When it comes to selecting the right metal alloy for industrial applications, two of the most popular choices are Hastelloy and Stainless Steel. Both offer exceptional corrosion resistance, durability, and high-temperature performance. But which one is better for your specific needs?
In this blog, we’ll compare Hastelloy vs Stainless Steel in terms of corrosion resistance, strength, temperature tolerance, cost, and applications to help you make an informed decision.
What is Hastelloy?
Hastelloy is a nickel-based superalloy designed for extreme environments. It contains varying amounts of nickel, molybdenum, and chromium, which enhance its resistance to corrosion, oxidation, and pitting.
Key Properties of Hastelloy:
Excellent corrosion resistance (especially in acidic and chloride-rich environments)
High ductility (can withstand extreme deformation without cracking)
Good high-temperature strength (up to 1000°C / 1832°F)
Non-magnetic (ideal for sensitive applications)
Common grades include Hastelloy C-276, C-22, and B-3.
What is Stainless Steel?
Stainless Steel is an iron-based alloy with at least 10.5% chromium, which forms a passive oxide layer to prevent rust. There are multiple grades (e.g., 304, 316, 317L, 904L), each with different corrosion resistance and mechanical properties.
Key Properties of Stainless Steel:
Good corrosion resistance (varies by grade)
High strength and hardness
Affordable and widely available
Magnetic (depending on grade, e.g., 430 is magnetic, 304 is not)
Hastelloy vs Stainless Steel: Head-to-Head Comparison
| Property | Hastelloy | Stainless Steel |
| Corrosion Resistance | Exceptional (especially in acids & chlorides) | Good (varies by grade) |
| High-Temperature Performance | Up to 1000°C (1832°F) | Up to 870°C (1600°F) |
| Mechanical Strength | Moderate (but ductile) | High (especially 316/317L) |
| Cost | Expensive (nickel-based) | More affordable |
| Magnetic Properties | Non-magnetic | Depends on grade (304 = non-magnetic, 430 = magnetic) |
| Weldability | Excellent (low thermal expansion) | Good (some grades prone to cracking) |
| Common Applications | Chemical processing, oil & gas, marine | Food industry, construction, medical |
When to Choose Hastelloy Over Stainless Steel?
Hastelloy is the best choice when:
- Extreme corrosion resistance is needed (e.g., acidic, chloride-heavy, or high-temperature environments).
- Weldability and ductility are critical (e.g., complex piping systems).
- Long-term durability in harsh conditions (e.g., chemical reactors, flue gas desulfurization).
Industries: Chemical processing, oil & gas, marine, aerospace, pharmaceuticals.
When to Choose Stainless Steel Over Hastelloy?
Stainless Steel is the better option when:
- Cost-effectiveness is a priority (e.g., architectural, food, or medical equipment).
- High mechanical strength is required (e.g., structural supports, pressure vessels).
- Magnetic properties matter (e.g., sensors, motors, or magnetic separators).
Industries: Food & beverage, construction, automotive, medical, manufacturing.
_____________________________________________________________________________________
Need Help Selecting the Right Alloy?
At Daxun Alloy Co., Ltd., we supply high-quality Hastelloy, Stainless Steel, and other specialty alloys for critical applications. Contact us today for expert advice on material selection, custom fabrication, and bulk supply solutions.
🔧 Explore Our Alloy Products