FeCoNiCrAl powder

FeCoNiCrAl powder is a high-performance alloy powder containing iron, cobalt, nickel, chromium, and aluminum. It offers excellent strength, hardness, wear resistance and corrosion resistance at high temperatures.  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 FeCoNiCrAl Powder

FeCoNiCrAl is a quinary alloy that exhibits good mechanical properties, oxidation resistance, and microstructural stability at elevated temperatures. Iron and cobalt provide strength. Nickel enhances toughness and ductility. Chromium imparts excellent oxidation and corrosion resistance. Aluminum improves high temperature mechanical properties.

Key characteristics of FeCoNiCrAl powder include:

  • Excellent high temperature strength and creep resistance
  • Good environmental stability and thermal fatigue strength
  • High hardness, wear resistance, and abrasion resistance
  • Good ductility and fabricability
  • Available in range of particle sizes and morphologies

FeCoNiCrAl powder is suitable for protective coatings, thermal spray, welding, brazing, and high temperature structural applications requiring thermal and environmental resistance.

Composition of FeCoNiCrAl Powder

FeCoNiCrAl powder has the nominal composition:

Element Composition
Iron (Fe) Balance
Cobalt (Co) 35-50%
Nickel (Ni) 10-30%
Chromium (Cr) 8-12%
Aluminum (Al) 1-5%
Carbon (C) <0.5%
Silicon (Si) <1.5%
Manganese (Mn) <1%

FeCoNiCrAl powder

The levels of cobalt, nickel, chromium and aluminum can be tailored to optimize high temperature strength, toughness, and environmental resistance based on application.

Properties of FeCoNiCrAl Powder

Key properties of FeCoNiCrAl 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 excellent high temperature strength, hardness, wear resistance, and environmental stability make it suitable for the most demanding applications.

Production Method for FeCoNiCrAl Powder

FeCoNiCrAl powder is produced using:

  • Gas Atomization – High pressure inert gas used to atomize molten alloy into fine spherical powder for excellent flow and packing density.
  • Water Atomization – High velocity water jet impacts molten stream to produce fine irregular powder particles. Lower cost but higher oxygen pickup.
  • Mechanical Alloying – Ball milling of elemental/pre-alloyed powders followed by sintering and gas atomization.

Gas atomization provides the best control over particle size distribution, morphology and purity.

Applications of FeCoNiCrAl Powder

Typical applications of FeCoNiCrAl powder include:

  • Thermal Spray Coatings – HVOF or plasma spraying to deposit thick, wear resistant coatings on components operating at high temperatures.
  • Additive Manufacturing – Selective laser melting to produce complex parts for extreme environments needing high temperature resistance.
  • Brazing Filler – For joining assemblies and sealing cracks in parts subjected to high temperatures during service.
  • Welding Consumables – Used as filler material to provide excellent elevated temperature strength in welded components.
  • Wear Parts – Powder metallurgy hot work tooling and fixtures resisting wear and thermal fatigue cracking.
  • Glass Processing – Chutes, conveyors and handlers used in glass melting furnaces.

Specifications of FeCoNiCrAl Powder

FeCoNiCrAl powder is available under various size ranges, morphologies and grades:

  • Particle Size: From 10-45 microns for AM methods, up to 150 microns for thermal spray processes.
  • Morphology: Spherical, irregular and blended shapes. Spherical powder has excellent flowability.
  • Purity: Ranging from commercial purity to ultra high purity grades based on stringent chemical analysis.
  • Surface Area: Low surface area preferred to minimize oxidation during handling and storage.
  • Grades: Customized composition and powder metallurgy tailored for application.

Global Suppliers of FeCoNiCrAl Powder

Some of the major global suppliers of FeCoNiCrAl powder include:

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

These companies produce various grades of FeCoNiCrAl powder using gas atomization, water atomization and other techniques tailored for AM, thermal spray, brazing and other demanding applications.

Pricing of FeCoNiCrAl Powder

FeCoNiCrAl powder prices depend on factors like:

  • Composition, purity levels
  • Powder size and morphology
  • Production method
  • Order volume
  • Supplier
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


Prices are higher for gas atomized, high purity and fine powders compared to simple commercial grades.

Storage and Handling of FeCoNiCrAl Powder

Proper storage and handling procedures for FeCoNiCrAl 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 FeCoNiCrAl Powder

Key quality control tests performed on FeCoNiCrAl 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 meeting performance requirements.

Comparison Between FeCoNiCrAl and 316L Stainless Steel Powder

FeCoNiCrAl and 316L stainless steel powder compared:

Parameter FeCoNiCrAl 316L SS
Composition Quinary 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


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

FeCoNiCrAl Powder FAQs

Q: How is FeCoNiCrAl powder produced?

A: FeCoNiCrAl 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 FeCoNiCrAl powder?

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

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 FeCoNiCrAl powder to maximize deposition efficiency and coating properties.

Q: Does FeCoNiCrAl powder require 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 FeCoNiCrAl powder for additive manufacturing?

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

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