Hastelloy Flanges
Hastelloy flanges are premium-grade components designed for piping systems that demand exceptional resistance to corrosion, extreme temperatures, and high mechanical strength. Manufactured from Hastelloy, a family of nickel-based superalloys, these flanges are engineered to perform in environments where stainless steel and conventional alloys cannot survive. Their unique combination of chemical stability and durability makes them a preferred choice across industries such as chemical processing, oil and gas, marine engineering, aerospace, power generation, and pharmaceuticals.
Flanges play a critical role in piping systems by connecting pipes, valves, pumps, and other equipment. When produced in Hastelloy, they not only ensure strong and leak-proof connections but also provide superior protection against aggressive media such as acids, chlorides, and seawater.
Chemical Composition of Hastelloy Flanges
The superior performance of Hastelloy flanges is a result of their carefully balanced alloying elements. Different grades are used depending on the intended application:
Hastelloy C22 is formulated with about 0.010% carbon, 12.5–14.5% molybdenum, 20–22.5% chromium, and 2.5–3.5% tungsten. Nickel forms the base of the alloy, while small amounts of iron, cobalt, manganese, silicon, and vanadium add strength and toughness. This grade offers resistance to both oxidizing and reducing agents, making it suitable for highly corrosive environments.
Hastelloy C276 has very low carbon (0.01%) with iron between 4% and 7%. It contains 15–17% molybdenum, 14.5–16.5% chromium, and up to 4.5% tungsten. With nickel as the primary element, this grade demonstrates excellent resistance to strong oxidizers and aggressive chloride-rich solutions.
Hastelloy B2 is rich in molybdenum (26–30%) and has nickel as its primary element. It contains minimal additions of manganese, phosphorus, silicon, and sulfur. This composition makes B2 highly resistant to hydrochloric acid and other strong reducing agents.
Hastelloy B3 improves upon B2 with greater stability and resistance to fluctuating conditions. It contains around 28.5% molybdenum, at least 65% nickel, and controlled amounts of chromium, iron, and tungsten. B3 resists pitting and crevice corrosion, even in highly reducing environments.
Hastelloy X is a high-temperature alloy consisting primarily of nickel, along with 20.5–23% chromium, 17–20% iron, and 8–10% molybdenum. Small amounts of cobalt, manganese, and silicon are also present. Hastelloy X is widely used in applications requiring oxidation resistance and strength at elevated temperatures.
Mechanical Properties of Hastelloy Flanges
Each grade of Hastelloy provides mechanical strength tailored for demanding conditions:
C22 has a tensile strength of about 100,000 psi (690 MPa), a yield strength of 45,000 psi (310 MPa), and an elongation of 45%. It has a density of 8.69 g/cm³ and a melting point around 1399 °C (2550 °F).
C276 offers superior strength with tensile values reaching 115,000 psi (790 MPa) and yield strength of 52,000 psi (355 MPa). It has 40% elongation, density of 8.89 g/cm³, and a melting point of 1370 °C (2500 °F).
B2 and B3 grades exhibit tensile strengths in the range of 110,000–115,000 psi and yield strengths around 51,000–52,000 psi, with elongation close to 40%. Their melting points are also near 1370 °C, highlighting their thermal stability.
Hastelloy X maintains strength even at high temperatures, with a tensile strength of 655 MPa, yield strength of 240 MPa, elongation of 35%, and a melting point of about 1355 °C. With a density of 8.22 g/cm³, it is particularly suited for furnace and turbine applications.
Key Features and Benefits
Exceptional Corrosion Resistance – Resistant to both oxidizing and reducing agents, Hastelloy flanges withstand hydrochloric acid, sulfuric acid, acetic acid, ferric chloride, and seawater.
High Mechanical Strength – Forged from superalloys, these flanges perform reliably in high-pressure, high-stress environments.
Resistance to Localized Attack – Molybdenum and tungsten content provides strong protection against pitting and crevice corrosion.
Thermal Stability – Retains mechanical properties and resists oxidation at elevated temperatures.
Versatility – Available in multiple grades and designs to match application-specific requirements.
Applications of Hastelloy Flanges
Hastelloy flanges are used in industries where ordinary materials fail:
Chemical Processing: Ideal for handling acids and aggressive chemicals.
Oil & Gas: Reliable in sour gas wells, offshore rigs, and refineries.
Marine Industry: Excellent resistance to seawater corrosion.
Aerospace and Power Generation: Suitable for turbines, furnaces, and heat exchangers.
Pharmaceutical and Food Industry: Ensures purity and prevents contamination in sensitive processes.
Types of Hastelloy Flanges
Hastelloy flanges are manufactured in different forms to meet varied piping needs, including:
Weld Neck Flanges – For high-pressure systems.
Slip-On Flanges – Easy to install and align.
Socket Weld Flanges – Used for small-diameter, high-pressure piping.
Blind Flanges – To close off pipeline ends.
Lap Joint Flanges – Paired with stub ends for easy disassembly.
Threaded Flanges – For connections without welding.
Conclusion
Hastelloy flanges combine the inherent corrosion resistance of nickel-based alloys with the strength and durability required in critical piping systems. With grades such as C22, C276, B2, B3, and X, these flanges provide tailored solutions for chemical plants, offshore installations, marine environments, and high-temperature aerospace or power applications. Their unmatched ability to withstand both chemical attack and mechanical stress makes them a trusted choice for industries worldwide.
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Explore moreFAQs - Hastelloy Flanges
Hastelloy flanges are used for connecting pipes, valves, and pumps in critical industries requiring superior corrosion resistance, high strength, and leak-proof pipeline performance.
Hastelloy flanges outperform stainless steel in aggressive chemical, marine, and high-temperature environments, offering enhanced durability, resistance to oxidizing agents, and superior performance in extreme operating conditions.
Industries such as chemical processing, oil and gas, aerospace, marine, pharmaceuticals, and power generation widely rely on Hastelloy flanges due to reliability, safety, and corrosion resistance.
Hastelloy flanges contain nickel, molybdenum, chromium, tungsten, and iron, with varying proportions across grades, providing unmatched strength, durability, and exceptional resistance to acids and oxidizers.
They exhibit excellent tensile and yield strength, elongation, ductility, density, and high melting points, ensuring thermal stability and structural reliability in demanding industrial conditions.
Hastelloy flanges deliver corrosion resistance, mechanical strength, oxidation resistance, leak-proof joints, and application versatility, ensuring long service life and efficiency in harsh environments.
Types include weld neck, slip-on, socket weld, blind, lap joint, and threaded flanges, each designed for specific industrial piping applications and operational requirements.
Hastelloy C22 provides excellent resistance to oxidizing and reducing agents, strong defense against pitting and crevice corrosion, high ductility, and outstanding weldability under extreme conditions.
In marine applications, Hastelloy flanges resist seawater corrosion, biofouling, and chloride-induced stress cracking, ensuring reliable offshore, shipbuilding, and underwater pipeline installations.
Despite higher costs, Hastelloy flanges minimize downtime, resist corrosion, extend operational life, and reduce replacement expenses, providing long-term cost-effectiveness and unmatched reliability in critical industries.