Introduction
Hastelloy is a nickel-based superalloy renowned for its exceptional corrosion resistance, high-temperature strength, and durability in the most demanding industrial environments. This comprehensive guide covers all major Hastelloy grades, including C-276, C-22, B-2, X, and C-2000, their chemical composition, mechanical properties, applications, and selection tips.
Industrial engineers, procurement professionals, and B2B buyers can use this guide to choose the right Hastelloy grade for chemical, marine, aerospace, and high-temperature applications.
Overview of Hastelloy Alloys
Hastelloy alloys are designed to perform in extreme chemical environments, resisting oxidation, pitting, and stress corrosion cracking. The alloys are divided into series based on their chemical composition and application focus:
C-series: Broad chemical resistance for oxidizing and reducing acids (C-276, C-22, C-2000)
B-series: Optimized for reducing acids like hydrochloric acid (B-2, B-3)
X-series: High-temperature strength and oxidation resistance (Hastelloy X)
Common Hastelloy Grades and Key Characteristics
| Grade | Composition Highlights | Corrosion Resistance | High-Temperature Performance | Typical Applications |
|---|---|---|---|---|
| C-276 | Ni–Cr–Mo–W | Excellent in oxidizing & reducing acids | Up to 600°C | Chemical reactors, heat exchangers, offshore equipment |
| C-22 | Ni–Cr–Mo | Superior pitting & crevice resistance | Up to 600°C | Flanges, chemical vessels, pharmaceutical equipment |
| C-2000 | Ni–Cr–Mo–Cu | Excellent in sulfuric & mixed acids | Up to 600°C | Sulfuric acid process, chemical reactors |
| B-2 | Ni–Mo (low Cr) | Excellent in reducing acids (HCl) | Up to 400–500°C | Hydrochloric acid systems, acid pickling |
| X | Ni–Cr–Fe | Moderate corrosion, high-temperature strength | Up to 1000°C | Gas turbines, furnace components, aerospace high-temp parts |
Key Insight:
C-series alloys are versatile and safe choices for mixed chemical environments.
B-series is specialized for reducing acid resistance.
X-series is the only Hastelloy grade designed primarily for high-temperature structural applications.
Chemical Composition Table (Major Grades)
| Alloy | Ni | Cr | Mo | W | Cu | Fe | Other Elements |
|---|---|---|---|---|---|---|---|
| C-276 | Balance | 14.5–16.5% | 15–17% | 3–4.5% | - | 4–7% | V ≤0.35% |
| C-22 | Balance | 21–22% | 12–14% | - | - | ≤3% | Mn ≤1% |
| C-2000 | Balance | 20–22% | 15–17% | - | 2–3% | ≤4% | Mn ≤1% |
| B-2 | Balance | 2–3% | 16–18% | - | - | ≤3% | Mn ≤1% |
| X | Balance | 21–23% | 8–10% | - | - | 3–6% | Nb + Ta 3.15–4.15% |
Corrosion Resistance Comparison
| Alloy | Reducing Acids | Oxidizing Acids | Chlorides | Stress Corrosion Cracking (SCC) |
|---|---|---|---|---|
| C-276 | Good | Excellent | Excellent | Excellent |
| C-22 | Good | Excellent | Excellent | Excellent |
| C-2000 | Moderate | Excellent | Good | Very Good |
| B-2 | Excellent | Poor | Moderate | Good |
| X | Moderate | Fair | Fair | Excellent |
Key Insight: Hastelloy outperforms stainless steels and most nickel alloys in chemical and mixed media environments.
Mechanical and High-Temperature Performance
| Alloy | Service Temperature | Yield Strength | Tensile Strength | Hardness | Notes |
|---|---|---|---|---|---|
| C-276 | Up to 600°C | 240 MPa | 655 MPa | 90 HRB | Excellent chemical resistance |
| C-22 | Up to 600°C | 280 MPa | 690 MPa | 95 HRB | Superior pitting resistance |
| C-2000 | Up to 600°C | 265 MPa | 680 MPa | 92 HRB | Resistant to sulfuric acid |
| B-2 | Up to 500°C | 205 MPa | 550 MPa | 85 HRB | Optimized for reducing acids |
| X | Up to 1000°C | 310 MPa | 760 MPa | 95 HRB | High-temp structural alloy |
Typical Applications by Grade
| Grade | Applications |
|---|---|
| C-276 | Chemical reactors, heat exchangers, offshore chemical processing, pharmaceutical vessels |
| C-22 | Flanges, valves, piping in mixed acid environments, chloride-rich chemical systems |
| C-2000 | Sulfuric acid tanks, acid recovery, chemical reactors |
| B-2 | Hydrochloric acid processing, acid pickling systems, industrial tanks |
| X | Gas turbines, furnace components, aerospace structural parts, high-temp heat exchangers |
Hastelloy vs Stainless Steel and Other Nickel Alloys
| Factor | Hastelloy | Stainless Steel 316L | Inconel 625 |
|---|---|---|---|
| Corrosion Resistance | Excellent in acids & chlorides | Moderate | Excellent at high temps, moderate chemical resistance |
| High-Temperature Strength | Up to 1000°C | ≤400°C | Up to 980°C |
| Stress Corrosion Cracking (SCC) | Very high | Low | High |
| Typical Industrial Use | Chemical reactors, marine, high-temp | Food, mild chemical | Gas turbines, furnace, aerospace |
| Lifecycle Cost | Lower due to durability | Higher in aggressive environments | Moderate |
Selection Tips for Industrial Buyers
Identify the chemical environment:
Reducing acids → B-2/B-3
Oxidizing or mixed acids → C-276/C-22/C-2000
High temperature → X-series
Check temperature limits:
≤600°C → C-series
600–1000°C → X-series
Consider mechanical and structural requirements:
High-temp creep resistance → X-series
Corrosion-focused → C-series or B-series
Evaluate cost vs lifecycle:
Hastelloy has higher upfront cost but lower maintenance and longer service life than stainless steel.
Hastelloy Grades – FAQ
1. What is the difference between Hastelloy C-276, C-22, B-2, X, and C-2000?
C-276: Excellent corrosion resistance in oxidizing and reducing acids, widely used in chemical reactors and offshore equipment.
C-22: Superior pitting and crevice corrosion resistance, ideal for mixed acid environments.
B-2: Optimized for reducing acids like hydrochloric acid; limited in oxidizing environments.
C-2000: Excellent in sulfuric and mixed acids, with added copper for enhanced resistance.
X: Designed for high-temperature oxidation and structural strength, used in gas turbines and furnace components.
2. Which Hastelloy grade is best for hydrochloric acid?
B-2 or B-3 are the preferred grades due to high molybdenum content and low chromium, which provide resistance to reducing acids.
3. Which grade is suitable for sulfuric acid or mixed acid environments?
C-2000, C-22, or C-276. These grades offer excellent chemical stability, making them ideal for chemical reactors, acid recovery, and flue gas systems.
4. Can Hastelloy alloys handle high temperatures?
C-series (C-276, C-22, C-2000): Up to 600°C
X-series: Up to 1000°C for high-temperature structural and oxidation applications
5. Are Hastelloy alloys easy to weld or fabricate?
Yes, but proper procedures are recommended to maintain corrosion resistance. Low carbon grades reduce the risk of intergranular corrosion.
6. Can Hastelloy be used in marine or chloride-rich environments?
Yes, C-series alloys (C-276, C-22) resist pitting and crevice corrosion in seawater, making them suitable for offshore and marine chemical equipment.
7. How does Hastelloy compare to stainless steel?
Corrosion resistance: Hastelloy >> stainless steel
High-temperature capability: Hastelloy C-series up to 600°C; X-series up to 1000°C; stainless steel ≤400°C
Stress corrosion cracking: Hastelloy superior
Lifecycle cost: Hastelloy often lower due to reduced maintenance and longer service life
8. What industries typically use Hastelloy?
Chemical & Petrochemical Processing – Reactors, heat exchangers, acid tanks
Pharmaceutical Equipment – High-purity chemical reactors
Marine & Offshore – Pumps, piping, and valves in chloride-rich environments
Aerospace & Power Generation – Furnace parts, gas turbines
Environmental Engineering – Flue gas desulfurization (FGD) scrubbers, wastewater treatment
9. How do I select the right Hastelloy grade?
Reducing acids (HCl): B-2/B-3
Oxidizing / mixed acids: C-276, C-22, C-2000
High-temperature applications: X-series
Mixed or unknown chemical environment: C-276 or C-22 for broad corrosion resistance
10. Is Hastelloy cost-effective for industrial applications?
While Hastelloy has a higher initial cost than stainless steel, it offers longer service life, reduced maintenance, and lower total lifecycle cost, especially in extreme chemical or high-temperature environments.
Conclusion
Hastelloy is a premium nickel-based superalloy engineered for extreme corrosion resistance and high-temperature performance. Selecting the correct grade-whether C-276, C-22, B-2, C-2000, or X-ensures long service life, safety, and efficiency in demanding industrial environments.
For technical advice, grade selection, or quotes for plates, pipes, bars, and custom components, contact your trusted Hastelloy supplier today.
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