Material & Chemical Resistance Chart

This comprehensive tool provides engineering data on chemical resistance for common industrial materials. Use the interactive calculator below to quickly check compatibility or scroll down to view the full reference table.

Ratings Key:

  • Excellent: Suitable for continuous service.
  • Good: Minor effect, generally suitable.
  • Fair: Moderate effect, not for continuous use.
  • Poor: Not recommended.

Interactive Compatibility Checker

Material Strong Acids (HCl, H2SO4) Weak Acids (Acetic) Strong Bases (NaOH) Weak Bases (NH4OH) Aliphatic Hydrocarbons Aromatic Hydrocarbons Halogenated Solvents Alcohols Water & Steam Oxidizers (Bleach) Notes/Standard
Stainless Steel 304 Poor Good Good Excellent Excellent Good Poor Excellent Excellent Fair ASTM A240
Stainless Steel 316 Good Excellent Excellent Excellent Excellent Excellent Fair Excellent Excellent Good ASTM A240 (Mo added)
Duplex SS 2205 Excellent Excellent Excellent Excellent Excellent Excellent Good Excellent Excellent Excellent ASTM A240
Hastelloy C-276 Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent ASTM B575
Inconel 625 Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent ASTM B443
Monel 400 Good Excellent Excellent Excellent Excellent Excellent Fair Excellent Excellent Poor ASTM B127 (Hydrofluoric ok)
Alloy 20 Excellent Excellent Excellent Excellent Excellent Excellent Good Excellent Excellent Excellent ASTM B463 (Sulfuric Specialist)
Titanium Good Excellent Excellent Excellent Excellent Excellent Fair Excellent Excellent Excellent ASTM B338 (Chloride Specialist)
Zirconium Excellent Excellent Excellent Excellent Excellent Excellent Good Excellent Excellent Fair ASTM B551
Copper Poor Good Poor Excellent Excellent Good Poor Excellent Good Poor ASTM B152
Brass Poor Fair Fair Good Excellent Good Poor Good Fair Poor ASTM B36
PTFE (Teflon) Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent Excellent ASTM D4894
Kynar (PVDF) Excellent Excellent Excellent Excellent Excellent Excellent Good Excellent Excellent Excellent ASTM D3222
HDPE Good Excellent Excellent Excellent Excellent Fair Poor Good Excellent Good ASTM D4976
UHMW-PE Good Excellent Excellent Excellent Excellent Good Poor Excellent Excellent Good ASTM D4020
PVC Good Excellent Excellent Excellent Poor Poor Poor Good Excellent Good ASTM D1784
Polycarbonate Poor Fair Poor Poor Good Fair Poor Good Excellent Fair ASTM D3935
Nylon 6/6 Poor Fair Good Excellent Excellent Good Poor Good Good Poor ASTM D4066
Polyurethane Poor Good Fair Good Excellent Good Poor Good Excellent Fair ASTM D3574
Viton (FKM) Poor Good Fair Excellent Excellent Excellent Good Good Fair Good ASTM D1418 (FKM)
EPDM Fair Good Excellent Excellent Poor Poor Poor Excellent Excellent Fair ASTM D1418 (EPDM)
Nitrile (Buna-N) Poor Good Good Good Excellent Fair Poor Good Fair Poor ASTM D1418 (NBR)
Natural Rubber Poor Good Good Good Poor Poor Poor Good Excellent Poor ASTM D1418 (NR)
Silicone Poor Good Good Good Poor Poor Poor Excellent Excellent Fair ASTM D1418 (VMQ)

← Scroll horizontally to see more data →

Engineering Guide: Material Selection & Chemical Resistance

A deep dive into the principles of corrosion, polymer degradation, and strategic material selection for industrial applications.

Corrosion Mechanics

Corrosion is not a single phenomenon. Materials fail through various mechanisms depending on the environment:

  • General Attack: Uniform material loss (e.g., carbon steel in acid). Predictable via corrosion allowance.
  • Pitting: Localized holes. Common in Stainless Steel exposed to Chlorides (seawater).
  • Stress Corrosion Cracking (SCC): Sudden failure under tensile stress in a corrosive environment (e.g., 304 SS in hot chlorides).

Metals vs. Plastics

Metals generally fail by electrochemical corrosion. They maintain strength at high temperatures but struggle with strong acids.

Plastics/Elastomers fail by absorption and solvation. They don't "rust"; they swell, soften, or crack. They offer superior resistance to strong acids/bases but have low temperature limits and mechanical strength.

The Temperature Factor

Temperature is the enemy of corrosion resistance. A material that is "Excellent" at 20°C may dissolve at 80°C.

Arrhenius Equation: Roughly states that reaction rates (corrosion) double for every 10°C rise. Always verify compatibility at the maximum design temperature.

High-Performance Alloys

When standard 316L SS fails, engineers turn to exotic alloys:

  • Duplex SS (2205): Higher strength and better pitting resistance than 316. Ideal for seawater.
  • Hastelloy C-276: The "Universal" alloy. Resists hot wet chlorine, hypochlorite, and sulfuric acid.
  • Titanium: Unbeatable for oxidizing environments (Nitric acid, Wet Chlorine, Seawater). Avoid in reducing acids (HCl) without inhibitors.

Elastomer Selection (Seals/O-Rings)

Seal failure causes leaks. Selection is critical:

  • Viton (FKM): Excellent for oils, fuels, and high temp. Bad for steam/ketones.
  • EPDM: Excellent for Steam, Water, and Ketones. Terrible for Oils/Fuels.
  • PTFE: Chemically inert to almost everything but has no memory (hard to seal) and cold flows (creeps).

Concentration Matters

Concentration changes chemistry. Sulfuric Acid is a prime example:

  • Dilute (< 10%): Attacks Carbon Steel aggressively.
  • Concentrated (> 90%): Carbon Steel forms a passivation layer and is acceptable (at low velocities).
  • High Velocity: Strips passivation, causing rapid failure.

International Standards Compliance

Material selection for critical industrial infrastructure is governed by stringent international codes to ensure safety and longevity.

ISO 15156 (NACE MR0175)

Materials for use in H2S-containing environments in oil and gas production. Defines resistance to Sulfide Stress Cracking (SSC).

ASTM G1-03

Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens. The baseline for all chemical resistance data.

ISO 12944

Corrosion protection of steel structures by protective paint systems. Classifies environments from C1 (low) to CX (extreme).

ASTM D543

Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents. The core standard for polymer compatibility.

Corrosion Science & Analytics

Understanding the physics of material degradation beyond simple "Pass/Fail" ratings.

PREN Ranking (Pitting Resistance)

$PREN = \%Cr + 3.3 \cdot (\%Mo + 0.5 \cdot \%W) + 16 \cdot \%N$

Acid Concentration vs. Corrosion Rate

Typical Isocorrosion curve for Sulfuric Acid ($H_2SO_4$)

Material Selection Decision Matrix

Choosing the right material requires balancing technical resistance with economic viability and thermal constraints.

Material Class Cost Index Max Temp (°C) Primary Use Case Key Limitation
Standard SS (304/316) $ (Base) 450°C General Purpose, Food Grade Chloride Pitting
Duplex Alloys $$ 300°C Marine & High Pressure Embrittlement > 315°C
Hastelloy/Inconel $$$$$ 900°C+ Severe Acids, High Temp Extremely High Cost
PTFE / Polymers $$ 260°C Full Chemical Inertness Pressure/Creep issues
Titanium $$$$ 500°C Oxidizing Media, Chlorine Reducing Acid failure

*Note: Cost Index is relative and fluctuates with global commodity markets. Temp limits are for atmospheric pressure.

Frequently Asked Questions

What is the difference between 'Excellent' and 'Good' compatibility?
'Excellent' implies the material can withstand the chemical for indefinite periods with negligible corrosion. 'Good' suggests minor swelling or discoloration over long durations or at elevated temperatures.
Is 316 Stainless Steel compatible with Seawater?
316 Stainless Steel has 'Good' resistance to flowing seawater but is susceptible to crevice corrosion and pitting in stagnant seawater. For critical marine applications, Super Duplex steels or Titanium are often preferred for 'Excellent' long-term performance.
Can PTFE (Teflon) be used with almost any chemical?
PTFE is chemically inert to almost all industrial chemicals, making it the 'Gold Standard' for seals and linings. Exceptions include molten alkali metals (like sodium) and elemental fluorine at high temperatures.
Why are elastomers like EPDM incompatible with oils?
EPDM (Ethylene Propylene Diene Monomer) swells and degrades rapidly when exposed to petroleum-based oils and fuels due to its chemical structure. Viton (FKM) or Nitrile (Buna-N) are the correct choices for hydrocarbon services.
How does temperature affect chemical compatibility?
Chemical reaction rates generally double for every 10°C rise in temperature. A material rated 'Good' at 20°C might fail rapidly at 60°C. Plastic and elastomer ratings are particularly sensitive to temperature increases.
What is Stress Corrosion Cracking (SCC)?
SCC is the growth of crack formation in a corrosive environment. It can lead to unexpected sudden failure of normally ductile metals subjected to a tensile stress, especially at elevated temperatures.
What does PREN stand for and why is it important?
PREN stands for Pitting Resistance Equivalent Number. It is a predictive measurement of a stainless steel's resistance to localized pitting corrosion in chloride-containing environments. Higher numbers indicate better resistance.
Are these ratings valid for mixtures of chemicals?
No. Chemical mixtures can behave very differently than pure substances. Synergistic effects can cause rapid degradation even if the material is resistant to each component individually. Always test specific mixtures.

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