NiCr 80/20 Powder: The Ultimate Guide for 2025

Overview

NiCr 80/20 powder is a nickel-chromium alloy consisting of 80% nickel and 20% chromium, widely recognized for its exceptional oxidation resistance, high-temperature stability, and superior corrosion resistance. This alloy is extensively used in thermal spray coatings, electrical heating elements, aerospace, and additive manufacturing (3D printing).

Key Properties

✔ Outstanding oxidation and corrosion resistance, even in extreme environments
✔ High-temperature stability, suitable for heating elements and aerospace applications
✔ Excellent electrical conductivity, making it ideal for electrical resistors and heating wires
✔ Superior adhesion and wear resistance, perfect for thermal spray coatings
✔ Optimized for additive manufacturing (AM), metal injection molding (MIM), and sintering

This guide will cover:

• Best NiCr 80/20 powder for 3D printing
• How to choose the right NiCr 80/20 powder
• Top suppliers of NiCr 80/20 powder
• Properties and industrial applications
• Production methods and cost analysis
• Comparing gas-atomized vs. water-atomized NiCr 80/20 powder

Best NiCr 80/20 Powder for 3D Printing in 2025

Why NiCr 80/20 Powder is Ideal for Additive Manufacturing?

• Exceptional high-temperature resistance, making it perfect for industrial heating elements
• Superior corrosion and oxidation resistance, ensuring long-lasting performance
• Excellent electrical conductivity, making it useful in electrical applications
• Good printability, reducing defects in metal 3D printing

Key Factors for Selecting NiCr 80/20 Powder for 3D Printing

• Spherical morphology ensures optimal powder flowability
• Controlled particle size distribution enhances printability and layer adhesion
• Low oxygen & impurity levels prevent oxidation defects
• Consistent mechanical performance post-processing

Comparison for Different 3D Printing Technologies

For high-performance 3D printing applications, Met3DP’s gas-atomized NiCr 80/20 powder is the preferred choice. Learn more about Met3DP’s high-quality metal powders.

How to Choose the Right NiCr 80/20 Powder

Choosing the right NiCr 80/20 powder depends on factors such as particle size distribution, atomization process, and specific application requirements.

1. Particle Size Distribution (PSD)

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

2. Powder Morphology

• Spherical Powder → Best for 3D printing and powder bed fusion technologies
• Irregular Powder → Suitable for Binder Jetting & Sintering

3. Atomization Process

• Gas-Atomized Powder → High purity, excellent flowability, best for 3D printing
• Water-Atomized Powder → Cost-effective, irregular shape, best for thermal spray coatings & MIM

Comparison of Different Types

For high-precision 3D printing, Met3DP’s gas-atomized NiCr 80/20 powder is the best choice. Contact Met3DP for more details.

Top Suppliers in 2025

Several manufacturers produce high-quality NiCr 80/20 powder, but not all powders meet 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 NiCr 80/20 product range.

Production Methods

The production method of NiCr 80/20 powder plays a crucial role in determining its particle shape, purity, flowability, and performance characteristics. Different atomization techniques are used depending on the application, whether for additive manufacturing (3D printing), thermal spray coatings, or metal injection molding (MIM).

Comparison of Production Methods

1. Gas Atomization (GA)

How It Works:

• Molten NiCr 80/20 is atomized using high-pressure argon or nitrogen gas, rapidly cooling the droplets into fine, spherical particles.

Advantages:
✔ High sphericity, improving powder flowability and layer uniformity
✔ Low oxygen content, preventing oxidation-related defects
✔ Excellent flowability, ensuring consistent deposition in 3D printing

Best for: Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), and Direct Energy Deposition (DED)

2. Water Atomization (WA)

How It Works:

• High-pressure water jets break molten NiCr 80/20, creating irregular-shaped powder particles.

Advantages:
✔ Lower production cost compared to gas-atomized powder
✔ Higher surface area, improving sintering properties

Disadvantages:
✖ Poor flowability, making it unsuitable for powder bed fusion processes
✖ Higher oxygen content, requiring additional post-processing

Best for: Metal Injection Molding (MIM), sintering, and thermal spray coatings

3. Plasma Rotating Electrode Process (PREP)

How It Works:

• A rotating NiCr 80/20 electrode is melted in a plasma environment, forming fine, highly spherical powders.

Advantages:
✔ Perfect spherical shape, ensuring superior flowability
✔ Ultra-high purity, making it ideal for high-performance AM applications
✔ Minimal satellite particles, leading to superior print quality

Disadvantages:
✖ Higher production costs
✖ Limited scalability for large-scale production

Best for: Aerospace, high-end 3D printing, and defense applications

For high-quality 3D printing, Met3DP’s gas-atomized NiCr 80/20 powder is the best choice. Explore Met3DP’s powder production solutions.

Cost Analysis in 2025

The price of NiCr 80/20 powder depends significantly on its production method, particle morphology, purity level, and application-specific requirements.

Factors Affecting Cost

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

Estimated Price Ranges

For cost-effective, high-quality NiCr 80/20 powder, Met3DP provides precision-engineered solutions tailored to industrial needs. Contact Met3DP for pricing and availability.

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

Choosing the right NiCr 80/20 powder depends on your application requirements.

Comparison of Different Atomization Methods

For additive manufacturing, gas-atomized NiCr 80/20 powder provides the best balance of quality and cost.

FAQ

Q1: What is the best NiCr 80/20 powder for 3D printing?

Gas-atomized spherical NiCr 80/20 powder is optimal for LPBF, EBM, and DED due to its excellent flowability and low oxygen content.

Q2: How does NiCr 80/20 compare to other nickel-chromium alloys?

NiCr 80/20 provides higher oxidation resistance and electrical conductivity compared to lower nickel-content alloys like NiCr 60/40.

Q3: Can NiCr 80/20 be used for metal injection molding (MIM)?

Yes, water-atomized NiCr 80/20 powder is commonly used in MIM and thermal spray applications.

Q4: Where can I buy high-quality NiCr 80/20 powder?

Met3DP is a leading supplier of gas-atomized NiCr 80/20 powder, optimized for 3D printing and high-performance applications. Contact Met3DP today! 🚀

Conclusion

NiCr 80/20 powder is an excellent high-performance alloy for thermal spray coatings, aerospace, heating elements, and additive manufacturing industries. Choosing the right powder type, production method, and supplier ensures optimal performance and reliability.

Why Choose Met3DP’s NiCr 80/20 Powder?

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

For high-performance NiCr 80/20 powder, Met3DP provides state-of-the-art solutions tailored to industrial demands.

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