Heat Exchanger Tubes – Best Materials, Failures & Selection Guide (2025 Updated)

Heat exchanger tubes transfer heat between two fluids — hot and cold — without mixing them. They are widely used in:

• Boilers
• Condensers
• Chillers
• Shell & Tube Exchangers
• Power Plants
• Petrochemical Units

• Straight Tubes – Most common, used in boilers & condensers.
• U-Bend Tubes – Ideal for U-shaped or compact heat exchangers.
• Finned Tubes – Higher surface area for improved heat transfer.
• Seamless vs Welded
  • Seamless – Best for high pressure
  • Welded – Cost-effective for general use

1. Stainless Steel (304, 316, 321, 347)

• Best for water & mild chemicals
• Affordable and corrosion-resistant
• Common in food & pharma

2. Copper Nickel (90/10, 70/30)

• Excellent seawater resistance
• High thermal conductivity
• Used in desalination & marine

3. Duplex & Super Duplex (2205, 2507)

• High chloride resistance
• High strength
• Ideal for offshore & oil industry

4. Nickel Alloys (Inconel 600, 625, 800, 825)

• Extreme corrosion resistance
• High temperature stability
• Used in petrochemical & chemical plants

5. Titanium

• Practically corrosion-proof
• Lightweight & high strength
• Premium choice for seawater, chlorides, acids

• Pitting Corrosion – Chlorides, seawater, untreated water
• Erosion – High velocity fluid damage
• Stress Corrosion Cracking (SCC) – High temperature + chlorides
• Scaling – Mineral deposits reduce heat transfer
• Thermal Fatigue – Continuous heating/cooling cycles
• Weld Failures – Due to poor-quality welded tubes

• If using seawater → Copper Nickel / Titanium / Super Duplex
• If using chemicals → Inconel / Hastelloy / SS 316L
• If using steam → Alloy Steel / Stainless Steel
• If using high pressure → Seamless stainless or alloy steel
• If using high temperature → Inconel 600 / 625 / Alloy Steel

Heat exchanger tubes face extreme pressure, temperature, vibration, and corrosion. Choosing the wrong material can cause failures within weeks, while the right one can last over 10 years.

Moksh Tubes helps industries select the ideal tube material based on media, temperature, pressure, and corrosion levels to ensure long-term performance and reliability.