How does powder quality affect SLM-printed Inconel 625 part performance?

Particle Size and Flowability

Consistent powder flow is essential for uniform layer deposition. Inconel 625 powder with narrow particle size distribution improves layer packing density and reduces the risk of voids or incomplete fusion during the SLM 3D printing process. Poor flowability leads to rough surfaces and variable density, affecting fatigue life and pressure resistance.

Oxygen Content and Chemical Purity

Excess oxygen or contamination in the powder can cause oxide formation during melting, leading to brittleness and reduced ductility. NewayAero uses high-purity powders and controlled handling environments to avoid oxidation and ensure stable mechanical properties for demanding sectors such as aerospace and marine.

Powder Reuse and Degradation

Repeated powder recycling can lead to morphology changes, increasing surface roughness and altering melting behavior. Controlled reuse strategies and powder screening are applied to maintain consistency and prevent degradation in dimensional accuracy or material performance.

Impact on Post-Processing and Fatigue Life

Powder quality directly influences the effectiveness of HIP and heat treatment. High-quality powders result in more uniform microstructures and reliable precipitation hardening, supporting long-term durability in high-temperature systems such as power generation and oil & gas modules.