Monel® alloy 400 (Ni65/Cu33/Fe 2) - Mesh, Rod & Tube - Material Information

Monel® Alloy 400 is a solid-solution nickel-copper alloy renowned for its outstanding resistance to corrosion and seawater environments. Containing approximately 65% nickel and 33% copper, it exhibits excellent mechanical strength, high ductility, and resistance to both neutral and alkaline salts. The alloy is widely used in marine and chemical processing industries where long-term exposure to corrosive media is unavoidable.

Material Overview

Monel 400 combines a tensile strength of around 480–550 MPa with excellent toughness over a broad temperature range. Its face-centered cubic structure ensures good ductility and formability, while the high nickel content provides immunity to stress-corrosion cracking in most neutral and alkaline environments. The alloy is resistant to hydrofluoric acid, seawater, and caustic solutions but can be attacked by nitric acid and ammonia systems. In marine settings, Monel 400 resists biofouling and maintains stability in brine and salt spray environments.

Recent research by Zhu et al. (2022, 2023) in Tribology International revealed that Monel 400 displays a unique antagonistic tribo-corrosion mechanism in seawater — corrosion products reduce mechanical wear at moderate velocities but deteriorate at high shear rates. The same group demonstrated that surface polarization and temperature affect this balance: cathodic conditions enhance crack propagation, whereas anodic conditions weaken protective oxide films. A 2024 study in Materials Chemistry and Physics showed that electroless Ni–P coatings can improve Monel 400’s abrasive resistance by up to 21× through the formation of a corrosion-inhibiting nickel-phosphate layer. These advances have expanded the alloy’s durability and service life in harsh marine environments.

Applications and Advantages

Due to its combination of strength and corrosion resistance, Monel 400 is employed in seawater valves, pumps, heat exchangers, and chemical reactors. It is also used in nuclear engineering and hydrocarbon processing equipment. The alloy’s excellent weldability and low magnetic permeability make it a preferred material for sensitive instrumentation and marine systems exposed to fluctuating temperatures and flow conditions. Electroless coatings and surface treatments further enhance its resistance to pitting and erosion, particularly in dynamic saline environments.

Goodfellow Availability

Goodfellow supplies Monel® Alloy 400 in mesh, rod, and tube forms, suitable for research, corrosion testing, and fabrication. Custom diameters and surface finishes can be provided to meet marine, chemical, or high-temperature application requirements. Explore Monel 400 and related corrosion-resistant alloys through the Goodfellow product finder.

References

• Zhu, Y., Wang, J., Liu, H., & Yan, F. (2022). Effect of polarization potentials on tribocorrosion behavior of Monel 400 alloy in seawater environment. Tribology International, 169, 107445. https://doi.org/10.1016/j.triboint.2022.107445
• Zhu, Y., Wang, J., Liu, H., Ren, P., & Yan, F. (2023). The tribocorrosion behavior of Monel 400 alloy in seawater at different temperatures. Tribology International, 182, 108975. https://doi.org/10.1016/j.triboint.2023.108975
• Zhu, Y., Liu, H., Ren, P., & Yan, F. (2024). Improvement in the corrosion and wear properties of Monel 400 alloy by electroless Ni–P deposition in seawater. Materials Chemistry and Physics, 320, 129684. https://doi.org/10.1016/j.matchemphys.2024.129684
• Devendranath, R. K., Arivazhagan, N., Narayanan, S., et al. (2011). Development of defect-free Monel 400 welds for marine applications. Advanced Materials Research, 383–390, 4693. https://doi.org/10.4028/WWW.SCIENTIFIC.NET/AMR.383-390.4693