Incoloy 800 Powder: The Ultimate Guide for 2025

Overview

Incoloy 800 powder is a nickel-iron-chromium alloy renowned for its excellent strength, oxidation resistance, and high-temperature stability. It is widely used in aerospace, chemical processing, power generation, and advanced manufacturing, particularly in additive manufacturing (3D printing) for high-performance components.

In this guide, we’ll explore:

• Best Incoloy 800 powder for 3D printing
• How to choose the right Incoloy 800 powder
• Top suppliers of Incoloy 800 powder
• Properties and industrial applications
• Production methods and cost analysis
• Comparing gas-atomized vs. water-atomized Incoloy 800 powder

Best Incoloy 800 Powder for 3D Printing in 2025

Why Incoloy 800 Powder is Ideal for Additive Manufacturing?

• Excellent high-temperature oxidation resistance
• Superior mechanical strength up to 1100°C
• Corrosion resistance in acidic and sulfur-rich environments
• Good weldability and printability in LPBF & DED

Key Factors for Selecting Incoloy 800 Powder for 3D Printing

• High sphericity for better flowability
• Controlled particle size distribution for consistent layer formation
• Low oxygen & impurity levels to prevent defects
• Excellent mechanical properties post-processing

Comparison for Different 3D Printing Technologies

For high-performance industrial applications, Met3DP’s gas-atomized Incoloy 800 powder is the preferred choice. Learn more about Met3DP’s high-quality metal powders.

How to Choose the Right Incoloy 800 Powder

Selecting the ideal Incoloy 800 powder requires considering factors such as particle size distribution, powder morphology, atomization process, and application requirements.

1. Particle Size Distribution (PSD)

• Fine powders (15-45µm) → Best for Laser Powder Bed Fusion (LPBF)
• Medium powders (45-105µm) → Suitable for EBM & Binder Jetting
• Coarse powders (50-150µm) → Used in Direct Energy Deposition (DED)

2. Powder Morphology

• Spherical Powder → Best for 3D printing due to superior flowability
• Irregular Powder → Suitable for Binder Jetting & Sintering

3. Atomization Process

• Gas-Atomized Powder → High purity, excellent flowability, best for 3D printing
• Water-Atomized Powder → More affordable, irregular shape, best for sintering & MIM

Comparison of Different Types

For high-precision 3D printing, Met3DP’s gas-atomized Incoloy 800 powder is the best choice. Contact Met3DP for more details.

Top Suppliers in 2025

Several global manufacturers produce high-quality Incoloy 800 powder, but not all powders meet the stringent additive manufacturing requirements.

Leading Suppliers and Their Offerings

Among these, Met3DP stands out due to its cutting-edge atomization technology and consistent powder quality. Explore Met3DP’s Incoloy 800 product range.

Properties

Key Physical and Chemical Properties

These outstanding properties make it the material of choice for high-temperature structural components, aerospace parts, and industrial processing equipment

Production Methods

The production method of it significantly impacts its particle shape, purity, flowability, and overall performance, especially in additive manufacturing (AM), metal injection molding (MIM), and sintering applications.

Main Production Methods

1. Gas Atomization

How It Works:

• High-pressure inert gas (argon or nitrogen) rapidly cools molten Incoloy 800, forming fine spherical particles.

Advantages:
✔ High sphericity, making it ideal for 3D printing
✔ Low oxygen content, reducing oxidation risks
✔ Consistent particle size distribution, improving packing density

Best for: LPBF, DED, and EBM 3D printing

2. Water Atomization

How It Works:

• High-pressure water jets break molten Incoloy 800 into fine particles, resulting in irregular-shaped powders.

Advantages:
✔ Lower cost than gas-atomized powders
✔ Higher surface area, making it suitable for sintering and MIM

Disadvantages:
✖ Poor flowability for additive manufacturing
✖ Higher oxygen content, which may require additional processing

Best for: MIM, sintering, and thermal spray coatings

3. Plasma Rotating Electrode Process (PREP)

How It Works:

• A rotating Incoloy 800 electrode is melted in a plasma environment, forming highly spherical, ultra-pure powders.

Advantages:
✔ Perfect spherical shape, excellent for high-end AM
✔ Ultra-high purity, suitable for aerospace and medical applications
✔ Superior flowability

Disadvantages:
✖ Expensive
✖ Limited production volume

Best for: Aerospace, industrial gas turbines, and precision engineering

For high-performance 3D printing applications, Met3DP’s gas-atomized Incoloy 800 powder is the top choice. Explore Met3DP’s powder production solutions.

Cost Analysis

Several factors influence the cost of Incoloy 800 powder, including production method, particle shape, purity, and market demand.

Factors Affecting Cost

1. Production Method – PREP powders are the most expensive, while water-atomized powders are the most affordable.
2. Particle Shape – Spherical powders (better for AM) are more expensive than irregular powders.
3. Purity Level – Higher purity = Higher cost.
4. Market Demand – Increased demand from aerospace, power plants, and chemical industries can impact pricing.

Estimated Price Ranges for Different Types

For cost-effective, high-quality Incoloy 800 powder, Met3DP provides optimized solutions tailored to industry needs. Contact Met3DP for pricing and availability.

Gas Atomized vs. Water Atomized vs. PREP: Which is Better?

Choosing the right Incoloy 800 powder depends on your application requirements.

Comparison of Different Atomization Methods

For additive manufacturing, gas-atomized Incoloy 800 powder is the best option, offering high purity, flowability, and printability.

FAQ

Q1: What is the best Incoloy 800 powder for 3D printing?

Gas-atomized spherical Incoloy 800 powder is best for LPBF, EBM, and DED due to its excellent flowability and low oxygen content.

Q2: How does Incoloy 800 perform at high temperatures?

It maintains excellent mechanical strength and oxidation resistance up to 1100°C, making it ideal for heat exchangers, reactors, and aerospace parts.

Q3: Can Incoloy 800 be used for metal injection molding (MIM)?

Yes, water-atomized Incoloy 800 powder is commonly used in MIM and sintering.

Q4: Where can I buy high-quality Incoloy 800 powder?

Met3DP is a leading supplier of gas-atomized Incoloy 800 powder, optimized for 3D printing and high-performance applications. Contact Met3DP today!

Conclusion

It is widely used in high-temperature applications, including aerospace, power plants, and chemical processing. Selecting the right powder type, production method, and supplier is essential for ensuring optimal performance and reliability.

Why Choose Met3DP’s Incoloy 800 Powder?

✅ Industry-leading gas atomization technology
✅ High-purity spherical powders for additive manufacturing
✅ Reliable supply chain & global distribution

For high-performance Incoloy 800 powder, Met3DP provides cutting-edge solutions tailored to demanding applications.

Want to learn more or get a quote? Contact Met3DP today!