What is Hastelloy?
Hastelloy Chemical Composition
Typical Hastelloy chemical composition includes:
|
Component |
Nickel (Ni) |
Chromium (Cr) |
Molybdenum (Mo) |
Iron (Fe) |
Others (Co, Ti, Mn) |
|
Typical % Range |
Majority |
15–20% |
10–16% |
Up to 7% |
Trace amounts |
|
Role |
Base element, corrosion resistance, thermal stability |
Oxidation resistance enhancer |
Resists pitting, crevice corrosion |
Increases strength and stability |
Minor alloying to enhance strength, corrosion resistance |
Hastelloy Properties
Key Hastelloy mechanical properties include:
- Superior tensile strength (up to around 800 MPa)
- High melting point (~1320–1370 °C)
- Excellent corrosion resistance across a broad range of chemicals
- Outstanding thermal shock resistance and compatibility with welding processes
These properties make Hastelloy alloys usable in advanced aerospace, nuclear, and chemical processing sectors.
What is Monel?
Monel Chemical Composition
|
Element |
Nickel (Ni) |
Copper (Cu) |
Iron (Fe) |
Manganese (Mn) |
Others (C, Si, S, etc.) |
|
Typical % |
60–70% |
20–30% |
≤2.5% |
≤2.0% |
Trace amounts |
|
Role |
Primary base, structural stability, corrosion resistance |
Enhances corrosion resistance in seawater and brine |
Adds strength and toughness |
Contributes to overall mechanical properties |
Trace elements improve specific alloy characteristics |
Monel Mechanical Properties
- Good tensile strength range (varies widely, around 550–1100 MPa based on grade)
- Moderate melting point (~1300–1350 °C)
- Excellent resistance to seawater corrosion and biofouling
- High work-hardening rate, giving good strength but making machining more challenging
Monel 400 vs Hastelloy C276: Grade Comparison
Hastelloy C276
Monel 400
Hastelloy vs Monel: Which is Better?
|
Alloy |
Melting Point (°C) |
|
Hastelloy C276 |
1320–1370 |
|
Monel 400 |
1300–1350 |
Tensile Strength of Monel and Hastelloy
| Alloy | Tensile Strength (MPa) |
| Hastelloy C276 | ~690–783 |
| Monel 400 | ~550–1100 |
Machinability of Monel vs Hastelloy
- Hastelloy machinability is generally challenging due to hardness and toughness; specialized tools and slower feed rates are often necessary.
- Monel machinability is better, though it work hardens and requires moderate machining care.
Corrosion Resistance: Monel vs Hastelloy Alloy
- Hastelloy corrosion resistance is superior in oxidizing and reducing acids, offering long-term durability in aggressive chemical plants.
- Monel 400 corrosion resistance excels in marine environments, resisting chloride stress corrosion and biofouling effectively.
Thermal Conductivity: Monel vs Hastelloy Alloy
- Monel has slightly better thermal conductivity (~21 W/m·K) compared to Hastelloy (~11 W/m·K), which matters in heat exchanger and cooling system design.
Monel vs Hastelloy Price Comparison
|
Alloy |
Average Price (USD/kg) |
|
Hastelloy C276 |
$50–$70 |
|
Monel 400 |
$30–$50 |
Hastelloy is more expensive due to its complex alloying and enhanced performance. Monel is an economical choice for corrosion resistance in less severe conditions.
Hastelloy vs Monel: Uses
- Hastelloy applications: Chemical reactors, nuclear fuel processing, aerospace parts, heat exchangers requiring resistance to oxidizing/reducing agents.
- Monel applications: Marine hardware, desalination plants, acid pickling equipment, piping and valves in moderate chemical environments.
Hastelloy vs Monel: Which Should You Choose?
The choice is depends on the environment and mechanical demands:
- Use Hastelloy for harsh chemical exposure, high temperature, and where mechanical strength cannot be compromised.
- Use Monel for cost-effective corrosion resistance, especially in seawater or mild acid conditions.
Leading manufacturer & supplier for Monel and Hastelloy
Understanding the difference between Monel and Hastelloy is key for engineers and procurement professionals aiming to maximize asset longevity while controlling costs. Hastelloy leads in strength and chemical resilience; Monel offers superior marine corrosion resistance and machinability benefits. Selecting the optimum alloy depends on application specifics, durability needs, and budget constraints.
Kalpataru Piping Solutions is a leading manufacturer & supplier offering premium Hastelloy and Monel products, including sheets, plates, pipes, and fittings for diverse global industries.
