Inconel 625 Powder:Introduction,Applications

Table of Contents

Inconel 625 is a nickel-chromium-molybdenum alloy widely used for its excellent corrosion and oxidation resistance at high temperatures. Inconel 625 powder enables manufacturing components from this alloy using advanced powder metallurgy techniques.

This guide covers Inconel 625 powder compositions, properties, production methods, particle characteristics, applications, advantages, limitations, pricing, and comparisons with alternative alloys.

Introduction to Inconel 625 Powder

Inconel 625 powder has the following key characteristics:

  • Made of Nickel-Chromium-Molybdenum alloy
  • Contains Ni-Nb strengthening precipitates
  • Excellent corrosion resistance
  • High strength and toughness
  • Stable at temperatures up to 980°C
  • Available in various size distributions
  • Mainly used for additive manufacturing
  • Also suitable for MIM, thermal spray, welding

The properties of Inconel 625 make it well-suited for parts exposed to extreme environments. The powder form enables manufacturing complex geometries using advanced methods.

inconel 625 powder

Typical Composition of Inconel 625 Powder

The nominal composition of Inconel 625 powder is:

Inconel 625 Powder Composition

ElementWeight %
Nickel58.0 min
Iron5.0 max
Cobalt1.0 max
Aluminum0.4 max
Titanium0.4 max
Carbon0.1 max
  • Nickel provides corrosion resistance and ductility
  • Chromium for oxidation and pitting resistance
  • Molybdenum and Niobium for strengthening
  • Controlled low impurities for reliable performance

The balanced alloy composition provides a combination of fabricability, weldability, and high temperature properties.

Properties and Characteristics of Inconel 625 Powder

Physical Properties

  • Density: 8.44 g/cm3
  • Melting point: 1260-1350°C

Mechanical Properties

  • Tensile strength: 760 MPa
  • Yield strength: 380 MPa
  • Elongation: 40%
  • Fatigue strength: 300 MPa at 107 cycles

High Temperature Properties

  • Retains tensile strength upto 980°C
  • Excellent creep rupture strength
  • Good metallurgical stability

Corrosion Properties

  • Highly resistant to pitting and crevice corrosion
  • Excellent chloride ion stress corrosion cracking resistance
  • Resistant to oxidation and carburization

Production Methods for Inconel 625 Powder

Key techniques for producing Inconel 625 powder include:

  • Gas Atomization – High pressure inert gas breaks up molten alloy stream into fine droplets. Most common method.
  • Plasma Atomization – Very high temperatures from plasma torches produce finer powders.
  • Rotating Electrode Process – Centrifugal forces disintegrate molten metal into droplets.
  • Water Atomization – Less common due to contamination risks.

Gas atomization allows cost-effective production of Inconel 625 powder with controlled particle sizes and minimal contamination.

Particle Characteristics of Inconel 625 Powder

Particle Morphology

  • Predominantly spherical particles
  • Satellites can be removed by thermal conditioning

Particle Size Distribution

  • Typical size ranges from 15 to 150 microns
  • Narrow distribution ensures density and quality
  • Smaller sizes used for better resolution

Flow Properties

  • Generally free flowing powders
  • Flow rates measured by Hall flowmeter test

Chemical Composition

  • Conforms to Inconel 625 nominal alloy content
  • Low oxygen and nitrogen levels
  • Meets chemical specification standards

Control over particle characteristics is critical for achieving required properties in finished components.

Applications of Inconel 625 Powder

Key application areas of Inconel 625 powder include:

Additive Manufacturing

  • Aerospace components
  • Turbine hot section parts
  • Exhaust system parts
  • Corrosion resistant fluid handling parts

Metal Injection Molding

  • Small, complex components
  • Corrosion resistant valves

Thermal Spray Coatings

  • High temperature corrosion protection
  • Wear resistant coatings


  • Corrosion resistant weld overlays
  • Similar composition filler metal

The unique properties of Inconel 625 allow manufacturing high performance components for demanding applications via powder metallurgy techniques.

Benefits and Advantages of Inconel 625 Powder

Key advantages of using Inconel 625 powder:

  • Excellent resistance to wide range of corrosive environments
  • Maintains high strength at elevated temperatures
  • Retains metallurgical stability upto 980°C
  • High fatigue, creep and rupture strength
  • Crack, pitting and crevice corrosion resistance
  • Oxidation and carburization resistance
  • Narrow melting range improves weldability
  • Powder form enables additive manufacturing
  • Allows manufacturing of complex, net-shape parts
  • Components can be engineered with superior properties
  • Economical compared to other Ni-alloys

The performance benefits of Inconel 625 combined with design flexibility make it an attractive alloy for critical applications.

Limitations and Disadvantages

Some limitations of using Inconel 625 powder include:

  • High material costs compared to steels
  • Poorer mechanical properties than latest Ni-alloys
  • Lower strength than high carbon alloys
  • Requires hot isostatic pressing for full density
  • Prone to micro-fissuring in some builds
  • Post-processing may be required
  • Controlling particle characteristics adds cost
  • Suitability testing needed for new applications
  • Requires handling precautions due to fine particles

The limitations can be overcome with proper parameter selection and testing for each application.

Inconel 625 Powder Pricing

Inconel 625 Powder Price Ranges:

  • 15-45 microns: $50-$65 per kg
  • 45-75 microns: $45-$55 per kg
  • 75-150 microns: $40-$50 per kg
  • Pricing depends on particle size, quality, quantity ordered
  • Requires high purity raw materials, increasing costs
  • Processing costs more than nickel/steel powders
  • Still economical for high performance applications

For suitable applications, Inconel 625 powder provides long term value despite higher initial costs.

Comparison with Alternative Alloy Powders

Compared to Inconel 718 Powder

  • Inconel 625 has better corrosion resistance
  • Higher service temperature capability
  • Lower strength and hardness than IN718
  • IN718 has higher tensile and fatigue strength

Compared to 316L Stainless Steel Powder

  • Inconel 625 has far superior high temperature strength
  • Much better corrosion resistance
  • Higher costs than 316L powder
  • 316L has better weldability and ductility

Compared to Cobalt Chrome Powder

  • Inconel 625 has higher ductility and fracture toughness
  • Poor wear resistance relative to cobalt alloys
  • Significantly lower cost than cobalt chrome

Inconel 625 provides the best combination of properties for applications where corrosion resistance with intermediate temperature properties are needed.


Q: How is Inconel 625 powder produced?

A: Gas atomization is the most common method. The alloy is induction melted and disintegrated into fine droplets using inert gas jets. The droplets solidify into powder.

Q: What particle sizes of Inconel 625 powder are available?

A: Typical size ranges are 15-45 microns, 45-75 microns and 75-150 microns. Finer powders provide better resolution but cost more. Size distribution affects final part properties.

Q: What applications use Inconel 625 powder?

A: Key applications are additive manufacturing of aerospace, gas turbine and corrosion resistant parts. Also used in metal injection molding, thermal spray, and for welding wire.

Q: What are the benefits of Inconel 625 vs stainless steels?

A: Inconel 625 has far superior high temperature strength and corrosion resistance compared to stainless steels. It is widely used for demanding applications.

Q: Does Inconel 625 powder require hot isostatic pressing?

A: HIP helps achieve full density and optimal properties. Critical components are often HIPed post additive manufacturing. For some applications sintering alone may suffice.

Q: How to minimize micro-fissuring when printing Inconel 625?

A: Optimizing build parameters, using spherical powders, HIPing, and stress-relieving heat treatments can minimize micro-fissuring issues.

Q: What precautions are necessary when handling Inconel 625 powder?

A: Use dust masks, gloves, and protective clothing to prevent inhalation or skin exposure during handling. Follow recommended safety protocols for metal powders.

Q: Is Inconel 625 weldable?

A: Yes, matching filler material provides good weld joint properties. Controlled processes are used to manage residual stresses and cracking.

Q: Is Inconel 625 powder reusable?

A: Unused powder can be reused after sieving to remove large particles. But reuse may introduce defects so fresh powder is generally recommended.

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