Hastelloy vs Stainless Steel – What’s the Difference

Hastelloy vs Stainless Steel

Knowing each type’s properties, advantages, and drawbacks is important when choosing the right metal for a particular application. Here, we’ll look at the differences between two popular types of metals: Hastelloy and Stainless Steel. Both of these metals have their unique characteristics, technologies, and uses. But what sets them apart? Read on to find out more.

What is Hastelloy?

Hastelloy is a family of high-performance nickel and chromium alloys used in demanding industrial applications. It combines excellent corrosion resistance with great strength and can withstand extreme temperatures, pressures, and chemical environments.

What is Stainless Steel?

Stainless steel is a corrosion-resistant metal alloy that contains at least 10.5% chromium. It is widely used in construction, industrial applications and consumer goods due to its strength, durability and low maintenance requirements.

Differences Between Hastelloy and Stainless Steel

Chemical Composition

Hastelloy is a nickel-based alloy containing chromium, molybdenum, iron, and other alloy elements such as tungsten and cobalt. Hastelloy is known for its excellent resistance to oxidation, corrosion, and high temperatures. Stainless Steel, on the other hand, is primarily composed of iron, carbon, and chromium. Chromium is the key element in Stainless Steel, which gives it its corrosion resistance.

Strength and Durability

Strength is a crucial factor in selecting a metal for engineering applications. Hastelloy is known for its high resistance to stress corrosion cracking, sulfidation, and pitting. It also has excellent mechanical strength, making it ideal for high-pressure applications. Stainless Steel, on the other hand, offers excellent corrosion resistance, strength, and durability at a lower cost.

Temperature Resistance

When it comes to high-temperature applications, Hastelloy outperforms Stainless Steel. Hastelloy can withstand temperatures up to 2,000°F, while Stainless Steel has a maximum operating temperature of 1,800°F. Hastelloy’s high-temperature strength and resistance to thermal shock make it ideal for chemical processing, aerospace, and nuclear plant applications.


Hastelloy is used in applications where corrosion resistance and high-temperature strength are critical. Some common applications include chemical processing, aerospace, nuclear power, and pharmaceutical industries. Stainless Steel is widely used in various industries such as food processing, medical equipment, automotive, and construction.


Cost is often a major consideration when selecting the right metal for a project. Hastelloy is a high-performance metal that is more expensive than Stainless Steel. However, the cost of Hastelloy may be justified in applications that require exceptional strength, resistance to corrosion, and high-temperature resistance.


To summarise, Hastelloy and Stainless Steel are excellent materials for different applications. Hastelloy is a high-performance metal with exceptional resistance to extreme temperatures and corrosion, making it ideal for critical industrial applications. Stainless Steel, on the other hand, offers excellent durability, corrosion resistance, and strength at a lower cost, making it a popular choice across various industries. The choice ultimately depends on the project’s specific needs, and understanding the differences between these two metals will help you make an informed decision.



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