Monel K500 vs Monel 400 Round Bars – What’s the Difference?

When it comes to finding the ideal material for industrial applications, Monel bars are the go-to materials for many engineers globally. These bars are known for their exceptional strength, corrosion resistance, and durability, making them suitable for use in various applications. But, when it comes to choosing between Monel K500 and Monel 400 round bars, things can get tricky. Therefore, in this blog post, we will compare Monel K500 vs Monel 400 round bars to help you make a well-informed decision.

What is Monel K500 and Monel 400 Round Bars?

Monel K500 and Monel 400 round bars are similar in that they both have excellent physical properties and corrosion resistance. The main difference between the two is that Monel K500 has higher strength and hardness than Monel 400, making it better suited for high-pressure applications requiring greater strength. Another major difference between these alloys is their respective price points, with Monel K500 costing more due to its increased strength and superior performance features. Ultimately, choosing one will depend on the specific application and budget availability.

Difference Between Monel K500 vs Monel 400 Round Bars


Both Monel K500 and Monel 400 are copper-nickel alloys, with Monel K500 having more copper, aluminium, and titanium added to its alloy composition than Monel 400. Monel 400, on the other hand, contains more than 60% nickel, making it an ideal option for applications that require high corrosion resistance.

Tensile Strength

Monel K500 has a tensile strength of 60000 – 100000 psi, which is higher than that of Monel 400, which is 48000 – 80000 psi. The increased strength of Monel K500 is due to the addition of age-hardening elements in its alloy composition. The tensile strength of Monel K500 round bars is typically about 24% higher than that of Monel 400 round bars. Monel K500 has a minimum ultimate tensile strength of 860 MPa compared to the 690 MPa for Monel 400. This higher tensile strength allows greater design elasticity and better suits applications with high stress or cyclic loading. Additionally, due to its good fatigue resistance, corrosion resistance and excellent weldability, it is commonly used in demanding environments such as marine and aerospace applications.

Corrosion Resistance

Both Monel K500 and Monel 400 are known for their exceptional corrosion resistance. Monel 400 is an ideal option for applications that require corrosion resistance in acidic environments, while Monel K500 is suitable for more severe environments, including marine and industrial environments. Monel K500 round bars boast superior corrosion resistance compared to Monel 400. This is due to the addition of aluminum and titanium in its alloy, which increases resistance to stress corrosion cracking in certain media. Monel K500 exhibits excellent strength and good ductility even in sub-zero temperatures, making it ideal for high-temperature applications like chemical processing and petrochemical production.

Mechanical Properties

Monel K500 has better mechanical properties than Monel 400, with a higher yield strength and an elongation limit. This means that Monel K500 is more malleable and ductile. However, Monel 400 has better thermal conductivity, making it ideal for heat transfer applications.

Monel K500 round bars offer superior mechanical properties over Monel 400 round bars, thanks to the addition of aluminium and titanium. They are approximately three times stronger than their counterparts, with a greater tensile strength (up to 138 ksi), a higher yield strength (to 95 ksi) and much better fatigue strength – up to 1000Mpa Vs 500 Mpa for Monel 400. Additionally, they possess increased ductility, improved formability and superior resistance to corrosion in comparison with conventional nickel-copper alloys like Monel 400.


Regarding weldability, Monel K500 is more challenging to weld than Monel 400. This is because Monel K500 has a higher copper content, making it more susceptible to cracking during welding. Therefore, Monel 400 is an excellent option for applications that require weldability.

Monel K500 and Monel 400 round bars’ welding process relies on the correct filler metal selection and heating temperature. The differences between these two alloys include alloy elements’ composition, melting points, and chemical reactions during welding. While using TIG or MIG processes, it is important to use proper preheating temperatures for Monel K500, which may range from 350-475°C while Monel 400 can be welded with 250-350°C when the base material’s diameter is 6 mm or more. However, preheating should not exceed 475°C for both materials as it could result in degradation due to embrittlement reaction. Lastly, special attention may be required while post-weld heat treatment as weld zones are susceptible to cracking in this stage due to their sensitivity towards PWHT (Post Weld Heat Treatment).


In conclusion, Monel K500 and Monel 400 round bars are excellent materials for various industrial applications. However, when choosing between the two, you must consider the specific application, as each has its unique advantages and disadvantages. If you need high strength and resistance to corrosion in severe environments, Monel K500 is the way to go. But, if you need excellent corrosion resistance in acidic environments and weldability, Monel 400 is the perfect option. Remember, make sure that you consult with your engineering team before making a final decision.

Monel K500 vs Monel 400 Round Bars – What’s the Difference?

by AB Steel time to read: 3 min