3D Printed Thermal Sprayed Spherical Stainless Steel Alloy Powder

This is a high-quality metal powder that serves as a versatile feedstock for multiple advanced manufacturing techniques.

This is the most critical feature.

Molten stainless steel is dispersed by a high-pressure inert gas (Argon, Nitrogen) to form fine, spherical droplets that solidify into powder.

• Excellent Flowability: Spherical particles roll over each other easily, which is essential for both automated powder spreading in 3D printers and consistent feeding in thermal spray guns.
• High Packing Density: Spheres pack together more efficiently than irregular shapes, leading to denser coatings in thermal spray and higher part density in 3D printing.
• Low Oxygen Content: The inert gas during atomization minimizes oxidation, which is vital for achieving good mechanical properties and corrosion resistance in the final part or coating.

• For 3D Printing (L-PBF): Fine powder, typically 15-45 µm.
• For Thermal Spray & 3D Printing (DED): Coarser powder, typically 45-106 µm or 53-150 µm. This size is ideal for being carried by the gas stream in thermal spray and DED systems.

• Laser Powder Bed Fusion (L-PBF): A thin layer of this fine spherical powder is spread across a build platform. A laser then selectively melts the powder according to the part's cross-section, building a solid, dense object layer by layer.
• Directed Energy Deposition (DED): The coarser spherical powder is blown through a nozzle into a focused laser beam, creating a melt pool on a substrate. This builds up material, either to create a new part or to add material to an existing component (e.g., for repair or feature addition).

• Process: The spherical powder is fed into a high-temperature, high-velocity stream (in Plasma Spray or HVOF). The particles are heated to a molten or semi-molten state and accelerated onto a prepared substrate surface.
• Result: Upon impact, the particles flatten, splatter, and rapidly solidify, forming a tightly bonded coating. The spherical morphology ensures consistent feeding and melting, leading to a uniform, low-porosity coating.

The same spherical powder grades are used in both fields:

• 316L: The most common, due to its excellent corrosion resistance.
• 304/L: For general purpose corrosion protection.
• 17-4PH: For applications requiring high strength and hardness after heat treatment.
• 420: For wear-resistant surfaces and tools.

The description "3D printed thermal sprayed spherical stainless steel alloy powder" is best understood as:

A single type of high-quality, gas-atomized, spherical stainless steel powder that is produced to a specification making it suitable as a feedstock for two different advanced manufacturing processes:

• 3D Printing (specifically L-PBF or DED) to create solid, complex parts.
• Thermal Spraying (specifically Plasma Spray or HVOF) to apply protective, wear-resistant, or corrosion-resistant coatings onto existing components.