FeCoNiCr powder

FeCoNiCr powder refers to an alloy composed of iron (Fe), cobalt (Co), nickel (Ni), and chromium (Cr). The combination of these elements brings forth a host of desirable characteristics, making it an ideal material for additive manufacturing processes. The powder is finely granulated and specifically formulated to enable efficient utilization in 3D printers, where it can be selectively deposited layer by layer to create intricate and complex structures.


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Table of Contents

Overview of FeCoNiCr Powder

FeCoNiCr belongs to a class of high performance alloys that exhibit good mechanical properties, microstructural stability and environmental resistance at elevated temperatures exceeding 750°C. Iron and cobalt provide strength. Nickel enhances ductility and toughness. Chromium provides oxidation and corrosion resistance.

Key characteristics of FeCoNiCr powder include:

  • Excellent high temperature strength and creep resistance
  • Good fatigue strength and toughness
  • High hardness, wear resistance, and abrasion resistance
  • Outstanding corrosion and oxidation resistance
  • Available in various particle size distributions and morphologies

FeCoNiCr powder is designed for protective coatings, thermal spray, welding, additive manufacturing and other high temperature applications requiring strength, hardness and environmental resistance.

Composition of FeCoNiCr Powder

FeCoNiCr powder has the following nominal composition:

Element Composition
Iron (Fe) Balance
Cobalt (Co) 35-50%
Nickel (Ni) 10-30%
Chromium (Cr) 8-12%
Carbon (C) <0.5%
Silicon (Si) <1.5%
Manganese (Mn) <1%

FeCoNiCr powder

The levels of cobalt, nickel and chromium can be adjusted based on requirements to optimize mechanical properties and environmental resistance. Impurities are minimized.

Properties of FeCoNiCr Powder

Key properties of FeCoNiCr powder include:

Property Value
Density 7.5-8.2 g/cm3
Melting Point 1300-1400°C
Thermal Conductivity 10-30 W/mK
Electrical Resistivity 65-85 μΩ.cm
Young’s Modulus 190-220 GPa
Poisson’s Ratio 0.28-0.32
Tensile Strength 600-1100 MPa
Yield Strength 450-800 MPa
Elongation 15-30%
Hardness 30-50 HRC


The properties like high temperature strength, hardness, wear resistance, and corrosion resistance make it suitable for the most demanding applications.

Production Method for FeCoNiCr Powder

FeCoNiCr powder can be produced via:

  • Gas Atomization – High pressure inert gas used to atomize molten alloy resulting in fine spherical powder ideal for AM.
  • Water Atomization – High velocity water jet breaks up molten metal into fine irregular powder particles. Economical but higher oxygen pickup.
  • Mechanical Alloying – Ball milling of blended elemental powders followed by sintering and secondary atomization.

Gas atomization provides the best control over particle size, shape, purity and microstructure.

Applications of FeCoNiCr Powder

Typical applications of FeCoNiCr powder include:

  • Thermal Spray Coatings – HVOF or plasma spraying to deposit thick wear and corrosion resistant coatings on tools, molds, valves, bearings etc.
  • Additive Manufacturing – Selective laser melting to produce complex components for high temperature environments.
  • Welding Filler – Provides excellent elevated temperature strength, hardness and corrosion resistance in the weld zone.
  • Brazing Filler – Used to join components operating at very high temperatures requiring oxidation resistance.
  • Glass Processing – Powder metallurgy conveyor rolls with high temperature strength used in glass melting furnaces.

Specifications of FeCoNiCr Powder

FeCoNiCr powder is available under various size ranges, shapes, grades and purity levels:

  • Particle Size: From 15-45 μm for AM methods, up to 150 μm for thermal spray processes.
  • Morphology: Spherical, irregular and blended shapes. Spherical powder provides optimal flow and packing.
  • Purity: From commercial purity to ultra high purity grades based on stringent chemical analysis and application requirements.
  • Surface Area: Low surface area preferred to minimize oxidation during handling and storage.
  • Grades: Customized composition and powder metallurgy tailored for intended application and processing method.

Global Suppliers of FeCoNiCr Powder

Some of the major global suppliers of FeCoNiCr powder include:

  • Sandvik Osprey (UK)
  • Erasteel (France)
  • Tekna (Canada)
  • Edgetech Industries (USA)
  • Hoganas (Sweden)
  • CNPC Powder (China)

These companies produce various grades of FeCoNiCr powder using gas atomization, water atomization and mechanical alloying processes tailored for specific applications.

Pricing of FeCoNiCr Powder

FeCoNiCr powder prices depend on factors like:

  • Composition, purity levels
  • Powder size and morphology
  • Production method
  • Order volume
  • Manufacturer and location
Grade Price Range
Commercial $60-120 per kg
High purity $120-250 per kg
Ultrafine $250-450 per kg
Special grade $450-850 per kg


Gas atomized, controlled particle size, high purity powders command much higher pricing compared to commercial grades.

Storage and Handling of FeCoNiCr Powder

Proper storage and handling procedures for FeCoNiCr powder include:

  • Store in sealed containers under inert gas to prevent oxidation
  • Avoid accumulation of fine powder to control explosion risks
  • Use appropriate PPE, ventilation, safety practices when handling
  • Prevent contact between powder and incompatible materials
  • Follow applicable safety guidelines from supplier SDS

Caution and protective measures are essential when handling this reactive alloy powder.

Inspection and Testing of FeCoNiCr Powder

Key quality control tests performed on FeCoNiCr powder:

  • Chemical analysis using OES or XRF to ensure composition is within specified limits
  • Particle size distribution using laser diffraction as per ASTM B822 standard
  • Morphology analysis through SEM imaging
  • Powder flow rate measurement as per ASTM B213 standard
  • Density determination by helium pycnometry
  • Impurity testing using ICP-MS
  • Microstructural characterization by XRD phase analysis

Thorough testing verifies powder quality and consistency for the intended high temperature application.

Comparison Between FeCoNiCr and 316L Stainless Steel Powders

FeCoNiCr and 316L stainless steel powders compared:

Parameter FeCoNiCr 316L SS
Composition Quaternary high-temp alloy Fe-Cr-Ni stainless alloy
Cost Higher Lower
High temperature strength Much better Moderate
Corrosion resistance Comparable Better
Thermal conductivity Higher Lower
Workability Moderate Excellent
Applications Thermal spray, AM Automotive, construction


FeCoNiCr offers far superior high temperature strength whereas 316L provides better fabrication characteristics and corrosion resistance at lower cost.

FeCoNiCr Powder FAQs

Q: How is FeCoNiCr powder produced?

A: FeCoNiCr powder is commercially produced using gas atomization, water atomization and mechanical alloying followed by sintering. Gas atomization offers the best powder characteristics.

Q: What are the main applications for FeCoNiCr powder?

A: Main applications include thermal spray coatings, additive manufacturing, brazing filler material, powder metallurgy hot work tooling, glass processing equipment where high temperature strength and resistance is required.

Q: What is the recommended particle size for thermal spraying?

A: For most thermal spray processes, a particle size range of 45-150 microns is preferred for FeCoNiCr powder to maximize deposition efficiency and coating properties.

Q: Does FeCoNiCr powder require any special handling precautions?

A: Yes, proper protective measures are essential when handling this reactive fine alloy powder including inert atmosphere, grounding, ventilation, PPE.

Q: Where can I purchase FeCoNiCr powder suitable for additive manufacturing?

A: For AM applications requiring high temperature strength, fine FeCoNiCr powder can be purchased from leading manufacturers including Sandvik, Erasteel, Tekna, and Edgetech Industries.

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