What Makes FeCrAl Alloy Powder a Top Choice for High-Temperature Oxidation Resistance

FeCrAl alloy powder is widely used in high-temperature applications where oxidation resistance, electrical conductivity, and mechanical stability are essential. Its unique combination of iron (Fe), chromium (Cr), and aluminum (Al) enables it to form a protective alumina layer, making it ideal for heating elements, filters, and structural components in harsh environments.

Outstanding Oxidation and Corrosion Resistance

FeCrAl alloys form a stable Al₂O₃ oxide layer during service, which offers:

• Long-term protection in oxidizing environments up to 1300°C

• Excellent resistance to carburization and sulfur-containing atmospheres

• Minimal scaling and material degradation during repeated thermal cycling

This makes FeCrAl especially suitable for heating systems, furnaces, and gas filtration units.

Excellent Electrical and Thermal Properties

In addition to oxidation resistance, FeCrAl powder provides:

• High electrical resistivity and stable heating performance

• Low thermal expansion, reducing thermal stress

• Long lifespan in resistive heating components and additive manufacturing

Ideal for Additive Manufacturing and Thermal Spraying

FeCrAl alloy powder is atomized to ensure:

• High powder sphericity and low porosity

• Excellent flowability and uniform layer spreading

• Compatibility with laser powder bed fusion, binder jetting, and thermal spraying

Application Scenarios

• Industrial heating elements and resistance wires

• Heat exchangers and radiant tubes

• High-temperature filters in metallurgy and petrochemicals

• Coatings for oxidation-resistant surfaces

Key Benefits

• Stable alumina scale for long-term oxidation protection

• Reliable thermal and electrical performance

• Suitable for AM and surface coating processes

• Good workability and weldability after sintering

Frequently Asked Questions (FAQ)

Q1: What maximum service temperature can FeCrAl withstand?
A1: It can operate continuously at temperatures up to 1300°C in air.

Q2: Is the powder compatible with 3D printing processes?
A2: Yes. FeCrAl powder is compatible with various AM technologies including LPBF and thermal spray systems.

Q3: What is the standard particle size range?
A3: Standard D50 is 15–45 μm for AM; other mesh sizes are available for spraying or sintering.

Conclusion

FeCrAl alloy powder provides a unique combination of oxidation resistance, electrical performance, and thermal stability. Its adaptability across different processing methods makes it a reliable material for advanced manufacturing in harsh industrial conditions.

For customized particle sizes, technical specifications, or AM compatibility, contact HUAXIAO TECH today.