High-Temperature Corrosion Resistance of Haynes Alloys

In high-temperature industrial environments such as gas turbines, furnaces, chemical reformers, and petrochemical processing, materials undergo extreme forms of corrosion that ordinary stainless steels and standard nickel alloys cannot survive.

The three most aggressive corrosion modes above 700°C are:

Oxidation
Carburization
Nitridation

Haynes alloys — especially Haynes 188, Haynes 230, and Haynes 214 — are engineered to resist these extreme conditions through advanced alloy chemistry and stable oxide formation.

This expert guide explains how Haynes alloys outperform standard nickel alloys like Inconel 600, 625, 800H, and 601, ensuring safer and longer-lasting high-temperature systems.

Understanding High-Temperature Corrosion

High-temperature corrosion happens when metals react with:

Oxygen
Carbon-rich gases
Nitrogen-rich gases
Sulfur-bearing gases
Process chemicals

At temperatures above 700°C, corrosion accelerates dramatically. Stainless steels form weak oxide layers that flake off. Standard nickel alloys resist heat but degrade in carburizing and nitriding environments. Haynes alloys form stable, continuous, protective oxide scales.

This makes Haynes alloys ideal for aerospace, gas turbines, furnaces, and chemical processing plants.

Oxidation Resistance: How Haynes Alloys Survive Extreme Heat

Oxidation occurs when oxygen reacts with hot metal to create an oxide layer.

Good oxides adhere to the surface and protect the metal
Bad oxides crack and flake, allowing further corrosion

Haynes alloys contain elements like chromium, aluminum, and silicon, which form stable, slow-growing, strongly adherent oxide layers.

Haynes 188 — Leading Alloy for Oxidation at 1100°C

Cobalt base improves thermal stability
Chromium provides strong oxidation protection
Excellent thermal shock resistance

Used in:

Jet engine combustors
Afterburners
Gas turbine hot sections

Haynes 230 — Best for Long-Term Oxidation Exposure

Exceptional resistance up to 1150°C
Maintains oxide integrity even during temperature cycling

Used in:

Furnace fixtures
Chemical reactors
Heat treatment equipment

Haynes 214 — Special Oxidation Alloy

High aluminium content forms Al₂O₃ protective scale
One of the best commercial oxidation-resistant alloys

Applications:

Radiant tubes
Burner nozzles
High-temperature heating elements

Carburization Resistance

Carburization occurs when carbon diffuses into metal at high temperatures.

Embrittlement
Loss of ductility
Reduced mechanical strength
Component failure

Standard nickel alloys resist oxidation but struggle in carburizing environments such as petrochemical plants and furnaces with hydrocarbons.

Haynes 230 — Best for Carburizing Environments

Furnace rolls
Petrochemical cracking coils
Reformer furnaces

Nitridation Resistance

Nitridation occurs when nitrogen reacts with hot metal surfaces forming brittle nitrides.

This happens in:

Ammonia reforming
Heat treatment furnaces
Nitrogen-rich atmospheres
Industrial gas processes

Haynes 230 and Haynes 214 provide exceptional nitridation resistance due to high chromium and aluminum content.

Haynes vs Standard Nickel Alloys

Feature	Haynes Alloys	Standard Nickel Alloys
Oxidation Resistance	Superior (up to 1150°C)	Good
Carburization Resistance	Excellent	Moderate
Nitridation Resistance	High	Poor–Moderate
Long-Term Strength	Higher	Medium
Thermal Shock Resistance	Excellent	Good

Industrial Applications Where Haynes Alloys Dominate

Aerospace & Turbines

Combustion chambers
Transition ducts
Afterburner components
High-temperature seals

Chemical Processing

Catalytic cracking
Ammonia processing
Nitrogen-rich atmospheres

Heat Treatment & Industrial Furnaces

Furnace rails
Radiant tubes
High-temperature fans
Containers & jigs

Petrochemical Processing

Reforming coils
Cracking tubes
Hydrogen furnaces

Advantages of Haynes High-Temperature Alloys

Survive up to 1150°C
Resist oxidation, nitridation & carburization
High creep and fatigue resistance
Long service life (10–30+ years)
Stronger than standard nickel alloys
Excellent structural stability

Limitations of Haynes Alloys

High cost due to cobalt and tungsten
Harder machining because of work-hardening
Complex weldability for some grades requiring special procedures

FAQ's

Which Haynes alloy has the best oxidation resistance?

Haynes 214, followed by Haynes 230 and Haynes 188.

Which Haynes alloy is best for carburizing atmospheres?

Haynes 230

Do Haynes alloys outperform Inconel?

Yes — in oxidation, carburization, nitridation, and high-temperature stability.

Which alloy is used in jet engines?

Haynes 188 and Haynes 263.

Which alloy lasts longest in furnaces?

Haynes 230 or Haynes 214, depending on temperature.