Inconel Powder

Inconel powder refers to nickel-chromium-based superalloys that are corrosion and heat resistant. This guide provides a comprehensive overview of inconel powder, its properties, applications, specifications, pricing, and more.

Overview of Inconel Powder

Inconel is a family of nickel-chromium-based superalloys known for their strength, heat resistance, and corrosion resistance properties. Inconel powders are used across industries like aerospace, oil and gas, chemical processing, power generation, and more.

Some key properties and characteristics of inconel powder:

Composition

Type	Nickel Content	Chromium Content	Iron Content	Other Alloying Elements
Inconel 600	72%	14-17%	6-10%	Cobalt, carbon
Inconel 625	58% min	20-23%	5% max	Molybdenum, niobium
Inconel 718	50-55%	17-21%	Balance	Niobium, molybdenum, aluminium, titanium

High Temperature Strength – Retains strength and resist creep deformation up to 700°C. Specific grades can withstand even higher temperatures exceeding 1000°C.

Oxidation and Corrosion Resistance – Forms protective chromia layer making it resistant to pitting and corrosion by acids, salts etc.

Easy Weldability and Machinability – Readily fabricated and machined into complex shapes. Requires post-weld heat treatment.

High Fatigue Strength – Withstand repeated stress cycles without failure making it suitable for dynamic load-bearing applications.

Compare the properties of common inconel powder grades:

Properties	Inconel 600	Inconel 625	Inconel 718
Melting Point	1350-1413°C	1260-1350°C	1260-1336°C
Density	8.47 g/cm3	8.44 g/cm3	8.19 g/cm3
Tensile Strength	485-860 MPa	760 MPa	1275 MPa
Elongation	30-35%	35%	19%
Thermal Expansion	16.0×10−6/°C	13.0×10−6/°C	13.0×10−6/°C
Thermal Conductivity	9.8-10.4 W/m.K	9.8 W/m.K	11.4 W/m.K

Table 1: Comparison of key inconel grades

Applications of Inconel Powder

Thanks to its unique material properties, inconel finds extensive use across industries like:

Industry	Applications	Powder Products Used
Aerospace	Turbocharger exhaust cases, thrust reverser systems, turbine blades	Inconel 718, Inconel 625
Oil and Gas	Wellhead systems, rupture discs, downhole tools	Inconel 718, Inconel 625, Inconel 600
Chemical Processing	Heat exchangers, reaction vessels, conveyor components	Inconel 600, Inconel 625
Power Generation	Heat exchanger tubing, coal gasification systems	Inconel 617, Inconel 625, Inconel 740
Automotive	Valve components, exhaust gas recirculation systems	Inconel 718, Inconel 600

Key Applications of Inconel Powder:

• High temperature strength allows use in gas turbine blades, rocket motor casings, nuclear fuel cladding etc.
• Corrosion resistance enables use in acid production systems, sea water applications etc.
• Oxidation resistance makes it suitable for aircraft exhaust systems, industrial furnace components etc.
• Easy fabrication into complex shapes through 3D printing or other methods.

Industry Trends Driving Adoption:

• Aerospace sector growth leading to increasing use in aeroengine components.
• Demand from chemical plants, oil refineries, LNG carriers due to high temperature and pressure needs.
• Growth in metal additive manufacturing for prototyping and production applications.

Table 2: Overview of inconel powder applications by industry

Inconel Powder Specifications

Inconel powder is available in various size ranges, shapes, and compositions to suit different applications:

Size Range	Common Shape	Typical Uses
15-45 microns	Spheroidal	Metal injection molding feedstock
45-106 microns	Irregular, spherical	Additive manufacturing, HIP applications
150-250 microns	Spherical, agglomerated	Thermal spray coatings
-140/+325 mesh	Irregular	Press and sinter process

Based on application needs, users can choose from ASTM, ASME, AWS, AMS, UNS, etc. grade specifications:

Specification	Common Grades
ASTM B168	Inconel 600, Inconel 601, Inconel 625, Inconel 718, Inconel X-750
ASME SB443	Inconel 82, Inconel 625, Inconel 718
AWS A5.14	Inconel 52, Inconel 152, Inconel 625
AMS Specs	Inconel 718 (AMS 5662), Inconel X-750 (AMS 5754)

Table 3: Overview of common inconel powder specifications

Characteristics Evaluated as per Standards

• Chemical composition – Ni, Cr, Fe, Nb, Ti, Al contents
• Particle size distribution, flow rates
• Microstructure – Gamma prime content, grain size
• Impurity levels – C, S, Si, Mn
• Mechanical properties – hardness, tensile and yield strength

Choosing the right specification grade ensures the powder meets design needs.

Suppliers and Pricing

Most nickel and superalloy powder manufacturers supply various inconel grades. Buyers can select suppliers based on factors like:

• Capability to manufacture different compositions and particle size distributions
• Quality certifications – AS9100, ISO 9001
• Customization options – ability to tailor powders
• Production capacity, lead times, minimum order quantities

Indicative Pricing Range

Inconel Grade	Price Per Kg
Inconel 600	$50 – $120
Inconel 625	$50 – $150
Inconel 718	$80 – $220

Prices vary based on:

• Purity levels, impurity limits
• Particle shape and size distribution
• Purchase volumes and production process used
• Level of customization for properties

Leading Inconel Powder Manufacturers

Company	Locations	Grades Offered
Sandvik	Europe, Asia	Inconel 718, Inconel 625
Praxair	US	Inconel 600, Inconel 625, Inconel 718
Hoganas	Europe	Inconel 718
Carpenter Technology	US	Inconel 600, Inconel 718
Erasteel	Europe	Inconel 718

Table 4: Indicative pricing range and major inconel powder suppliers

Pros and Cons of Inconel Powder

Advantages

• Extreme temperature resistance – can operate up to 1000°C
• Withstands thermal fatigue and dynamic loads without failure
• High corrosion and oxidation resistance protects surface
• Tailorable mechanical properties by adjusting composition
• Easy to fabricate into complex shapes

Limitations

• Very expensive compared to steel, titanium alloys
• Lower thermal conductivity than aluminium, copper
• Susceptible to grain boundary cracking if improperly processed
• Difficult to fully recycle and reuse after service life
• Requires post-weld heat treatment for optimal properties

Carefully weigh the unique performance benefits with higher costs compared to alternatives when choosing inconel.

Comparison to Key Alternatives

How does inconel fare compared against other high temperature alloys?

Parameter	Inconel	Stainless Steel	Hastelloy	Haynes Alloys
Oxidation Resistance	Excellent	Moderate	Excellent	Excellent
Corrosion Resistance	Excellent	Good	Excellent	Excellent
Thermal Conductivity	Moderate	Low	Low	Moderate
Thermal Expansion	Low	High	Moderate	Moderate
Common Applications	Aerospace, oil and gas	Industrial equipment	Chemical processing	Aerospace

Key Takeaways

• Inconel offers the best high temperature performance but at very high cost
• Stainless steel is cheaper but has much lower temperature limits
• Hastelloy and Haynes alloys rival inconel but have higher material costs
• Consider actual operating conditions, cost constraints before choosing

Carefully evaluate application needs before paying the price premium for inconel over other alternatives.

Table 5: Comparison of key properties between inconel and alternative alloys

FAQ

Q: What is inconel powder used for?

A: Inconel powder is used to manufacture high performance components for extreme environments in aerospace, oil and gas, chemical processing and power generation requiring good mechanical strength and corrosion resistance at high temperatures above 1000°C.

Q: What is the difference between inconel 600, 625 and 718?

A: The main differences are – Inconel 600 offers the best high temperature corrosion resistance but lower strength, while Inconel 718 provides the highest strength but lower oxidation and chemical resistance compared to Inconel 625 which provides the best balanced properties.

Q: Does inconel contain nickel?

A: Yes, inconel is a nickel-chromium-iron based superalloy. Most inconel grades have at least 50% nickel along with 14-23% chromium which gives inconel its excellent high temperature performance.

Q: What powder size is used in additive manufacturing?

A: Inconel powders ranging from 15 microns to 150 microns with spherical morphology are commonly used in laser powder bed fusion, direct energy deposition additive manufacturing processes used to produce metal components across industries.

Q: Is inconel hazardous?

A: Inconel powders are generally considered non-hazardous and safe for handling with standard protective equipment. However, the fine nickel and chromium components pose irritation issues and it is recommended to take precautions and prevent excessive skin contact or inhalation.

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