Basic information of Nickel-based metal and alloy powders

Nickel (Ni, atomic number 28) is a corrosion-resistant, high-strength metal with a melting point of 1,455°C and a face-centered cubic (FCC) crystal structure. Discovered in 1751 by Axel Fredrik Cronstedt, its name comes from kupfernickel (meaning “false copper”) due to miners’ early confusion. Nickel and its alloys, such as Monel 400 and Monel K-500 (Ni-Cu), Inconel 601, 625, and 718 (Ni-Cr), Incoloy 800 and 825 (Nickel-Iron-Chromium), Hastelloy C22 and C276 (Ni-Mo), and Nickel-Titanium (Nitinol) are standardized under ASTM and UNS designations for aerospace, marine, and chemical applications. These alloys offer exceptional heat resistance, oxidation protection, and mechanical strength, making them crucial in jet engines, nuclear reactors, and medical devices. Additionally, nickel plays a key role in rechargeable batteries, stainless steel production, and shape-memory alloys like Nitinol for medical implants.

Morphology and Particle Sizes

Nickel and nickel alloy powders are available in various morphologies

Spherical: Produced via gas atomization or plasma atomization, ideal for additive manufacturing (AM), thermal spray, and powder metallurgy due to high flowability and packing density.
Irregular/Spongy: Created by electrolytic or carbonyl processes, offering high surface area, making them suitable for battery electrodes and catalysts.
Flaky: Generated by mechanical milling, used in conductive coatings and EMI shielding.
Dendritic: Formed through electrodeposition, providing excellent green strength for sintering applications.

Nickel and its alloy powders are classified by particle size, measured in microns (µm)

<1 µm: Nanopowders used in catalysts, coatings, and energy storage.
1–10 µm: Fine powders for conductive inks, catalysts, and high-performance coatings.
10–45 µm: Preferred for Metal Injection Molding (MIM) and powder metallurgy.
45–150 µm: Suitable for laser powder bed fusion (LPBF), binder jetting, and direct energy deposition (DED) in additive manufacturing.

Properties & Applications:

Corrosion Resistance: Excellent resistance to oxidation and acids, making nickel alloys ideal for marine, chemical, and aerospace industries.
High-Temperature Strength: Alloys like Inconel withstand extreme heat in jet engines, turbines, and reactors.
Electrical and Magnetic Properties: Used in superconductors, batteries (NiMH, Li-ion), and magnetic shielding.
Biocompatibility: Nickel-titanium (Nitinol) is used in medical implants, stents, and orthodontics.

Nickel-based metal and alloy powders

Princeton Powder is a leading supplier of Nickel-based metal and alloy powders, specializing in a comprehensive range of spherical powder and nano particles, micro size particles.

Nitinol Powder:

Nitinol (Nickel-Titanium) powder is mainly produced by plasma atomization, gas atomization, and hydride-dehydride (HDH) methods. Plasma and gas atomization create highly spherical powders ideal for additive manufacturing, while HDH results in irregular particles suitable for sintering applications.
Nitinol powder is processed via Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), and Direct Energy Deposition (DED) for medical implants, Metal Injection Molding (MIM) for precision components, Hot Isostatic Pressing (HIP) for aerospace actuators, and thermal spray coating for wear-resistant surfaces.

Inconel 625 Powder:

Inconel 625 (Nickel-Chromium-Molybdenum) powder is primarily produced by gas atomization and plasma atomization, resulting in highly spherical particles with excellent flowability for high-performance applications.
Inconel 625 powder is processed via Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), and Direct Energy Deposition (DED) for aerospace and marine components, Hot Isostatic Pressing (HIP) for high-strength structural parts, and thermal spray coating for corrosion and oxidation resistance.

Inconel 718 Powder:

Inconel 718 (Nickel-Chromium-Iron) powder is mainly produced using gas atomization and plasma atomization, ensuring uniform particle distribution for additive manufacturing and powder metallurgy.
Inconel 718 powder is processed via LPBF, EBM, and DED for turbine blades and aerospace components, Metal Injection Molding (MIM) for high-strength fasteners, HIP for improving fatigue resistance, and thermal spray coating for wear-resistant surfaces.

Inconel 738 Powder:

Inconel 738 (Nickel-Chromium-Cobalt) powder is produced by vacuum induction melting (VIM) with gas atomization, yielding fine, oxidation-resistant particles for high-temperature applications.
Inconel 738 powder is processed via LPBF and DED for gas turbine components, HIP for high-temperature creep-resistant parts, and thermal spray coating for extreme heat resistance in jet engines.

Hastelloy X Powder:

Hastelloy X (Nickel-Chromium-Iron-Molybdenum) powder is manufactured through gas atomization and plasma atomization, producing spherical particles ideal for demanding thermal environments.
Hastelloy X powder is processed via LPBF, EBM, and DED for aerospace combustion chambers, HIP for high-strength structural parts, and thermal spray coating for oxidation-resistant furnace components.

Hastelloy C-276 Powder:

Hastelloy C-276 (Nickel-Molybdenum-Chromium) powder is primarily produced using gas atomization, resulting in corrosion-resistant particles suitable for harsh chemical environments.
Hastelloy C-276 powder is processed via LPBF and DED for chemical reactors, HIP for dense and corrosion-resistant industrial components, and thermal spray coating for anti-corrosion protection in aggressive environments.

Key factors to select Nickel-Based Metal and Alloy Powders:

Application Requirements

Corrosion Resistance: For harsh environments (marine, chemical processing), choose alloys like Inconel 625 or Hastelloy C-276.
High-Temperature Strength: For aerospace or turbine applications, consider Inconel 718 or Inconel 738 due to their heat resistance and mechanical strength.
Shape Memory or Flexibility: Choose Nitinol powder for medical implants or actuators requiring shape-memory properties.

Particle Size and Morphology

Spherical Powders: Preferred for additive manufacturing (AM) and thermal spraying due to excellent flowability and packing density (e.g., gas or plasma atomization).
Irregular Powders: Suitable for sintering and applications that need high surface area (e.g., HDH processes for Nitinol).
Fine vs. Coarse: Choose fine powders (<50 µm) for precision components, and coarser powders (>50 µm) for thermal spray coatings

Mechanical Properties

Consider the tensile strength, creep resistance, and fatigue life needed for your application.
Inconel 718 is ideal for high-strength, low-fatigue components, while Inconel 625 offers better corrosion resistance.

Manufacturing Method

3D Printing: LPBF or EBM is suitable for precise parts, while DED is ideal for large-scale, complex geometries.
Metal Injection Molding (MIM): For creating small, complex parts with high precision, especially in the medical and aerospace industries.

Nickel-based metal and alloy powders Scholar Articles

Powder Bed Fusion of nickel-based superalloys: A review

Abstract: Powder Bed Fusion (PBF) techniques constitute a family of Additive Manufacturing (AM) processes, which are characterised by high design flexibility and no tooling requirement. This makes PBF techniques attractive to many modern manufacturing sectors (e.g. aerospace, defence, energy and automotive) where some materials, such as Nickel-based superalloys, cannot be easily processed using conventional subtractive techniques. Nickel-based superalloys are crucial materials in modern engineering and underpin the performance of many advanced mechanical systems. Their physical properties (high mechanical integrity at high temperature) make them difficult to process via traditional techniques. Consequently, manufacture of nickel-based superalloys using PBF platforms has attracted significant attention.

FAQ Nickel-based metal and alloy powders

1.What is the difference between gas atomization and plasma atomization in producing nickel-based powders?

Gas atomization uses high-pressure gas to break molten metal into droplets, producing spherical powders with good flowability, ideal for additive manufacturing.
Plasma atomization uses a plasma arc to melt metal, resulting in fine, spherical powders with better consistency and purity for high-performance applications.

2.How do nickel-based alloy powders compare to other metal powders like titanium or stainless steel?

Nickel-based alloy powders typically offer better high-temperature strength and corrosion resistance than stainless steel and are more cost-effective than titanium alloys. However, titanium alloys have superior strength-to-weight ratios and are better for aerospace applications where weight is critical.

3.Are there specific standards for nickel-based powder?

Yes, standards exist for nickel-based powders, such as:

ASTM B323 for Inconel 625 powder.
ASTM B441 for Inconel 718 powder.
ASTM F2063 for Nitinol powder. These standards cover aspects like particle size, purity, and morphology for specific applications.

4.How should nickel-based powders be stored?

Nickel-based powders should be stored in a dry, controlled environment to prevent moisture absorption and oxidation. Typically, powders are kept in airtight containers to maintain quality and prevent contamination.