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When should you use a nickel alloy instead of stainless steel?
Short answer
Use a nickel alloy when stainless steel cannot survive: hot concentrated acids, severe chlorides with stress-corrosion risk, very high temperatures, or sour service beyond stainless limits. Nickel alloys cost several times more, so the usual path is to check duplex, super duplex and 6Mo stainless grades first.
Nickel Alloy vs Stainless Steel at a glance
| Nickel Alloy | Stainless Steel | |
|---|---|---|
| Base metal | Iron | Nickel (or Fe-Ni) |
| Chloride SCC | Susceptible (austenitic) | Highly resistant |
| Severe acids | Limited | Excellent (C276, C22) |
| High temperature | To ≈ 1,100 °C (SS 310S) | To ≈ 1,200 °C (601) |
| Cost | Lower | Much higher |
Which should you choose?
There's no universal "winner": the right choice depends on service conditions, codes and cost. Share your conditions with us for a recommendation.
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Frequently asked questions
Are nickel alloys magnetic?
Most are non-magnetic. Pure nickel 200 is magnetic.
Can nickel alloys be welded to stainless steel?
Yes, with suitable nickel-alloy filler; this is common in clad and overlay construction.
What is the main difference between Nickel Alloy and Stainless Steel?
Stainless steels are iron-based with at least 10.5% Cr. Nickel alloys are nickel-based (or high-nickel), giving far greater resistance to severe acids, chlorides and high temperatures, at several times the cost.
When should I choose Stainless steel?
Most corrosive and hygienic duties.
When should I choose Nickel alloy?
Severe chemicals, chloride SCC, extreme temperatures.