In industries where materials are exposed to extreme conditions, selecting the right alloy is crucial for ensuring long-term performance, reliability, and safety. Hastelloy and Inconel are two widely used nickel-based superalloys that offer exceptional resistance to heat, corrosion, and stress. While both materials are known for their durability in harsh environments, they each possess unique properties that make them better suited for specific applications.
In this article, we will explore the differences between Hastelloy and Inconel, comparing their compositions, mechanical properties, corrosion resistance, and typical applications. We’ll also discuss why sasaalloy is the ideal source for these high-performance alloys, ensuring you make the right choice for your project needs.
1. Overview of Hastelloy and Inconel
What is Hastelloy?
Hastelloy is a family of nickel-molybdenum-chromium alloys, known for their exceptional resistance to corrosion, particularly in highly acidic environments. Developed by Haynes International, Hastelloy is ideal for applications in industries like chemical processing, aerospace, and marine environments, where materials are subjected to extreme heat, pressure, and corrosive substances.
Some of the most popular grades of Hastelloy include:
-
Hastelloy C-276
-
Hastelloy C-22
-
Hastelloy X
These alloys are especially resistant to oxidizing and reducing environments, including chlorides, sulfuric acid, and phosphoric acid.
What is Inconel?
Inconel is a nickel-chromium-based superalloy, developed by Special Metals Corporation, that is specifically designed to perform at high temperatures and under extreme mechanical stress. Inconel alloys are commonly used in aerospace, turbine engines, and power generation, where both high thermal stability and resistance to oxidation are required.
Popular Inconel grades include:
-
Inconel 625
-
Inconel 718
-
Inconel 600
Inconel’s strength at elevated temperatures, combined with its ability to resist oxidation, makes it ideal for gas turbines, jet engines, and high-stress mechanical components.
2. Chemical Composition Comparison
Hastelloy
The primary components of Hastelloy alloys include:
-
Nickel (Ni): The base metal, providing the alloy with corrosion resistance and thermal stability.
-
Chromium (Cr): Improves resistance to oxidation and enhances the overall strength of the alloy.
-
Molybdenum (Mo): Increases resistance to localized corrosion, especially pitting and crevice corrosion.
For example, Hastelloy C-276 is composed of:
-
Nickel (Ni): ~57%
-
Molybdenum (Mo): ~16%
-
Chromium (Cr): ~16%
-
Iron (Fe): ~5%
-
Tungsten (W): ~4%
Hastelloy alloys often contain higher amounts of molybdenum and tungsten, which provide excellent resistance to aggressive corrosive agents like acids.
Inconel
Inconel alloys are primarily made of:
-
Nickel (Ni): Forms the base of the alloy, providing heat resistance and stability.
-
Chromium (Cr): Enhances the alloy’s resistance to oxidation and corrosion at high temperatures.
-
Iron (Fe): Acts as a strengthening agent.
-
Molybdenum (Mo) and Niobium (Nb): Improve resistance to thermal expansion and cracking under high-temperature stress.
For example, Inconel 625 is composed of:
-
Nickel (Ni): ~58%
-
Chromium (Cr): ~21.5%
-
Molybdenum (Mo): ~9%
-
Niobium (Nb): ~3.5%
-
Iron (Fe): Balance
Inconel alloys tend to have higher levels of chromium and iron, making them more resistant to high-temperature oxidation and improving their strength under stress.
3. Corrosion Resistance Comparison
Hastelloy
One of the standout features of Hastelloy alloys is their superior resistance to corrosion in both oxidizing and reducing environments. They are highly resistant to:
-
Sulfuric acid
-
Hydrochloric acid
-
Chlorides and seawater
-
Phosphoric acid
-
Acidic and caustic conditions
Hastelloy C-276 and Hastelloy C-22 offer excellent protection against localized corrosion, including pitting and crevice corrosion, making them ideal for industries like chemical processing and marine applications, where exposure to aggressive chemicals is common.
Inconel
While Inconel excels in high-temperature oxidation resistance, its corrosion resistance in acidic environments is generally not as strong as that of Hastelloy. However, Inconel 625 and Inconel 718 provide excellent protection against:
-
High-temperature oxidation
-
Corrosion in exhaust systems
-
Chemical environments at elevated temperatures
Inconel is a better choice for applications where resistance to oxidation and thermal stress at high temperatures is more critical than resistance to acid or corrosive agents.
4. High-Temperature Performance
Hastelloy
Hastelloy alloys are known for their heat resistance, but they are primarily used in environments where high-temperature corrosion resistance is more important than strength under extreme heat. Hastelloy C-276, for example, is effective in continuous service at temperatures up to 1900°F (1038°C).
Inconel
Inconel is specifically engineered to handle extreme temperatures and mechanical stress in applications such as turbine engines and jet propulsion systems. Inconel alloys like Inconel 718 can perform effectively at temperatures as high as 1300°F (704°C), and Inconel 625 is suitable for even higher temperatures. Inconel’s high-temperature performance makes it the material of choice for industries that deal with high-stress, high-heat environments, such as aerospace and power generation.
5. Weldability and Fabrication
Hastelloy
Hastelloy is highly weldable, and its ability to be welded and formed into complex shapes without compromising its integrity is a major advantage. It is particularly useful in applications where custom components need to be fabricated, such as in reactors and heat exchangers.
Inconel
Inconel also offers excellent weldability, but certain grades like Inconel 625 require more careful heat treatment to avoid stress corrosion cracking during welding. It is often used for welded components exposed to high temperatures, but requires more stringent welding controls than Hastelloy in certain situations.
6. Applications of Hastelloy and Inconel
Hastelloy Applications
-
Chemical processing industries: Heat exchangers, piping systems, and reaction vessels exposed to acidic environments.
-
Marine environments: Offshore oil rigs, seawater cooling systems, and desalination plants.
-
Power generation: Furnace components, boilers, and reactors.
Inconel Applications
-
Aerospace: Turbine blades, jet engine components, and exhaust systems.
-
Power generation: Gas turbines, steam turbines, and boilers.
-
Petrochemical industries: Heat exchangers, refining equipment, and gas compressors.
7. Cost Comparison
Both Hastelloy and Inconel are premium alloys, and their cost reflects their high-performance capabilities. Inconel tends to be slightly less expensive than Hastelloy due to the lower cost of its base elements, but the exact price depends on factors like the grade and form of the alloy.
8. Why Choose sasaalloy for Hastelloy and Inconel?
At sasaalloy, we specialize in providing high-quality Hastelloy and Inconel products to meet the demanding needs of industries like aerospace, chemical processing, and power generation. Here’s why you should choose sasaalloy:
-
High-Quality Materials: Our alloys are sourced from trusted manufacturers to ensure top-notch quality and performance.
-
Expert Advice: Our team can help you select the best alloy for your specific application, whether you need Hastelloy for corrosion resistance or Inconel for high-temperature strength.
-
Custom Solutions: We offer customized sizes, shapes, and grades to suit your needs.
-
On-Time Delivery: We understand the importance of deadlines and provide fast, reliable delivery to keep your projects on track.
-
Competitive Pricing: Get the best value for your investment with our competitive pricing on Hastelloy and Inconel alloys.
9. Conclusion
When choosing between Hastelloy and Inconel, it’s important to understand the specific needs of your application. Hastelloy excels in corrosion resistance and chemical processing, while Inconel is the go-to material for high-temperature and high-stress applications like those in aerospace and power generation.
For the highest quality Hastelloy and Inconel alloys, trust sasaalloy to provide the perfect solution for your project. Whether you need resistance to heat or corrosion, we have the materials and expertise to ensure your project’s success.
For more information or to place an order, contact sasaalloy today.
Post time: Jul-11-2025