Choosing the Right Exhaust System | What is the difference between 304 and 409 stainless steel?

Exhaust Materials - 304 vs. 409 Stainless Steel

All stainless steel contains chromium and other elements. The added elements make the metal harder, stronger, and resist corrosion. The 2 main types of stainless steel used for exhaust parts are 304 and 409.

The difference between the types of stainless steel is the amount of chromium and nickel found in each. 304 stainless steel contains a much higher percentage of chromium and nickel. This makes it much more resistant to rust. 409 stainless steel is still more rust-resistant than

409 Stainless Steel
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Chromium: 10.5% - 11.75%

Nickel: 0.5%
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304 Stainless Steel
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Chromium: 18% - 20%
Nickel: 8% - 10%
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How can you tell the difference?

409 stainless steel can be almost 90% iron. This means a magnet will stick to it. It will also develop surface rust over time, especially after being exposed to heat.

304 stainless steel has a much lower concentration of iron. A magnet will not stick to it. It will also develop a golden color over time, after being exposed to heat.

**Welded or bent areas of 304 stainless steel could be magnetic. If you do check it with a magnet, check a straight section that has not been welded.**

What are the pros and cons?

In general, stainless steel is more difficult to bend and weld than mild steel. In some cases, working with stainless steel could require heat treatment. This relieves the internal stress caused by bending and welding. Stainless steel is more likely to crack, due to this internal stress.

Most modern factory exhaust systems are made from 409 stainless steel. It is strong and will last 8-10 years in a moderate climate. 409 stainless steel will rust on the surface. However, this is not a concern for most people because it is hidden under the vehicle. Surface rust can be cleaned with a wire brush.

304 stainless is the highest quality material used for exhaust parts. It will last 10+ years in a moderate climate. However, it is the most expensive. It will not rust for many years. But, it will turn a golden brown color after being exposed to heat.
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Detailed Factors to Consider VS. Aluminized Steel.

Aluminized Steel

• Pros:
  • Cost-effective: Aluminized steel is generally cheaper than stainless steel options.
  • Heat Resistance: The aluminum coating provides excellent resistance to heat and oxidation, making it suitable for high-temperature applications.
  • Reflects Heat: Aluminized steel can reflect a significant amount of radiant heat, which can be beneficial in some applications.
• Cons:
  • Corrosion: While the aluminum coating protects against corrosion, it can be vulnerable if damaged, and the underlying steel can rust.
  • Surface Rust: Aluminized steel can rust if the aluminum coating is damaged or in humid environments.

T409 Stainless Steel

• Pros:
  • Durable: T409 is more durable than aluminized steel and can last longer in moderate climates.
  • Stronger: T409 is a stronger material than aluminized steel.
• Cons:
  • Surface Rust: T409 is prone to surface rust, especially when exposed to road salt or other harsh conditions.
  • Not as Corrosion-Resistant as T304: T409 has lower corrosion resistance than T304 stainless steel.

T304 Stainless Steel

• Pros:
  • Best Corrosion Resistance: T304 stainless steel offers the highest level of corrosion resistance due to its high chromium and nickel content.
  • Long-lasting: T304 is known for its durability and long lifespan.
• Cons:
  • Most Expensive: T304 is the most expensive of the three option
  • Availability: Many Offroad Exhaust systems are made in aluminized or t409 and very few offer t304.
    
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