the appropriate welding filler material to avoid contamination.


Incoloy 800 tubes can be bent to fit specific shapes using various bending methods such as rotary draw bending, 3-roll bending, or mandrel bending. The key to successful bending is to avoid material damage or distortion and maintain the desired tubing wall thickness.

Flaring and Swaging:

Flaring and swaging are techniques used to expand or reduce the diameter of the tube ends to fit into other tubes or fittings. These methods require precision and attention to detail to ensure proper alignment and fit.


Cutting and fabricating Incoloy 800 tubes for custom applications require expertise, precision, and attention to detail. Following the tips in this guide, you can achieve accurate and clean cuts and fabricate the material to fit specific customer applications. Remember to select the right cutting method, prepare the tube thoroughly, cut the tube precisely, and fabricate the material using the appropriate techniques to achieve optimal results.