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:
- Suitable for continuous service.
- Minor effect, generally suitable.
- Moderate effect, not for continuous use.
- 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.
1. Corrosion Mechanics & Concentration Effects
Corrosion rates depend heavily on concentration. Materials fail through general uniform loss (e.g., carbon steel in acids), chloride-induced local pitting, or Stress Corrosion Cracking (SCC) under tensile stress. Solute concentration shifts chemical equilibrium—for instance, concentrated sulfuric acid (>90%) forms a passive layer on carbon steel, whereas dilute acid attacks it rapidly.
2. Metals vs. Polymers Sizing Principles
Metals undergo electrochemical electron transfer (dissolution) governed by electrode potential. They offer high mechanical strength and temperature tolerance. Plastics and elastomers do not corrode electrochemically; instead, they undergo solvent absorption, swelling, matrix softening, or chain scission, offering high chemical resistance but restricted thermal bounds.
3. The Temperature Factor & Arrhenius Degradation
Thermal energy accelerates molecular kinetic activity. The Arrhenius equation dictates that chemical reaction and corrosion rates scale exponentially with temperature (often doubling for every $10^\circ\text{C}$ rise). Sizing and compatibility checks must always evaluate parameters at peak operating temperatures rather than base room conditions.
4. High-Performance Alloys & Passivation
When standard 304/316 stainless steels fail under chloride pitting or acid attack, exotic alloys are required: Duplex 2205 provides high strength and pitting immunity ($PREN > 34$), Hastelloy C-276 offers universal resistance in oxidizing and reducing media, and Titanium passivates rapidly in oxidizing chlorine or nitric acid environments.
5. Elastomer Selection & Seal Mechanics
Sealing interfaces demand careful material matching to prevent chemical leak hazards: Viton (FKM) resists high temperature, hydrocarbons, and fuels but fails in steam or ketone service. EPDM is ideal for steam, water, and polar solvents but degrades in oils. PTFE is universally inert but has low elastic memory and tends to cold flow under load.
6. Approved International and National Standards
Industrial material selection and corrosion testing are governed by global codes to guarantee setup safety: ASTM G102 governs calculations for corrosion rates from electrochemical measurements; ISO 15156 (NACE MR0175) regulates materials for sour gas ($H_2S$) service; ASTM G48 defines pitting tests; and ASTM D543 governs chemical resistance evaluations of polymers.
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.
7. Industrial Forensic FAQ
What is the difference between 'Excellent' and 'Good' compatibility ratings?
'Excellent' (A-Rating) indicates that the material can withstand continuous contact with the chemical for indefinite periods at the design temperature with negligible corrosion rate ($<0.05\text{ mm/yr}$) or mechanical degradation. 'Good' (B-Rating) denotes minor material reaction, causing slight oxidation, superficial pitting, or minor swelling in elastomers over extended periods, which may limit the service life.
Forensic Remedy: For high-pressure flanged piping or critical seal containment, only select 'Excellent' rated materials to prevent creeping leaks.
Is 316 Stainless Steel compatible with Seawater?
316 Stainless Steel has 'Good' resistance to flowing seawater due to its $2.5\%$ Molybdenum content, which helps maintain the passive oxide film. However, in stagnant seawater conditions, chloride ions ($Cl^-$) migrate into micro-pores, creating local acidic concentration cells that lead to severe pitting and crevice corrosion.
Forensic Remedy: In stagnant seawater services or splash zones, transition to Duplex 2205 or Grade 2 Titanium to guarantee immunity from chloride pitting.
Can PTFE (Teflon) be used with almost any industrial chemical?
PTFE is chemically inert to almost all industrial acids, bases, and organic solvents due to the extremely high bond strength of the Carbon-Fluorine ($C-F$) bonds. Exceptions are highly reducing molten alkali metals (e.g., sodium) and elemental fluorine at high temperatures, which strip fluorine atoms from the chain.
Forensic Remedy: Use PTFE as lining material for severe chemical services, but apply structural backing as PTFE is subject to creep (cold flow) under load.
Why are EPDM elastomers incompatible with hydrocarbon oils and fuels?
EPDM is a non-polar elastomer. Hydrocarbon solvents and petroleum-based oils are also non-polar. According to the chemical principle of "like dissolves like," the hydrocarbon molecules readily penetrate and dissolve the EPDM polymer matrix, causing rapid swelling, structural softening, and total seal failure.
Forensic Remedy: For hydrocarbon services, specify Viton (FKM) or Nitrile (Buna-N), which have polar polymer chains that resist hydrocarbon absorption.
How does temperature affect chemical compatibility and lifetime?
Temperature increases the kinetic energy of reactant ions and molecules, which exponentially increases chemical activity. According to the Arrhenius relation, the corrosion rate generally doubles with every $10^\circ\text{C}$ rise. Elevated temperatures also accelerate polymer permeation and swelling rates.
Forensic Remedy: Always sizing components based on the maximum peak system temperature, not the nominal baseline ambient temperature.
What is Stress Corrosion Cracking (SCC) and how does it happen?
SCC is the growth of crack formation in a corrosive environment under tensile stress. It causes sudden, catastrophic failure of normally ductile alloys (like 304/316 SS in chloride solutions at temperatures $>60^\circ\text{C}$) without showing uniform wall thinning beforehand.
Forensic Remedy: Avoid pairing standard austenitcs with chlorides at elevated temperatures. Use Duplex 2205 or nickel alloys, which have higher threshold stress limits.
What does PREN stand for and how is it used in engineering sizing?
PREN stands for Pitting Resistance Equivalent Number. Calculated as $PREN = \%Cr + 3.3(\%Mo + 0.5\%W) + 16\%N$. It is a standard code (ASTM G48) to rank alloy resistance to localized chloride pitting. Higher PREN values correlate with higher breakdown voltages.
Forensic Remedy: For seawater environments, mandate alloys with $PREN \ge 35$ (such as Duplex 2205 or Super Duplex 2507) to ensure pitting immunity.
Are compatibility ratings valid for mixtures of different chemical media?
No. Standard tables are valid only for pure chemical components. Mixtures can cause synergic reactions, where chemical elements combine to passivate or accelerate attacks. For instance, adding trace moisture to dry chlorine gas shifts it from dry (compatible with steel) to wet (highly corrosive acid).
Forensic Remedy: Perform autoclave electrochemical corrosion tests on the actual fluid mixture to verify component integrity.
What is Galvanic Corrosion and how can it be avoided at piping joints?
Galvanic corrosion occurs when two different metals are electrically connected in a conductive chemical media. The material with the lower standard potential (more negative) acts as the anode and corrodes rapidly. For example, coupling copper to steel accelerates steel degradation.
Forensic Remedy: Use dielectric insulation kits (non-conductive gaskets and sleeves) to isolate the metals electrically, or select materials close in potential.
When should Titanium be specified instead of Hastelloy C-276?
Titanium passivates by forming a highly stable, self-healing titanium dioxide ($TiO_2$) passive film in oxidizing environments (nitric acid, wet chlorine gas, hypochlorites). It outperforms Hastelloy in these media. However, in reducing acids (like hydrochloric or sulfuric acid), the oxide film is stripped, leading to rapid corrosion.
Forensic Remedy: Select Titanium for oxidizing halide chemistry and seawater. Specify Hastelloy C-276 for reducing acids and mixed acidic refinery effluents.