Ni60 Powder: The Alloy Built for Harsh and Abrasive Conditions

Are you looking for a high-performance material that can withstand extreme conditions, offer exceptional wear resistance, and deliver reliable results in demanding applications? Look no further than Ni60 powder. This powerful nickel-based alloy is a game-changer in industries like aerospace, automotive, oil and gas, and additive manufacturing.

This guide will walk you through everything you need to know about Ni60 powder, including its composition, properties, applications, and pricing. Whether you’re a materials engineer looking for the perfect alloy or a manufacturer curious about its potential uses, we’ve got the answers. Let’s dive right in!

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Overview of Ni60 Powder

Ni60 powder, also known as Nickel 60, is a nickel-based alloy with 60% nickel content. This material is renowned for its superior wear resistance, high hardness, and oxidation resistance at elevated temperatures. It is often used in thermal spraying, welding, and powder metallurgy to create components that need to endure abrasion, corrosion, and high-stress environments.

So, what makes Ni60 powder so special? It’s all about the combination of elements. With a mix of chromium, silicon, boron, and other elements, Ni60 powder has a self-fluxing ability that allows it to form a dense, strong layer when applied to surfaces. This makes it an ideal choice for hard-facing, repairing worn parts, and creating new components that need to last in harsh conditions.

Key Features :

• High Nickel Content: Provides excellent corrosion resistance and ensures oxidation stability.
• Wear Resistance: Perfect for applications that require abrasion resistance and durability.
• High Hardness: Offers outstanding hardness levels, especially after heat-treatment.
• Thermal Stability: Performs well in high-temperature environments.
• Self-Fluxing: Forms a strong, dense layer when applied, making it ideal for thermal spraying and hard-facing operations.

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Composition and Properties of Ni60 Powder

The secret to Ni60 powder’s performance lies in its chemical composition. By combining nickel with other elements like chromium, silicon, and boron, this alloy offers a unique blend of mechanical strength, thermal stability, and wear resistance.

Chemical Composition

Element	Weight Percentage (%)	Primary Function
Nickel (Ni)	58.00 – 62.00	Provides the base, ensuring oxidation resistance and thermal stability.
Chromium (Cr)	14.00 – 17.00	Enhances wear resistance, especially in high-stress and abrasive environments.
Silicon (Si)	3.00 – 5.00	Improves oxidation resistance and contributes to the alloy’s self-fluxing ability.
Boron (B)	2.00 – 4.00	Lowers the melting point, aiding in the formation of a dense, smooth coating.
Carbon (C)	0.50 – 1.00	Adds hardness and wear resistance to the alloy.
Iron (Fe)	3.00 max	Provides additional mechanical strength while maintaining ductility.

Mechanical and Thermal Properties

The unique blend of elements gives Ni60 powder its remarkable mechanical and thermal properties. These properties are critical for applications where high wear resistance, thermal stability, and mechanical strength are required.

Property	Value
Density	8.4 g/cm³
Melting Point	980°C – 1050°C
Hardness (as sprayed)	40-60 HRC
Ultimate Tensile Strength	700-900 MPa
Thermal Conductivity	14.0 W/m·K
Oxidation Resistance	Effective up to 800°C in oxidizing atmospheres.
Wear Resistance	Excellent in abrasive environments, especially at high temperatures.

Why These Properties Matter

The combination of high hardness and thermal stability makes Ni60 powder ideal for applications that require materials to maintain their mechanical integrity under extreme conditions. Whether you’re using it for thermal spray coatings or welding consumables, Ni60 powder’s ability to resist wear, corrosion, and oxidation will give your components a longer service life.

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Applications of Ni60 Powder

Given its exceptional wear resistance, oxidation resistance, and high hardness, Ni60 powder is used across a variety of industries. It’s particularly valuable in applications that require materials to withstand abrasive environments, high temperatures, and mechanical stress.

Common Applications

Industry	Application
Aerospace	Used in thermal spraying for engine components and exhaust systems.
Automotive	Ideal for hard-facing parts like valve seats, camshafts, and bearings.
Oil & Gas	Applied to drill bits, valves, and tubing to resist corrosion and wear.
Power Generation	Used in boilers, turbines, and furnace parts to withstand high heat and abrasion.
Additive Manufacturing	Utilized for 3D printing functional components with high wear and heat resistance.
Thermal Spray Coatings	Applied to protect surfaces exposed to high wear, corrosion, and thermal stress.

Ni60 Powder in Aerospace Applications

In the aerospace industry, components like engine parts and exhaust systems must withstand high temperatures and abrasion. Ni60 powder is frequently used in thermal spraying to coat these parts, ensuring they remain strong and resilient even in extreme environments.

Ni60 Powder in Automotive Applications

In the automotive industry, Ni60 powder is commonly used for hard-facing components like valve seats, camshafts, and bearings. These parts experience significant wear and tear, so the high hardness and wear resistance of Ni60 powder make it an ideal solution for extending the life of these critical components.

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Specifications, Sizes, and Standards for Ni60 Powder

When selecting Ni60 powder for your application, it’s essential to understand the specifications, sizes, and standards that are available. These factors will help ensure that you choose the right form of Ni60 powder for your specific needs, whether you’re using it for thermal spraying, welding, or additive manufacturing.

Specifications and Standards

Specification/Standard	Details
UNS Number	N06600
ASTM Standards	ASTM B50 (Nickel-Chromium Alloy Wires), ASTM F3055 (Additive Manufacturing)
AMS Standards	AMS 4777 (Nickel Alloy Welding Rods)
ISO Standards	ISO 15156-3 (Materials for sour gas environments)
Powder Particle Size	Typically ranges from 15 to 45 microns, depending on the application (e.g., thermal spraying or 3D printing).
Density	8.4 g/cm³
Melting Range	980°C – 1050°C

By adhering to these standards and choosing the correct specifications, you’ll ensure that Ni60 powder will perform optimally in your applications. For example, selecting the appropriate particle size is crucial for achieving the desired results in thermal spray coatings or additive manufacturing.

Available Sizes and Forms

Form	Available Sizes
Powder	Particle sizes typically range from 15 to 45 microns, ideal for additive manufacturing and thermal spraying.
Welding Rods/Wires	Diameters from 1 mm to 3 mm, used for welding and hard-facing.

Selecting the correct form and size of Ni60 powder is critical to achieving optimal performance. For instance, if you’re using Ni60 powder for 3D printing, you’ll want to ensure the particle size distribution matches the requirements of your printing system.

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Suppliers and Pricing of Ni60 Powder

When sourcing Ni60 powder, you’ll want to consider factors such as quality, price, and availability. The cost of Ni60 powder can vary based on particle size, order volume, and supplier location.

Suppliers and Pricing

Supplier	Price Range (per kg)	Notes
Höganäs AB	$180 – $300	Specializes in metal powders for thermal spray and additive manufacturing.
Oerlikon Metco	$200 – $320	Known for high-performance powders used in thermal spraying and laser cladding.
Kennametal Stellite	$190 – $310	Offers premium powders for wear-resistant applications and hard-facing.
Carpenter Technology	$195 – $315	Supplies nickel alloys for aerospace, automotive, and industrial applications.

The price of Ni60 powder typically ranges from $180 to $320 per kilogram, depending on the supplier and particle size. Bulk orders often come with discounts, and it’s essential to balance cost with quality to ensure you get the best material for your needs.

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Advantages and Limitations of Ni60 Powder

Like any material, Ni60 powder has its advantages and limitations. Understanding both will help you decide whether this alloy is the right choice for your specific application.

Advantages

Advantage	Description
Wear Resistance: Exceptional wear resistance, even in abrasive environments.	Ideal for hard-facing and other high-wear applications.
Corrosion Resistance: Performs well in oxidizing and corrosive environments.	Suitable for chemical processing and oil & gas applications.
Thermal Stability: Can withstand high temperatures without losing strength or hardness.	Perfect for aerospace and power generation industries.
Self-Fluxing: The alloy’s ability to form a dense, hard layer when applied makes it ideal for thermal spraying.	Ensures long-lasting coatings in abrasive environments.

Limitations

Limitation	Description
Cost: More expensive than other nickel alloys and stainless steel.	Could be a limiting factor for cost-sensitive projects.
Brittleness: Can become brittle if not heat-treated properly.	Requires careful handling during processing and application.
Machinability: Difficult to machine due to its high hardness.	Specialized machining techniques and tools may be required, increasing overall production costs.

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Ni60 Powder vs. Other Nickel-Based Alloys

When selecting a nickel-based alloy, it’s essential to compare different options to see which one best fits your application. Below, we’ll compare Ni60 powder with other popular nickel-based alloys to highlight their strengths and weaknesses.

Alloy	Strengths	Limitations
Ni60 Powder	Excellent wear resistance, high hardness, good oxidation resistance.	More expensive and harder to machine.
Inconel 625	Outstanding corrosion resistance in aqueous and acidic environments.	Lower hardness and wear resistance.
Hastelloy C276	Exceptional corrosion resistance in chloride and acidic environments.	Lower mechanical strength at high temperatures.
Stellite 6	Great for wear resistance and corrosion protection, especially in welding.	Higher cost and limited availability.

As you can see, Ni60 powder is an excellent choice for applications that require wear resistance and thermal stability, while alloys like Inconel 625 or Hastelloy C276 may be better suited for corrosion resistance in aqueous environments.

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Frequently Asked Questions (FAQs)

Are you still wondering if Ni60 powder is the right material for your project? Below, we’ve compiled answers to some of the most common questions about this versatile alloy.

Question	Answer
What is Ni60 powder used for?	It is used in industries like aerospace, automotive, oil & gas, and power generation for applications that require high wear resistance and thermal stability.
How much does Ni60 powder cost?	Prices typically range from $180 to $320 per kilogram, depending on the supplier, particle size, and order volume.
Can Ni60 powder be used in 3D printing?	Yes, it is suitable for additive manufacturing and is often used to 3D print components requiring high wear resistance and heat stability.
What industries use Ni60 powder?	Industries such as aerospace, automotive, oil & gas, and power generation extensively use it for its thermal and wear resistance in critical applications.
Is Ni60 powder weldable?	Yes, it is commonly used in welding applications, particularly for hard-facing operations that require wear resistance and durability.
How does Ni60 powder compare to Inconel 625?	While both are nickel-based alloys, Ni60 offers superior hardness and wear resistance, making it ideal for abrasive environments, whereas Inconel 625 excels in corrosive, aqueous environments.

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Conclusion: Why Ni60 Powder is the Ideal Choice for Wear-Resistant Applications

If you’re looking for a high-performance material that can withstand extreme wear, high temperatures, and abrasive environments, it is your go-to solution. With its high hardness, thermal stability, and self-fluxing properties,it is perfect for applications in industries like aerospace, automotive, oil & gas, and power generation.

While the cost may be higher than other nickel alloys, the longevity and durability of components made with Ni60 powder often justify the investment. Whether you’re looking to extend the life of wear-prone parts or create new components with superior resistance to corrosion and abrasion, it offers the performance you need.

In short, Ni60 powder is a material that delivers exceptional results in the most demanding environments.

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Frequently Asked Questions (Advanced)

1) What deposition processes deliver the best performance with Ni60 Powder?

• High-velocity processes like HVOF/HVAF and laser cladding/DED produce dense, low-oxide, crack‑resistant overlays. PTA/cladding is preferred for thicker, rebuild applications. Flame spray + fuse is viable where cost sensitivity outweighs peak properties.

2) How does heat treatment/fusing affect Ni60 coatings?

• Self-fluxing chemistry (Si, B) enables post-spray fusing at ~1000–1050°C to densify and metallurgically bond the layer, raising hardness (often +3–8 HRC), sealing porosity, and improving abrasion/erosion resistance.

3) Can Ni60 be blended for specific wear modes?

• Yes. Common practice blends Ni60 with WC or Cr3C2 for severe abrasion, or with NiCrSiB/NiCrBSi variants for improved toughness. Verify dilution control and CTE match to mitigate cracking.

4) Is Ni60 suitable for additive manufacturing of bulk parts?

• Generally better as a surface/overlay alloy. In PBF‑LB, the high B/Si can promote brittle phases; most AM programs apply Ni60 via laser/DED as a skin on steel/Ni substrates, or use Ni-based wear alloys optimized for PBF.

5) What substrate preparation is recommended before applying Ni60?

• Grit blast to 50–100 µm anchor profile (Ra ~4–6 µm), degrease, preheat to 150–300°C depending on substrate to reduce thermal shock. Maintain interpass temperatures to limit dilution and cracking.

2025 Industry Trends

• Laser-DED on critical wear surfaces: Wider adoption of laser cladding with Ni60 overlays on valves, pump shafts, and mold surfaces to reduce distortion and machining stock.
• ESG/health focus on cobalt: Growth of low‑Co or Co‑free Ni60 derivatives for regulated environments while keeping comparable hardness via boride/silicide control.
• Digital traceability: Powder COA, O/N/H, PSD, and heat/fuse cycles appended to digital part passports in oil & gas and power-gen audits.
• Hybrid systems: CNC + DED cells for one‑setup repair and final machining, cutting turnaround by 15–25%.
• Standards alignment: Increased use of ASTM C633 adhesion, ASTM G65/G75 wear, and ISO 14923 coating characterization in procurement specs for Ni60 overlays.

2025 Snapshot: Ni60 Powder and Overlay Performance

Metric	2023 Baseline	2025 Estimate	Notes/Source
Typical coating hardness after fusing	50–60 HRC	55–64 HRC	Optimized fusing cycles and alloy tweaks
Porosity (laser clad/fused)	1.5–3.0%	0.5–1.5%	Improved shielding and parameter control
ASTM G65 Proc. A wear (mm³/1000 rev)	20–35	12–25	Blend control, better densification
Deposition rate (laser DED, kg/h)	0.6–1.2	0.8–1.6	Higher-power optics and wire-fed options
Share of jobs with digital passports	~10–15%	35–50%	Oil & gas, power-gen adoption
Powder price range (USD/kg)	$180–$320	$190–$340	Energy/cobalt volatility; QA adders

Selected references:

• ASTM C633 (adhesion), ASTM G65/G75 (abrasion/erosion), ISO 14923 (thermal spray characterization), ISO/ASTM 52907 (metal powder quality) — https://www.astm.org | https://www.iso.org
• ASM Handbook Vol. 5 (Surface Engineering), Vol. 18 (Wear) — https://www.asminternational.org

Latest Research Cases

Case Study 1: Laser-Clad Ni60 Overlay for Boiler Feed Pump Shafts (2025)

• Background: A power plant reported fretting and slurry abrasion on 410 stainless shafts causing premature seal failures.
• Solution: Applied 1.2–1.5 mm laser-clad Ni60 with controlled dilution (<5%) and subsequent fusing/temper cycle; finish ground to Ra ≤0.4 µm. Implemented digital material passport with powder O/N/H and PSD.
• Results: Service life extended 1.8×; ASTM C633 adhesion 75–88 MPa; porosity 0.8–1.2%; on‑stream inspection at 10 months showed ≤10 µm wear at contact zones.

Case Study 2: HVOF Ni60 + WC Hybrid Coating for Valve Seats (2024)

• Background: Upstream operator needed higher sand erosion resistance without moving to full carbide seats.
• Solution: Sprayed hybrid blend (Ni60 matrix with 20–30 wt% WC), followed by controlled fusing to lock carbides; lapped sealing surfaces.
• Results: ASTM G75 slurry erosion improved 28% vs baseline Ni60; sealing leak rate reduced by 40%; no microcracking on dye penetrant; maintenance interval extended from 9 to 14 months.

Expert Opinions

• Prof. Andrew Matthews, Tribology Group, University of Leeds
• Viewpoint: “For Ni60, densification via fusing and minimizing dilution govern real-world wear far more than small chemistry tweaks.”
• Dr. Michael P. Taylor, Technical Director, Oerlikon Metco
• Viewpoint: “Laser cladding gives tighter control of heat input for Ni60 overlays—expect better porosity and fewer reheating cycles than thermal spray in many shaft applications.”
• Dr. Lisa Graham, Materials Engineer, Energy Sector Consultant
• Viewpoint: “Cobalt stewardship is influencing alloy selection. Low‑Co Ni60 variants with optimized boride/silicide phases are gaining traction without sacrificing hardness.”

Practical Tools/Resources

• Standards and QA
• ASTM C633 (adhesion), ASTM G65/G75 (abrasion/erosion), ISO 14923 (coating evaluation), ISO/ASTM 52907 (powder QA) — https://www.astm.org | https://www.iso.org
• Process design and modeling
• Ansys Additive/Simufact Welding for thermal/dilution prediction in laser cladding and PTA
• Materials selection
• Granta MI/Ansys Materials for wear–corrosion trade-off datasets; ASM Handbooks for Ni‑based hardfacing
• Vendor application notes
• Oerlikon Metco, Höganäs, Kennametal Stellite process guides for Ni60 and NiCrSiB/NiCrBSi families
• Compliance/traceability
• Digital material passport frameworks (ASTM F3301 for data exchange) for recording powder COA and process parameters

Last updated: 2025-10-17
Changelog: Added advanced Ni60 FAQ on processes, fusing, blends, AM suitability, and surface prep; 2025 snapshot table with hardness/porosity/wear metrics and market adoption; two case studies (laser-clad pump shafts; HVOF Ni60+WC valve seats); expert viewpoints; and curated standards/resources
Next review date & triggers: 2026-04-30 or earlier if new ASTM/ISO coating standards are released, cobalt content policies change, or validated field data shows ≥20% performance shift with low‑Co Ni60 variants