In industries where materials are constantly exposed to extreme environments—be it corrosive chemicals, high temperatures, or saltwater—ordinary metals just don’t suffice. This is where Hastelloy metals and alloys come in. Known for their outstanding resistance to corrosion and ability to perform in the harshest environments, Hastelloy alloys are trusted in critical applications such as chemical processing, aerospace, marine, and nuclear power generation.
This article provides a comprehensive overview of Hastelloy metals and alloys, including their composition, types, properties, applications, and why they are considered some of the most reliable materials in modern engineering.
sasaalloy
What Is Hastelloy?
Hastelloy is a trademarked name owned by Haynes International, used to describe a family of corrosion-resistant metal alloys primarily made from nickel, combined with elements such as molybdenum, chromium, cobalt, and iron. These alloys are specifically engineered to withstand aggressive industrial environments where other materials would fail.
Unlike standard stainless steel or carbon steel, Hastelloy alloys are built for performance in reducing and oxidizing environments, making them ideal for handling acids, chlorides, and high-pressure steam.
Key Characteristics of Hastelloy Metals
-
Exceptional Corrosion Resistance
Resistant to both oxidizing and reducing agents, Hastelloy is especially effective in sulfuric, hydrochloric, nitric, and phosphoric acids. -
High-Temperature Strength
Many Hastelloy grades maintain strength and structural integrity at elevated temperatures above 1000°C. -
Stress Corrosion Cracking Resistance
Offers superior resistance to stress-related corrosion, especially in environments with chlorides or fluctuating temperatures. -
Good Fabricability
Hastelloy can be formed, welded, and machined using standard methods with the right tools and processes. -
Broad Chemical Compatibility
Suitable for use with a wide range of industrial chemicals and mixtures.
Common Grades of Hastelloy Alloys
1. Hastelloy C-276 (UNS N10276)
-
Composition: Nickel, molybdenum, chromium, iron, tungsten
-
Features: Exceptional resistance to strong oxidizers and a broad range of acids
-
Applications: Chemical reactors, scrubbers, heat exchangers, marine equipment
2. Hastelloy C-22 (UNS N06022)
-
Composition: Nickel, chromium, molybdenum, tungsten
-
Features: Outstanding protection against pitting, crevice corrosion, and stress corrosion cracking
-
Applications: Pollution control, pulp and paper industry, pharmaceutical processing
3. Hastelloy B-2 (UNS N10665)
-
Composition: Nickel and molybdenum
-
Features: Resistant to hydrochloric acid and reducing environments
-
Applications: Pickling operations, vacuum furnaces, chemical manufacturing
4. Hastelloy X (UNS N06002)
-
Composition: Nickel, chromium, iron, molybdenum
-
Features: Excellent high-temperature strength and oxidation resistance
-
Applications: Gas turbines, jet engines, furnace components
5. Hastelloy G-30 (UNS N06030)
-
Composition: Nickel, chromium, iron
-
Features: Excellent resistance to phosphoric acid and nitric acid
-
Applications: Fertilizer production, acid regenerators
Mechanical Properties of Hastelloy
| Property | Typical Range (varies by grade) |
|---|---|
| Tensile Strength | 690 – 870 MPa |
| Yield Strength | 280 – 400 MPa |
| Elongation | 40 – 60% |
| Hardness (Brinell) | 150 – 240 |
| Density | ~8.9 g/cm³ |
| Melting Range | ~1320 – 1390°C |
These properties contribute to Hastelloy’s ability to perform under pressure, heat, and corrosive attack.
Comparison with Other Alloys
| Property | Stainless Steel 316 | Inconel 625 | Hastelloy C-276 |
|---|---|---|---|
| Nickel Content | 10–14% | ~58% | ~57% |
| Corrosion Resistance | Moderate | High | Very High |
| Temperature Resistance | ~870°C | ~980°C | ~1040°C |
| Cost | Low | High | High |
Verdict: While stainless steel is suitable for many general-purpose uses, Hastelloy far exceeds in extreme chemical and thermal environments.
Applications of Hastelloy Alloys
1. Chemical Processing
-
Ideal for reactors, vessels, piping, and storage tanks exposed to acids
-
Resistant to corrosion fatigue and acid-induced embrittlement
2. Marine Industry
-
Used in saltwater cooling systems, exhaust manifolds, and heat exchangers
-
Effective against seawater corrosion and marine biofouling
3. Aerospace
-
Jet engine parts, turbine blades, and exhaust ducts
-
High temperature and oxidation resistance under extreme conditions
4. Nuclear Power
-
Fuel rods, reactor components, and containment systems
-
Excellent stress corrosion cracking resistance
5. Pollution Control and Waste Treatment
-
Incinerator liners, scrubbers, and stack liners
-
Can withstand harsh gases and chemical mixtures
Fabrication Tips for Hastelloy
-
Welding: Generally requires filler metals like Hastelloy C-22 or C-276 for consistency and integrity.
-
Machining: Hastelloy work-hardens quickly, so use carbide tools, slow speeds, and high feed rates.
-
Forming: Cold and hot forming are both possible; intermediate annealing may be needed during cold working.
Certifications and Standards
Hastelloy products comply with major global standards, including:
-
ASTM B575 (plates, sheets)
-
ASTM B619/B622 (welded/seamless pipes)
-
ASTM B564 (forgings)
-
ASME Boiler and Pressure Vessel Code
-
NACE MR0175/ISO 15156 (sour service)
Make sure to source materials from reliable suppliers like sasaalloy, who can provide proper documentation and quality assurance.
Why Choose Hastelloy?
-
Long-term resistance in the harshest environments
-
Lower maintenance and downtime costs
-
Reliable performance in life-critical industries
-
Excellent mechanical and chemical stability
-
Proven service life in real-world industrial applications
Final Thoughts
Hastelloy metals and alloys are engineered for performance when failure is not an option. From corrosive acids to extreme heat, these materials stand out for their unmatched durability and reliability.
Choosing Hastelloy may involve a higher upfront investment, but the long-term benefits in safety, durability, and reduced maintenance more than justify the cost. Whether your application is in chemical processing, aerospace, or power generation, Hastelloy is one of the best-performing material families available today.
For high-quality Hastelloy products, expert guidance, and global delivery support, turn to sasaalloy—a trusted name in specialty metals and alloys.
Post time: Aug-01-2025