FeCoNiCrMo Powder

FeCoNiCrMo powder is a complex alloy powder consisting of iron (Fe), cobalt (Co), nickel (Ni), chromium (Cr), and molybdenum (Mo). These elements work synergistically to create a powder with remarkable characteristics suitable for numerous applications.


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Table of Contents

Overview of FeCoNiCrMo Powder

FeCoNiCrMo belongs to a class of high temperature alloys exhibiting good mechanical properties, microstructural stability and environmental resistance at temperatures exceeding 750°C. Iron and cobalt provide strength. Nickel enhances ductility and toughness. Chromium imparts oxidation and corrosion resistance. Molybdenum further improves high temperature strength and creep resistance.

Key characteristics of FeCoNiCrMo 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

FeCoNiCrMo powder is designed for protective coatings, thermal spray, welding, additive manufacturing and other demanding high temperature applications.

Composition of FeCoNiCrMo Powder

FeCoNiCrMo powder has the following nominal composition:

Element Composition
Iron (Fe) Balance
Cobalt (Co) 35-50%
Nickel (Ni) 10-30%
Chromium (Cr) 8-12%
Molybdenum (Mo) 1-3%
Carbon (C) <0.5%
Silicon (Si) <1.5%
Manganese (Mn) <1%

The levels of alloying elements can be adjusted to optimize mechanical properties and environmental resistance based on application requirements. Impurities are minimized.

FeCoNiCrMo Powder

Properties of FeCoNiCrMo Powder

Key properties of FeCoNiCrMo powder include:

Property Value
Density 8.0-8.5 g/cm3
Melting Point 1350-1450°C
Thermal Conductivity 15-30 W/mK
Electrical Resistivity 70-85 μΩ.cm
Young’s Modulus 190-220 GPa
Poisson’s Ratio 0.28-0.32
Tensile Strength 650-1200 MPa
Yield Strength 450-900 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 FeCoNiCrMo Powder

FeCoNiCrMo 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 characteristics like size, shape, purity and microstructure.

Applications of FeCoNiCrMo Powder

Typical applications of FeCoNiCrMo powder include:

  • Thermal Spray Coatings – HVOF or plasma spraying to deposit thick wear and corrosion resistant coatings on valves, seals, bearings etc. operating at high temperatures.
  • Additive Manufacturing – Selective laser melting to produce complex components like turbine blades for extreme 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 FeCoNiCrMo Powder

FeCoNiCrMo 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 to ultra high purity levels 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 characteristics tailored for application and processing method.

Global Suppliers of FeCoNiCrMo Powder

Some of the major global suppliers of FeCoNiCrMo powder include:

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

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

Pricing of FeCoNiCrMo Powder

FeCoNiCrMo powder prices depend on factors like:

  • Composition, purity levels
  • Particle size distribution and morphology
  • Production method
  • Order quantity
  • Manufacturer and geographical location
Grade Price Range
Commercial $80-120 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 of powder.

Storage and Handling of FeCoNiCrMo Powder

FeCoNiCrMo powder requires careful storage and handling:

  • Should be stored in sealed containers under inert gas to prevent oxidation
  • Avoid accumulation of fine powder to minimize explosion risks
  • Use proper PPE, ventilation, grounding and safety practices during handling
  • Prevent contact between powder and incompatible materials
  • Follow applicable safety guidelines from supplier SDS

Proper protective measures are essential when handling this reactive alloy powder.

Inspection and Testing of FeCoNiCrMo Powder

Key quality control tests performed on FeCoNiCrMo 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 X-ray diffraction

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

Comparison Between FeCoNiCrMo and 316L Stainless Steel Powders

FeCoNiCrMo and 316L stainless steel powders compared:

Parameter FeCoNiCrMo 316L SS
Composition High-temp quinary alloy Fe-Cr-Ni stainless alloy
Cost Higher Lower
High temperature strength Far superior Moderate
Corrosion resistance Comparable Better
Thermal conductivity Higher Lower
Workability Moderate Excellent
Applications Thermal spray, AM Automotive, construction

FeCoNiCrMo offers much better high temperature strength whereas 316L provides good fabrication characteristics and corrosion resistance at lower cost.

FeCoNiCrMo Powder FAQs

Q: How is FeCoNiCrMo powder produced?

A: FeCoNiCrMo 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 FeCoNiCrMo 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 FeCoNiCrMo powder to maximize deposition efficiency and coating properties.

Q: Does FeCoNiCrMo 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 FeCoNiCrMo powder suitable for additive manufacturing?

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

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