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. Hastelloy (also known as Hastelloy C, UNS10276) and Alloy 20 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 Incoloy, Inconel, Monel, Precision Alloy, Titanium Alloy.
Supported Shape Products: Hastelloy Plate & Sheet, Hastelloy Coil, Hastelloy Bar, Hastelloy Strip, Hastelloy Pipe & Tube, Hastelloy Wire & Mesh.
This paper will compare Hastelloy Alloy with the Stainless Steel, 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 Hastelloy Alloy?
Chemical Composition
Hastelloy is a family of nickel-based superalloys designed for extreme environments. These alloys are known for their exceptional resistance to corrosion, high-temperature stability, and mechanical strength. Common grades include Hastelloy C276, Hastelloy B2, and Hastelloy X. Hastelloy Alloy is a super austenitic stainless steel containing nickel, chromium, molybdenum, and tungsten, designed to resist various harsh corrosive environments. Welcome to inquiry and ask for the informations about alloy.
The chemical composition of Hastelloy alloys varies depending on the grade, but they generally contain high levels of nickel, chromium, and molybdenum. Below is the composition of Hastelloy C276, one of the most widely used grades:
| Element | Composition (%) |
|---|---|
| Nickel (Ni) | 57.0 (min) |
| Chromium (Cr) | 15.5 – 16.5 |
| Molybdenum (Mo) | 15.0 – 17.0 |
| Iron (Fe) | 4.0 – 7.0 |
| Tungsten (W) | 3.0 – 4.5 |
| Cobalt (Co) | 2.5 (max) |
| Manganese (Mn) | 1.0 (max) |
| Silicon (Si) | 0.08 (max) |
| Carbon (C) | 0.01 (max) |
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Physical properties
Hastelloy alloys exhibit excellent physical properties, making them suitable for harsh environments.
| Property | Hastelloy C276 |
|---|---|
| Density (g/cm³) | 8.89 |
| Melting Point (°C) | 1325 – 1370 |
| Thermal Conductivity (W/m·K) | 10.2 (at 100 °C) |
| Electrical Resistivity (µΩ·m) | 1.30 |
| Coefficient of Thermal Expansion (µm/m·K) | 11.2 (20 – 100 °C) |
Mechanical properties
Hastelloy alloys offer superior mechanical strength and ductility, even at high temperatures.
| Property | Hastelloy C276 |
|---|---|
| Tensile Strength (MPa) | 790 |
| Yield Strength (MPa) | 415 |
| Elongation (%) | 40 |
| Hardness (Rockwell B) | 90 |
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What Is Incoloy Alloy?
Incoloy alloy, also known as Incoloy, is a family of high-performance nickel-based alloys renowned for their exceptional resistance to corrosion, oxidation, and high-temperature environments. Common variants include Incoloy 800, 825, 925, and Alloy 20 (N08020), each tailored for specific applications. Below is a detailed overview of their chemical composition and physical properties.
Incoloy Alloy of Chemical Composition
| Element | Incoloy 800 | Incoloy 825 | Incoloy 925 |
|---|---|---|---|
| Ni | 30-35 | 38-46 | 40-45 |
| Cr | 19-23 | 19.5-23.5 | 19-23 |
| Fe | Balance | Balance | Balance |
| Mo | – | 2.5-3.5 | 2.5-3.5 |
| Cu | 0.75 max | 1.5-3.0 | 1.5-3.0 |
| Ti | 0.15-0.6 | 0.6-1.2 | 1.5-2.5 |
| Al | 0.15-0.6 | 0.2 max | 0.1-0.5 |
High-Temperature Performance
- Incoloy 800: Retains strength up to 1,150°C, with tensile strength ≥620 MPa at 700°C.
- Incoloy 825: Maintains stability in oxidizing and reducing environments up to 900°C.
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Incoloy Alloy of Physical properties
| Property | Incoloy 800 | Incoloy 825 | Incoloy 925 |
|---|---|---|---|
| Density (g/cm³) | 7.95 | 8.14 | 8.05 |
| Melting Range (°C) | 1350-1400 | 1370-1400 | 1350-1400 |
| Thermal Conductivity (W/m·K) | 12.2 | 11.1 | 10.8 |
| Electrical Resistivity (μΩ·m) | 1.02 | 1.15 | 1.20 |
Notes:
Low thermal conductivity suits high-temperature applications.
High density ensures structural stability.
Incoloy Alloy of Mechanical properties
| Property | Incoloy 800 (Annealed) | Incoloy 825 (Annealed) | Incoloy 925 (Aged) |
|---|---|---|---|
| Tensile Strength (MPa) | 500-650 | 586-689 | 827-1034 |
| Yield Strength (MPa) | 200-300 | 241-345 | 586-827 |
| Elongation (%) | 30-45 | 30-55 | 15-25 |
| Hardness (Rockwell B) | 75-85 | 80-90 | 25-35 (HRC) |
Key Observations:
Incoloy 925 (precipitation-hardened) offers superior strength for downhole oil/gas tools.
Incoloy 825 balances ductility and corrosion resistance for chemical processing.
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.Our company offers a variety of nickel alloy materials for your selection. If you have any questions, please feel free to contact us via email.
Hastelloy Alloy Vs Incoloy Alloy Cost Considerations
1. Material Composition and Corrosion Resistance:
- Composition: Hastelloy metal alloys are primarily nickel-based, with significant additions of chromium, molybdenum, and other elements such as tungsten, cobalt, and iron. These alloys are designed to provide exceptional corrosion resistance in severe environments.
- Corrosion Resistance: Hastelloy alloys are renowned for their ability to withstand corrosion in highly aggressive conditions, including strong acids, alkalis, and oxidizing environments. They exhibit high resistance to stress corrosion cracking and pitting corrosion.
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
2. Mechanical Properties:
- Strength and Ductility: Hastelloy metal alloys often exhibit high tensile strength, yield strength, and ductility, allowing them to withstand high loads and maintain flexibility.
- High-Temperature Performance: Many Hastelloy alloys maintain their mechanical properties at elevated temperatures, making them suitable for high-temperature applications.
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)
3. Application-Specific Considerations:
- Chemical Processing: Hastelloy metal alloys are widely used in chemical processing equipment due to their resistance to a wide range of corrosive chemicals.
- Petrochemical Industry: They are essential in refining and processing units where high temperatures and aggressive chemicals are present.
- Aerospace and Marine: Their high-temperature stability and corrosion resistance make them suitable for engine components and marine applications.
- Decommissioning costs partially offset by scrap value (Ni recovery)
Alternative analysis: Titanium sometimes competes on strength/weight basis
3. Application-Specific Cost Considerations
- Power Generation: Nuclear reactors, steam generators.
- Chemical Processing: Equipment handling nitric acid, sulfuric acid, and alkali solutions..
Corrosion Resistance:Resists sulfuric/phosphoric acids (Incoloy 825), chlorides, and stress-corrosion cracking.
High-Temperature Performance: Stable up to 700°C (Incoloy 800H) with creep resistance.
Versatility: Used in heat exchangers, nuclear reactors, marine components, and sour gas wells.
Fabrication Ease: Weldable and machinable with standard techniques.
Incoloy is cost-effective for moderate temperatures and corrosive environments, while Inconel excels in extreme heat.
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For a complete list of our stock items, please contact us or fill out our online quote form. Our company offers a variety of nickel alloy materials for your selection. If you have any questions, please feel free to contact us via email.
Hastelloy Alloy Vs Incoloy Alloy Advantages
Hastelloy Alloy
Exceptional Corrosion Resistance: Resists pitting, crevice corrosion, and stress corrosion cracking in aggressive environments.
High-Temperature Stability: Maintains mechanical properties at elevated temperatures.
Versatility: Performs well in both oxidizing and reducing conditions.
Weldability: Can be welded using standard techniques without post-weld heat treatment.
Longevity: Reduces maintenance costs and extends equipment life.
Incoloy 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
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.Our company offers a variety of nickel alloy materials for your selection. If you have any questions, please feel free to contact us via email.
Hastelloy Alloy Vs Incoloy Alloy Applications
Applications of Hastelloy Alloy:
Hastelloy alloys are used in industries requiring resistance to highly corrosive environments and high temperatures.
| Industry | Applications |
|---|---|
| Chemical Processing | Reactors, heat exchangers, piping systems |
| Oil and Gas | Downhole equipment, pipelines, valves |
| Aerospace | Combustion chambers, turbine components |
| Pollution Control | Scrubbers, flue gas desulfurization systems |
| Pharmaceuticals | Equipment for handling corrosive chemicals |
Applications of Incoloy Alloy:
Huaxiao Metal Manufacturer provides manny of hastelloy alloy. Incoloy 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.
Incoloy alloys combine Ni-Cr-Fe chemistry for balanced corrosion resistance, mechanical strength, and affordability. Selection depends on environment (e.g., acidic, high-pressure) and temperature requirements. Our company offers a variety of nickel alloy materials for your selection. If you have any questions, please feel free to contact us via email.