When it comes to selecting materials for industrial applications, Hastelloy alloys and stainless steel are two of the most commonly used options. Both materials offer excellent corrosion resistance and mechanical properties, but they differ significantly in composition, performance, and cost. This blog provides a detailed comparison of Hastelloy alloys and stainless steel, covering their chemical composition, physical and mechanical properties, advantages and disadvantages, applications, and cost considerations. Inconel Alloy and Monel Alloy are two high-performance alloy materials that are widely used in various industrial fields.
Huaxiao Metal Manufacturer provides all kinds of alloy products and the price is suitable and afforrable for you, welcome to inquiry and learn about the more details.
Huaxiao Metal Manufacturer also provides other alloys, such as Hastelloy, Incoloy, Inconel, Monel, Precision Alloy, Titanium Alloy.
Supported Shape Products: Sheets&plates, bars&rods，coils， strips，tubes&pipes，wires&meshes.
This paper will compare Monel Alloy with the Inconel Alloy, which will help you better understand the similarities and differences between the two materials and then choose the alloy that suits your needs.
What Is Monel Alloy?
Monel alloy is a high-performance nickel-copper alloy renowned for its exceptional corrosion resistance, high strength, and good thermal stability. It is widely used in industries where materials are exposed to harsh environments, such as marine engineering, chemical processing, oil and gas, and aerospace. The alloy’s unique combination of properties makes it an ideal choice for applications requiring long-term durability and reliability.
Monel alloy comes in various grades, with Monel 400 (UNS N04400) being the most commonly used. Other grades include Monel K-500 (UNS N05500), which is precipitation-hardenable and offers higher strength. The alloy is available in multiple forms, including sheets, plates, bars, rods, wires, and tubes, to cater to different manufacturing needs.
| Grade | UNS Number | Standard | Form | Key Features |
|---|---|---|---|---|
| Monel 400 | N04400 | ASTM B164, ASME SB164 | Sheet, Bar, Tube | General-purpose, seawater-resistant |
| Monel K-500 | N05500 | ASTM B865, AMS 4676 | Forged, Fasteners | Age-hardenable, higher strength |
| Monel R-405 | N04405 | ASTM B164 | Machined Parts | Free-machining variant of 400 |
| Monel 404 | N04404 | ASTM F96 | Electronics | Low permeability, specialized uses |
Chemical Composition
| Element | Monel 400 | Monel K-500 | Monel R-405 |
|---|---|---|---|
| Nickel (Ni) | 63-70% | 63-70% | 63-70% |
| Copper (Cu) | 28-34% | 27-33% | 28-34% |
| Iron (Fe) | ≤2.5% | ≤2.0% | ≤2.5% |
| Manganese (Mn) | ≤2.0% | ≤1.5% | ≤2.0% |
| Aluminum (Al) | – | 2.3-3.15% | – |
| Titanium (Ti) | – | 0.35-0.85% | – |
| Sulfur (S) | ≤0.024% | ≤0.01% | 0.025-0.060% |
Key Notes:
Monel 400: Balanced Ni-Cu for general corrosion resistance.
Monel K-500: Age-hardenable (Al/Ti addition increases strength).
Monel R-405: Added sulfur improves machinability.
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Physical properties
| Property | Monel 400 | Monel K-500 |
|---|---|---|
| Density (g/cm³) | 8.80 | 8.44 |
| Melting Range (°C) | 1300-1350 | 1315-1350 |
| Thermal Conductivity (W/m·K) | 21.8 | 19.2 |
| Electrical Resistivity (μΩ·m) | 0.48 | 0.54 |
| Magnetic Permeability | Non-magnetic | Slightly magnetic (when hardened) |
- Density: 8.83 g/cm³
- Melting Point: 1300–1390°C
- Thermal Conductivity: Approximately 21.8 W/(m·K) at room temperature (20°C)
- Coefficient of Thermal Expansion: Varies with temperature (e.g., 7.7 at 70–200°F, 8.6 at 70–400°F)
These properties make Monel alloy suitable for high-temperature applications and environments where thermal stability is critical.
Mechanical properties
| Grade | Tensile (MPa) | Yield (MPa) | Elongation (%) | Hardness (HRB) |
|---|---|---|---|---|
| Monel 400 | 480-620 | 170-345 | 35-50 | 65-85 |
| Monel K-500 | 1000-1200 (aged) | 550-800 | 20-30 | 25-35 HRC |
| Monel R-405 | 480-620 | 170-345 | 35-50 | 65-85 |
Fatigue & Creep Resistance:
Monel 400: Endurance limit ~240 MPa (10⁷ cycles)
Monel K-500: Superior stress rupture strength at 400°C
Monel alloy exhibits impressive mechanical properties, which vary depending on the processing state:
- Tensile Strength: 70–110 ksi for bars, 70–95 ksi for plates
- Yield Strength: 480–760 MPa for bars, 482–655 MPa for plates
- Elongation: 25–85% for bars, 28–75% for plates
- Hardness: 170–585 Brinell for bars, 193–517 Brinell for plates
The alloy’s strength and ductility make it suitable for structural components in demanding environments.
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What Is Inconel Alloy?
Popular Inconel Grades & Their Key Additives:
Inconel 600 (Ni-Cr-Fe) – Good general-purpose resistance
Inconel 625 (Ni-Cr-Mo-Nb) – Excellent fatigue & thermal fatigue resistance
Inconel 718 (Ni-Cr-Fe-Nb-Ti-Al) – High strength up to 1300°F (704°C)
Inconel X-750 (Ni-Cr-Fe-Nb-Ti-Al) – Used in high-stress applications
Chemical Composition
Inconel alloys primarily consist of:
| Element | Typical Composition (%) | Role in the Alloy |
|---|---|---|
| Nickel (Ni) | 50-70% | Provides corrosion resistance & high-temperature stability |
| Chromium (Cr) | 15-23% | Enhances oxidation & sulfidation resistance |
| Iron (Fe) | 5-20% | Improves structural integrity |
| Molybdenum (Mo) | 2-10% (varies by grade) | Increases strength & corrosion resistance |
| Niobium (Nb) | 1-5% (in some grades) | Prevents carbide precipitation & improves weldability |
| Titanium (Ti), Aluminum (Al) | Small amounts | Strengthens via precipitation hardening |
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Physical properties
| Property | Typical Values | Significance |
|---|---|---|
| Density | 8.1-8.5 g/cm³ | Heavier than steel but more durable |
| Melting Point | 1350-1450°C (2462-2642°F) | Retains strength at high temperatures |
| Thermal Expansion | 12-14 µm/m°C (20-1000°C) | Low expansion reduces thermal stress |
| Thermal Conductivity | 10-15 W/m·K | Lower than steel, but excellent heat resistance |
| Electrical Resistivity | 1.15-1.30 µΩ·m | Useful in electrical applications |
Mechanical properties
| Property | Inconel 625 | Inconel 718 | Inconel X-750 |
|---|---|---|---|
| Tensile Strength (MPa) | 830-1030 | 1240-1450 | 1030-1310 |
| Yield Strength (MPa) | 410-690 | 1030-1240 | 690-1030 |
| Elongation (%) | 30-45 | 12-20 | 20-30 |
| Hardness (Rockwell B) | 90-100 | 35-45 (HRC) | 25-35 (HRC) |
| Fatigue Strength | Excellent | Very High | High |
Huaxiao Metal Manufacturer is the top of processing hastelloy alloy in China, and the products are all premium in using and purchasing. For a complete list of our stock items, please contact us or fill out our online quote form.
Monel Alloy Vs Inconel Alloy Cost Considerations
Machining: Use slow speeds/carbide tools (work-hardens easily)
Welding: GTAW/GMAW preferred (avoid sulfur-bearing fillers for K-500)
Heat Treatment: K-500 requires aging at 595-620°C for 16h
Cost Drivers:
Nickel price volatility (~60% of material cost)
Precision machining requirements
Certifications (NACE, ASTM)
1. Material Composition & Corrosion Resistance
High Nickel Content Drives Base Material Cost
Nickel (50-70% composition) is the primary cost driver, with prices historically 3-5× higher than iron
Chromium (15-23%) adds oxidation resistance but further increases material costs
Corrosion Resistance Value Proposition
Lifecycle savings: 5-10× longer service life in chloride/sulfide environments offsets initial cost
Maintenance reduction: Eliminates need for protective coatings in most applications
Monel 400: $25-40/kg (stable supply)
Monel K-500: $50-80/kg (premium for age-hardening)
- Market Trends: 5-8% annual price increase.
- Direct Purchase from Manufacturers: Ideal for large-scale or custom orders.
- Distributors/Stockists: Offer quicker delivery and smaller lot sizes, suitable for urgent needs.
- Online Marketplaces: Provide access to a wide range of suppliers and competitive pricing.
2. Mechanical Properties:
Strength-to-Cost Optimization
Tensile strength (up to 1450 MPa) justifies cost in weight-critical applications
Manufacturing Cost Factors
Machining costs are 3-5× higher than steel due to:
Extreme work hardening (requires specialized tooling)
- Reduced Maintenance: The alloy’s corrosion resistance minimizes the need for repairs and replacements.
- Extended Lifespan: Components made from Monel alloy can last 20–30 years in marine environments, compared to 5–10 years for lower-grade materials.
- Lower Total Cost of Ownership (TCO): Studies show that Monel alloy can reduce TCO by 15–25% over its lifespan.
- Melting and Casting: Producing ingots or billets.
- Hot and Cold Working: Rolling, forging, or extruding into desired shapes.
- Heat Treatment: Annealing or precipitation hardening to optimize properties.
- Finishing: Machining, grinding, or polishing to meet specifications.
3. Application-Specific Cost Considerations
Aerospace Applications
Justified costs: 30-50% of engine components use Inconel despite 5-8× material cost
Oil & Gas Economics
Downhole tools: Inconel pays back in H₂S service (3-5× lifespan vs. duplex steels)
Nuclear Industry
Regulatory requirements often mandate Inconel regardless of cost
Irradiation resistance provides unparalleled value in reactor cores
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Monel Alloy Vs Inconel Alloy Advantages
Monel Alloy
Unmatched seawater corrosion resistance (ideal for marine propellers, pumps)
Resists sulfuric/hydrochloric acids (chemical processing equipment)
High strength-to-weight ratio (vs. stainless steels)
Biofouling resistance (heat exchangers, desalination plants)
- Non-Magnetic Properties: Certain grades, like Monel 400, are non-magnetic at room temperature, making them suitable for electronic and magnetic applications.
Inconel Alloy
- Extreme Temperature Resistance: Performs well in continuous service up to 2200°F (1200°C).Resists creep deformation
- Superior Corrosion & Oxidation Resistance: Excellent against chlorides, acids, and seawater. Forms a protective oxide layer at high temps
- High Strength-to-Weight Ratio: Stronger than many steels but lighter than tungsten alloys
- Fabrication Flexibility： Can be welded, machined, and formed (though difficult due to work-hardening)
- Long Service Life： Resists thermal fatigue, cracking, and degradation
Hastelloy Alloy Vs Inconel Alloy Applications
Applications of Monel Alloy:
By understanding the alloy’s properties, applications, and cost considerations, engineers and procurement professionals can make informed decisions that optimize performance and cost-effectiveness in their projects.
| Industry | Application | Why Monel? |
|---|---|---|
| Marine | Propeller shafts, pumps | Seawater corrosion resistance |
| Oil & Gas | Valve trim, downhole tools | H₂S resistance |
| Chemical | Reactor vessels, heat exchangers | Acid resistance |
| Aerospace | Turbine blades, fasteners | High-strength at temperature |
| Medical | Surgical instruments | Non-magnetic, sterilizable |
Applications of Inconel Alloy:
Huaxiao Metal Manufacturer provides manny of hastelloy alloy. Inconel Alloy is used in a wide range of industries due to its versatility and cost-effectiveness.
| Industry | Applications |
|---|---|
| Construction | Structural components, facades, roofing |
| Food Processing | Tanks, conveyors, processing equipment |
| Medical Devices | Surgical instruments, implants, medical equipment |
| Automotive | Exhaust systems, trim, decorative elements |
| Household Appliances | Sinks, cutlery, cookware |
In Conclusion
Huaxiao Metal Supplier has the various alloy products for sale online Hastelloy alloys are a cornerstone of modern industrial applications, offering unmatched corrosion resistance, high-temperature stability, and mechanical strength. While they come at a higher cost compared to materials like stainless steel, their performance in extreme environments justifies the investment. By understanding their chemical composition, physical and mechanical properties, and cost considerations, industries can optimize their use of Hastelloy alloys for long-lasting and reliable performance. If you have any purchase needs, please feel free to contact us.
Monel alloy stands out as a versatile material for industries requiring high performance in challenging environments. Its exceptional corrosion resistance, strength, and workability make it a preferred choice over conventional materials like stainless steel. While the initial cost may be higher, the long-term benefits in terms of durability, reduced maintenance, and extended lifespan often justify the investment. As industries continue to push the boundaries of technology and environmental exposure, Monel alloy will remain an indispensable material for critical applications.