Nimonic 80A vs Monel 400 vs Monel 500: Which Nickel Alloy Is Right for Your Application?
At FULLERKREG, we help engineers and procurement teams select the right nickel alloy for demanding service conditions. Nimonic 80A (N07080), Monel 400 (N04400), and Monel 500 (N05500) represent three distinct families of nickel alloys — a precipitation-hardened superalloy for high-temperature service, a solid-solution nickel-copper alloy for corrosive aqueous environments, and an age-hardenable nickel-copper alloy combining the corrosion resistance of Monel 400 with significantly higher strength.
This guide provides a direct technical comparison of all three grades per their respective ASTM standards, covering chemical composition and mechanical properties to support your material selection decision.
Alloy Overview
- Nimonic 80A (N07080) — A precipitation-hardenable nickel-chromium alloy strengthened by titanium and aluminum additions. Designed for high-stress service at temperatures up to 815°C. Widely used in gas turbine components and high-temperature fasteners. Governed by ASTM B637.
- Monel 400 (N04400) — A solid-solution nickel-copper alloy with excellent corrosion resistance in seawater, hydrofluoric acid, and alkaline environments. Non-magnetic and tough from cryogenic temperatures to ~480°C. Governed by ASTM B164.
- Monel 500 (N05500) — An age-hardenable nickel-copper alloy (also known as K-500) with titanium and aluminum additions that provide approximately three times the yield strength of Monel 400 while retaining its corrosion resistance. Governed by ASTM B865.
Chemical Composition Comparison
All values are weight percent (%). Min = minimum required; Max = maximum allowed per respective ASTM standard.
Nimonic 80A — N07080 (ASTM B637)
| C | Mn | P | S | Si | Cr | Ti | Al | Fe | Ni | |
|---|---|---|---|---|---|---|---|---|---|---|
| Min | — | — | — | — | — | 18.00 | 1.80 | 0.50 | — | Rem. |
| Max | 0.10 | 1.00 | — | 0.015 | 1.00 | 21.00 | 2.70 | 1.80 | 3.00 | — |
Monel 400 — N04400 (ASTM B164)
| C | Mn | P | S | Si | Ni | Cu | Fe | |
|---|---|---|---|---|---|---|---|---|
| Min | — | — | — | — | — | 63.0 | 28.0 | — |
| Max | 0.3 | 2.0 | — | 0.024 | 0.5 | 34.0 | — | 2.5 |
Monel 500 — N05500 (ASTM B865)
| C | Mn | Ti | S | Si | Al | Ni | Cu | Fe | |
|---|---|---|---|---|---|---|---|---|---|
| Min | — | — | 0.35 | — | — | 2.30 | 63.0 | 27.0 | — |
| Max | 0.18 | 1.5 | 0.85 | 0.010 | 0.50 | 3.15 | 33.0 | — | 2.0 |
Mechanical Properties Comparison
| Grade | UNS | Condition | Tensile Strength Rm (N/mm²) min | Yield Strength Rp0.2 (N/mm²) min | Elongation A (%) min | Reduction of Area (%) min | Hardness HRC max |
|---|---|---|---|---|---|---|---|
| Nimonic 80A | N07080 | Age hardened | ≥930 | ≥620 | ≥20 | — | — |
| Monel 400 | N04400 | Annealed | ≥480 | ≥170 | ≥35 | — | — |
| Monel 500 | N05500 | Age hardened | ≥965 | ≥690 | ≥15 | ≥25 (ref.) | ≤27 |
Key Differences at a Glance
| Parameter | Nimonic 80A (N07080) | Monel 400 (N04400) | Monel 500 (N05500) |
|---|---|---|---|
| Alloy family | Ni-Cr superalloy | Ni-Cu alloy | Ni-Cu alloy (age-hardenable) |
| Ni content (%) | Rem. (≥72) | 63.0–34.0 | 63.0–33.0 |
| Cu content (%) | — | 28.0 min | 27.0 min |
| Cr content (%) | 18.0–21.0 | — | — |
| Key alloying additions | Ti, Al (precipitation hardening) | — (solid solution) | Ti, Al (age hardening) |
| Strengthening mechanism | Precipitation hardening (γ’) | Solid solution | Precipitation hardening (γ’) |
| Tensile Strength min (N/mm²) | 930 | 480 | 965 |
| Yield Strength min (N/mm²) | 620 | 170 | 690 |
| Elongation min (%) | 20 | 35 | 15 |
| Max service temperature | ~815°C (high stress) | ~480°C (aqueous) | ~260°C (age-hardened) |
| Magnetic properties | Non-magnetic | Non-magnetic | Non-magnetic |
| Primary corrosion resistance | Oxidation, hot corrosion | Seawater, HF acid, alkalis | Seawater, HF acid, alkalis |
| Governing ASTM standard | B637 | B164 | B865 |
Application Selection Guide
Choose Nimonic 80A (N07080) when:
- High mechanical strength is required at elevated temperatures up to 815°C
- Resistance to oxidation and hot corrosion in gas turbine or combustion environments is critical
- Long-term creep and stress rupture life at high temperature are design criteria
- Typical applications: gas turbine blades and discs, high-temperature fasteners and bolting, exhaust valves, springs for high-temperature service, nuclear engineering components
Choose Monel 400 (N04400) when:
- Excellent corrosion resistance in seawater, brackish water, or hydrofluoric acid is required
- High ductility and toughness from cryogenic temperatures to ~480°C are needed
- Non-magnetic properties are required (e.g., minesweeper hardware, instrument components)
- Typical applications: marine hardware, pump shafts, valve bodies, heat exchanger tubing, HF acid alkylation plant components, chemical processing equipment
Choose Monel 500 (N05500) when:
- The corrosion resistance of Monel 400 is required but with significantly higher strength
- Age-hardened yield strength up to ~690 N/mm² is needed without sacrificing corrosion resistance
- Non-sparking and non-magnetic properties are required in marine or hazardous environments
- Typical applications: marine propeller shafts, pump impellers, oil & gas downhole components, valve stems, fasteners for seawater service, doctor blades in paper manufacturing
FULLERKREG Supply Capabilities
FULLERKREG supplies precision fasteners and engineered components in Nimonic 80A, Monel 400, and Monel 500:
- Material Test Certificates (MTC) — EN 10204 3.1 / 3.2 available on request
- ASTM B637 / B164 / B865 compliance — rod and bar forms for fastener and structural applications
- Custom fastener dimensions — non-standard thread forms, head styles, and lengths
- Bulk wholesale pricing — OEM and MRO procurement with competitive lead times
- Global shipping — from our manufacturing base in China to customers worldwide
Need a quote or technical consultation for Nimonic 80A, Monel 400, or Monel 500 fasteners? Contact FULLERKREG with your specification and our engineering team will respond promptly.
FULLERKREG — Precision Fasteners. Global Standards. Reliable Supply.