Aluminum Alloy Powder Al-Si-Mg Family | Gas atomization is commonly used for high-flow additive-manufacturing powder. | 15–63 µm for laser powder bed fusion; coarser cuts may be supplied for other processes. | Mostly spherical with low satellite content when well classified. | Approximately 1.0–1.6 g/cm³, depending on alloy and measurement method. | Low density, good thermal conductivity, high specific strength, and good powder flow when spherical. Sensitive to oxidation and moisture. | 3D-printed housingsAutomotive partsAerospace componentsHeat exchangers | Check oxygen level, hydrogen content, size distribution, flowability, and compatibility with the selected print parameters. |
| Copper and Copper-Alloy Powder | Gas atomization is preferred for spherical AM powder; water atomization is also used for press-and-sinter grades. | 15–63 µm for AM; approximately 45–150 µm for many powder-metallurgy grades. | Gas-atomized: generally spherical. Water-atomized: more irregular and angular. | Approximately 2.5–4.5 g/cm³, depending on morphology and alloy. | Very high electrical and thermal conductivity. Copper reflects some common laser wavelengths, so process settings and energy input are important. | Electrical contactsInduction componentsThermal managementBrazingPowder metallurgy | Compare purity, oxygen content, tap density, conductivity, particle morphology, and process-specific absorptivity. |
| Stainless Steel 316L Powder | Gas atomization is widely used for additive manufacturing; water atomization is common for conventional powder metallurgy. | 15–63 µm for AM; approximately 45–150 µm for press-and-sinter applications. | Gas-atomized grades are predominantly spherical; water-atomized grades are irregular. | Approximately 2.8–4.5 g/cm³, depending on morphology and test method. | Good corrosion resistance, weldability, ductility, and broad processing compatibility. Low carbon content helps reduce sensitization risk. | Chemical equipmentMedical instrumentsFood-processing partsGeneral AM components | Verify chemical composition, oxygen and nitrogen levels, flow rate, Hall flow, apparent density, and lot-to-lot consistency. |
| Stainless Steel 17-4 PH Powder | Gas atomization is typical for laser and electron-beam additive manufacturing. | 15–63 µm for many AM systems. | Predominantly spherical with a controlled fine-particle fraction. | Approximately 2.8–4.5 g/cm³. | Precipitation-hardening stainless steel offering high strength after suitable solution and aging treatments. Corrosion resistance is generally lower than 316L in some environments. | ToolingValvesAerospace hardwareIndustrial components | Compare heat-treatment response, retained-austenite control, oxygen level, particle-size distribution, and post-build strength data. |
| Nickel-Based Superalloy Powder | Gas atomization under controlled atmosphere is normally selected to limit oxidation and inclusions. | 15–63 µm for laser powder bed fusion; 45–106 µm is common for some directed-energy processes. | Mostly spherical, with strict control of satellites, pores, and nonmetallic inclusions. | Approximately 3.0–5.0 g/cm³. | High-temperature strength, oxidation resistance, and creep resistance. Powder cleanliness and thermal history strongly affect build quality. | Turbine componentsCombustion hardwareOil and gas partsHigh-temperature tooling | Review trace elements, oxygen, nitrogen, inclusion content, internal porosity, flowability, and high-temperature mechanical data. |
Titanium Alloy Powder Ti-6Al-4V Family | Plasma or inert-gas atomization is commonly used for aerospace and medical AM grades. | 15–63 µm for laser powder bed fusion; 45–106 µm for some directed-energy processes. | Highly spherical powder with low oxygen pickup and controlled satellites. | Approximately 1.8–2.8 g/cm³. | High strength-to-weight ratio, excellent corrosion resistance, and strong biocompatibility potential. Highly reactive at elevated temperatures and requires controlled handling. | Aerospace structuresOrthopedic implantsMotorsport partsChemical equipment | Pay particular attention to oxygen, nitrogen, hydrogen, iron, morphology, flow rate, and storage under controlled conditions. |
| Cobalt-Chromium Alloy Powder | Gas atomization is commonly selected for dental, medical, and high-wear AM grades. | 15–63 µm for many laser powder bed fusion systems. | Predominantly spherical with controlled fine particles and low porosity. | Approximately 2.8–4.5 g/cm³. | High wear resistance, corrosion resistance, stiffness, and elevated-temperature capability. Requires suitable processing and post-treatment to manage residual stress. | Dental frameworksOrthopedic componentsWear-resistant partsHigh-temperature tooling | Compare chemical limits, powder cleanliness, flowability, internal porosity, biocompatibility documentation, and heat-treatment data. |
| Iron-Based Powder | Water atomization is common for press-and-sinter grades; gas atomization is used where higher sphericity is required. | Approximately 45–180 µm for conventional powder metallurgy; finer grades are available for specialized processes. | Water-atomized: irregular and porous. Gas-atomized: more spherical and free-flowing. | Approximately 2.5–4.2 g/cm³. | Cost-effective, widely available, and suitable for compaction. Irregular morphology improves green strength but can reduce flowability. | GearsBushingsStructural partsMagnetic componentsFriction materials | Compare oxygen content, compressibility, green strength, sintered density, dimensional change, and lubricant compatibility. |
| Tool Steel Powder | Gas atomization is generally used for powder-bed fusion and hot-isostatic-processing feedstock. | 15–63 µm for many AM systems; coarser distributions may be used for other consolidation routes. | Predominantly spherical, with controlled carbide-forming elements and low inclusion content. | Approximately 2.8–4.5 g/cm³. | High hardness, wear resistance, and dimensional stability after suitable heat treatment. Cracking sensitivity varies with composition and thermal history. | Molds and diesCutting toolsWear insertsRepair cladding | Evaluate crack sensitivity, carbon and alloy content, particle size, oxygen, heat-treatment response, and achievable hardness. |