Incoloy 802 modifies the standard 800-series iron-nickel-chromium formula by deliberately raising carbon content to as much as 0.35% — several times the 0.10% ceiling on standard 800 — along with a stronger aluminum and titanium addition (aluminum 0.60% min, titanium 0.70% min). That higher carbon level promotes the formation of a stable network of chromium carbides that resists carburizing attack in carbon-rich, high-temperature atmospheres, which is exactly the environment 802 was developed for: sintering equipment, carburizing furnace fixtures, and other components that spend their service life absorbing carbon from the surrounding atmosphere.

The elevated aluminum and titanium also give 802 useful high-temperature strength on top of its carburization resistance, making it a practical choice for sinter deck plate and similar abrasive, high-heat equipment where both properties matter. As with the rest of the 800 family, building on an iron-rich rather than nickel-rich base keeps material cost more reasonable than a solid nickel-base alloy while still delivering meaningful resistance to a specific, demanding failure mode. It is typically supplied and used in the annealed condition.

Nickel-iron-chromium superalloys like Incoloy 802 are demanding to machine for a consistent set of reasons: low thermal conductivity concentrates the heat generated by the cut right at the tool edge instead of carrying it away in the chip, the alloy work-hardens noticeably wherever a previous pass rubbed instead of cut, and it holds onto its strength at elevated temperature rather than softening the way steel does as the cutting zone heats up. 802's deliberately elevated carbon content raises this difficulty further — the chromium carbide network that gives it carburizing resistance in service is also considerably more abrasive to a cutting edge than the lighter carbide structure in standard 800.

802 is still more machinable than a solid nickel-base alloy like Inconel or Hastelloy thanks to its iron-rich matrix, but expect tool life closer to a high-carbon tool steel in terms of abrasive wear, layered on top of the heat and work-hardening challenges typical of this alloy family.

Rigid setups, sharp positive-rake carbide, and a wear-resistant coating suited to heat-resistant alloys are essential. Run at conservative speeds, keep feed rates high enough to cut beneath any work-hardened layer, and expect to index inserts more frequently than on lower-carbon 800-series grades.