Hastelloy C276 vs Duplex Steel – What’s the Difference

Hastelloy C276 vs Duplex Steel

Regarding corrosion-resistant alloys, two popular options in the market are Hastelloy C276 and Duplex Steel. Both these materials are widely used in chemical processing, oil and gas, and marine applications. But what sets them apart, and how do you know which one to choose for your specific needs? This blog post will examine the differences between Hastelloy C276 and Duplex Steel.

What is Hastelloy C276?

Hastelloy C276 is a nickel-molybdenum-chromium alloy with remarkable corrosion resistance in various aggressive media. It has an excellent mix of strength, weldability, and oxidation resistance at high temperatures. It is commonly used for marine applications and chemical process equipment.

What is Duplex Steel?

Duplex Steel is a type of Stainless Steel featuring both austenitic and ferritic microstructures, resulting in an alloy with high strength and excellent corrosion resistance. It also offers good mechanical properties, high thermal conductivity, low coefficient of thermal expansion, and good weldability.

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Difference Between Hastelloy C276 and Duplex Steel

Composition and Properties

Hastelloy C276 is a nickel-molybdenum-chromium alloy that also contains tungsten and cobalt. It’s high nickel and molybdenum content offers excellent resistance to a wide range of corrosive environments. It is also highly resistant to pitting, crevice corrosion, and stress corrosion cracking.

On the other hand, Duplex Steel is a mixture of austenitic and ferritic stainless steels that contain chromium, nickel, and molybdenum. It has a two-phase microstructure giving it good mechanical properties and high resistance to chloride stress corrosion cracking and pitting. It is also relatively low in nickel content compared to Hastelloy C276, which makes it a more cost-effective option.


Hastelloy C276 is an excellent choice for applications requiring resistance to high temperatures and aggressive chemicals, such as in chemical processing, oil and gas, and pulp and paper industries. It is also used in marine applications due to its resistance to chloride-induced stress corrosion cracking.

Duplex Steel, on the other hand, is widely used in petrochemical, marine, and chemical processing applications where resistance to corrosion, high strength, and good weldability are required. Its two-phase microstructure gives it good toughness and resistance to localized corrosion and erosion.


Welding Hastelloy C276 can be challenging due to its high nickel and molybdenum content, making it prone to cracking and porosity if not welded correctly. It requires proper preheating, filler materials, and post-weld heat treatment to ensure a reliable welded joint.

On the other hand, Duplex Steel has good weldability properties and can be easily welded using common welding techniques such as MIG, TIG, and SMAW. However, proper welding techniques and filler materials must ensure a high-quality weld.


Hastelloy C276 is a high-end alloy that is more expensive than Duplex Steel due to its high composition of nickel and molybdenum. The cost of Hastelloy C276 can be a significant factor in determining the suitability of this alloy for certain applications.

Duplex Steel, conversely, is relatively low-cost compared to Hastelloy C276 due to its lower nickel content and the ability to be easily welded. This makes it a cost-effective option for applications requiring corrosion resistance and strength.


In conclusion, choosing between Hastelloy C276 and Duplex Steel depends on various factors such as the specific application requirements, chemical compatibility, and project budget. While both materials offer excellent corrosion resistance and mechanical properties, each has its unique composition and cost differences that must be considered when selecting. Discussing your project’s requirements with a corrosion-resistant alloy specialist can help determine the best option to ensure the highest product longevity and performance.



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