Cobalt-based alloy powder is a premium high-performance metal material composed of cobalt (Co) as the base, combined with chromium (Cr), molybdenum (Mo), iron (Fe), and other alloying elements. Renowned for its exceptional high strength, high hardness, wear resistance, high-temperature stability, and corrosion resistance, it has become a core material in industries requiring reliability under harsh conditions—including aerospace, automotive, electronics, and chemical engineering.

1. Core Properties of Cobalt-Based Alloy Powder

The unique performance of cobalt-based alloy powder stems from its chemical composition and microstructural characteristics:

• High-temperature strength: Maintains mechanical stability at temperatures above 1200°C, outperforming many metal materials.
• Wear & corrosion resistance: Chromium and molybdenum form a dense oxide layer, resisting abrasion and chemical erosion (e.g., acids, alkalis).
• Low thermal expansion coefficient: Minimizes deformation under temperature fluctuations, critical for precision components.
• Good plasticity & machinability: Easy to process into complex shapes while retaining performance.

2. Preparation Methods of Cobalt-Based Alloy Powder

Common manufacturing processes for cobalt-based alloy powder include:

2.1 Mechanical Alloying (Most Widely Used)

This method mixes pure metal powders (Co, Cr, Mo, etc.) and applies high-energy ball milling. Repeated rolling, collision, and cold welding under mechanical force form uniform alloy powder with:

• Consistent particle size (typically 10-50 μm).
• Homogeneous alloy composition, suitable for large-scale production.

2.2 Organic Chemical Reduction

Uses reducing agents (e.g., hydrazine) to reduce cobalt salts and other metal compounds in solution. Produces ultra-fine powder (1-5 μm) ideal for high-precision applications like electronic magnetic materials.

2.3 Plasma Spraying

Melts cobalt-based alloy ingots via high-temperature plasma, then atomizes into powder. Offers excellent flowability, making it suitable for coating processes.

3. Key Applications of Cobalt-Based Alloy Powder

Critical for manufacturing high-temperature engine components:

• Superalloy blades: Withstand 1300°C+ gas temperatures, improving engine thrust by 15-20%.
• Turbine discs & combustion chambers: Resist thermal fatigue, extending engine lifespan by 30%.

3.2 Automotive Industry

Enhances performance of high-load engine parts:

• Valves & piston rings: Reduce wear by 50% compared to steel components, lowering maintenance costs.
• Crankshafts: Improve impact resistance, suitable for high-performance vehicles (e.g., racing cars).

3.3 Electronics Industry

Core material for high-density magnetic components:

• Magnetic heads & hard disk platters: High magnetic permeability ensures fast data transmission and storage stability.

3.4 Chemical Industry

Manufactures corrosion-resistant equipment:

• Valves & pump bodies: Resist corrosive media (e.g., sulfuric acid, seawater) for 5-8 years of service life.

4.Weldability, Formability & Material Advantages

• Castings: Produce small precision parts (molds, blades, nozzles, sealing rings) via investment casting.
• Welding materials: Made into cast welding rods, tubular welding wires, and spray-welding powder—ideal for repairing parts under thermal/mechanical shock (e.g., turbine blades).
• Cost-saving coatings: For large parts/molds, coating with cobalt-based alloy powder reduces material costs by 40-60% compared to full alloy components.

4.2 Comparison with Nickel/Iron-Based Alloys

5. Processing & Coating Technologies

Cobalt-based alloy powder can be customized via:

• Pressing + sintering + heat treatment: Converts into plates, pipes, rods, rings, and other shapes for structural parts.

• Surface coating processes：

1. Plasma spraying: Coats substrates (steel, aluminum) to improve wear resistance.
2. Electrochemical deposition: Creates thin, uniform coatings for electronic components.