Nickel-based corrosion-resistant alloys are a class of advanced metallic materials engineered primarily to withstand extreme corrosive environments. Their foundation is a nickel (Ni) matrix, which is inherently resistant to many corrosives, alloyed with other key elements—primarily chromium (Cr), molybdenum (Mo), and sometimes copper (Cu) and nitrogen (N)—to create a versatile and powerful family of materials for the most aggressive chemical and industrial applications.
They are the go-to solution when stainless steels are no longer sufficient.
Exceptional Corrosion Resistance: This is their defining property. They offer outstanding resistance to a wide range of corrosives, including:
Acids: Sulfuric acid, hydrochloric acid, phosphoric acid.
Caustics: Strong alkaline solutions.
Chloride-Induced Attacks: Pitting and crevice corrosion, which are the primary failure modes for standard stainless steels.
Stress Corrosion Cracking (SCC): Highly resistant to cracking under the combined action of tensile stress and a corrosive environment.
Versatility: A wide range of alloy compositions allows for tailoring properties to target specific corrosive conditions (e.g., high Mo for chloride resistance, high Cr for oxidizing environments).
Good High-Temperature Performance: Many of these alloys form a stable, protective oxide scale (based on Cr₂O₃), allowing them to resist oxidation and carburization at elevated temperatures.
Excellent Mechanical Properties: They maintain good strength and toughness from cryogenic temperatures up to high temperatures.
Nickel-based corrosion-resistant alloys can be categorized into several major families, each optimized for different challenges.
| Alloy Family | Key Alloying Elements | Iconic Examples | Primary Corrosion Resistance & Applications |
| Nickel-Chromium | Ni, Cr | Alloy 600 | Oxidation resistance at high temperatures; caustic environments. |
| Nickel-Chromium-Iron | Ni, Cr, Fe | Alloy 800/800H | High-temperature oxidation and carburization resistance; heat treatment equipment. |
| Nickel-Chromium-Molybdenum | Ni, Cr, Mo | C-276, C-22, C-2000 | The most versatile family. Superior resistance to pitting, crevice corrosion, and a wide range of acids and chlorides. Used in chemical processing, flue gas desulfurization, and pollution control. |
| Nickel-Chromium-Molybdenum with Copper | Ni, Cr, Mo, Cu | Alloy 400, Alloy 825 | Excellent resistance to sulfuric and phosphoric acids; widely used in marine and chemical processing applications. |
| Nickel-Molybdenum | Ni, Mo | Alloy B-2, B-3 | Exceptional resistance to reducing environments (non-oxidizing acids) like hydrochloric acid. |
| Nickel-Chromium-Molybdenum with Nitrogen | Ni, Cr, Mo, N | Alloy 625, Alloy 718 | Combines high strength (from precipitation hardening) with excellent corrosion and oxidation resistance. Used in aerospace, chemical, and marine engineering. |