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When choosing materials for challenging industrial environments, Hastelloy and stainless steel are two primary options. Each offers unique advantages in terms of corrosion resistance, mechanical strength, and cost. Understanding their differences helps in selecting the right material for your specific needs. This article provides a detailed comparison between Hastelloy and stainless steel, including chemical composition, mechanical properties, corrosion resistance, applications, and more.
Hastelloy is a trademarked name for a family of corrosion-resistant metal alloys primarily made of nickel, with additions of molybdenum, chromium, cobalt, and iron. Hastelloy alloys are known for their exceptional resistance to harsh chemical environments and extreme temperatures.
Stainless steel is a group of iron-based alloys that contain at least 10.5% chromium, which provides corrosion resistance. There are various types of stainless steels (austenitic, ferritic, martensitic, duplex) each suited for different environments and applications.
| Element | Hastelloy C-276 (%) | 304 Stainless Steel (%) |
|---|---|---|
| Nickel (Ni) | Min 57 | 8.0 - 10.5 |
| Chromium (Cr) | 14.5 - 16.5 | 18.0 - 20.0 |
| Molybdenum (Mo) | 15.0 - 17.0 | None |
| Iron (Fe) | 4.0 - 7.0 | Balance |
| Carbon (C) | 0.01 Max | 0.08 Max |
| Other Elements | W, Co | Mn, Si |
| Property | Hastelloy C-276 | 304 Stainless Steel |
|---|---|---|
| Tensile Strength (MPa) | 760 | 515 |
| Yield Strength (MPa) | 283 | 205 |
| Elongation (%) | 60 | 40 |
| Hardness (HRB) | 100 | 90 |
Hastelloy C-276 offers outstanding corrosion resistance in both oxidizing and reducing environments. It is highly resistant to pitting, crevice corrosion, and stress-corrosion cracking. Stainless steel, especially grades like 304, provides good general corrosion resistance but is more susceptible to pitting and crevice corrosion in chloride-rich environments.
| Material | Maximum Service Temperature |
|---|---|
| Hastelloy C-276 | up to 1038°C (1900°F) |
| 304 Stainless Steel | up to 870°C (1600°F) |
| Industry | Hastelloy Applications | Stainless Steel Applications |
|---|---|---|
| Chemical Processing | Reactors, heat exchangers | Storage tanks, piping |
| Marine | Seawater valves and pumps | Ship components, fittings |
| Aerospace | Engine parts, exhaust ducts | Structural components |
| Food Processing | Highly corrosive environment tools | Food-grade storage and transport |
Both Hastelloy and stainless steel have good weldability. Hastelloy C-276 requires special care during welding to maintain its corrosion resistance, while 304 stainless steel is easily welded without significant loss of properties.
| Material | Relative Cost |
|---|---|
| Hastelloy C-276 | Very High |
| 304 Stainless Steel | Low to Moderate |
| Category | Hastelloy C-276 | 304 Stainless Steel |
|---|---|---|
| Corrosion Resistance | Superior in harsh chemicals | Good in mild environments |
| Temperature Resistance | Very High | High |
| Mechanical Strength | Excellent | Good |
| Weldability | Requires expertise | Easy |
| Cost | Very High | Affordable |
Hastelloy is significantly more corrosion-resistant than stainless steel, particularly in highly aggressive chemical environments.
Yes, Hastelloy generally has higher tensile and yield strength compared to standard grades like 304 stainless steel.
Hastelloy's higher cost is due to its complex composition with high nickel and molybdenum content, along with its superior performance in extreme environments.
