The Global Ni-Based MCrAlY Alloy Powder Market was valued at USD 485.7 Million in 2024 and is projected to reach USD 685.2 Million by 2030, growing at a Compound Annual Growth Rate (CAGR) of 5.9% during the forecast period (2024–2030). This robust growth is fueled by the surging demand for high-performance thermal barrier coatings (TBCs) in the aerospace and power generation sectors, coupled with continuous advancements in additive manufacturing and refurbishment of critical industrial components.

Ni-Based MCrAlY alloys, where M represents elements like cobalt (Co) and/or iron (Fe), are the bond coat of choice for TBC systems. They provide exceptional oxidation and hot-corrosion resistance, forming a protective alumina (Al₂O₃) scale that shields superalloy substrates in turbine engines and other high-temperature applications. As industries push the boundaries of efficiency and durability, the focus turns to the powder manufacturers who enable these technological leaps. This blog profiles the Top 10 Companies in the Ni-Based MCrAlY Alloy Powder Industry—specialty metal producers and advanced materials innovators shaping the future of high-temperature protection.

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🔟 1. Powder Alloy Corporation

Headquarters: Cincinnati, Ohio, USA
Key Offering: NiCoCrAlY, NiCrAlY, CoNiCrAlY Alloy Powders

Powder Alloy Corporation is a leading US-based manufacturer specializing in gas-atomized superalloy and MCrAlY powders. The company serves the thermal spray and additive manufacturing industries with high-purity, spherical powders tailored for demanding aerospace, industrial gas turbine, and automotive applications.

Innovation & Market Focus:

• Advanced gas atomization technology for superior powder flowability and density
• Custom alloy development for specific customer performance requirements
• Strong focus on quality control and traceability for critical aerospace components

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9️⃣ 2. Oerlikon Metco

Headquarters: Pfäffikon, Switzerland
Key Offering: Metco 4460 (NiCrAlY), Metco 4436 (NiCoCrAlY), Amperit® Powders

Oerlikon Metco is a global surface solutions leader and a dominant force in the thermal spray market. Its comprehensive portfolio includes a wide range of premium MCrAlY powders designed for both atmospheric plasma spraying (APS) and high-velocity oxygen fuel (HVOF) processes, supporting engine OEMs and MRO providers worldwide.

Innovation & Market Focus:

• Extensive R&D in coating durability and lifetime extension
• Global application and technical support network
• Development of optimized powders for next-generation, high-efficiency turbines

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8️⃣ 3. H.C. Starck (a part of Masan High-Tech Materials)

Headquarters: Munich, Germany
Key Offering: Amperit® and AMPERPRINT® Ni-Based and Co-Based MCrAlY powders

H.C. Starck, with its renowned Amperit® brand, is a key supplier of metal and ceramic powders for thermal spraying. Its MCrAlY powders are known for their consistent quality and performance, catering to the stringent demands of the aviation and energy sectors. The AMPERPRINT® line is specifically engineered for additive manufacturing.

Innovation & Market Focus:

• Pioneering spherical powder production for AM and cold spray
• Focus on supply chain sustainability and responsible sourcing of raw materials
• Tailored particle size distributions for specific coating processes

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7️⃣ 4. Sandvik

Headquarters: Sandviken, Sweden
Key Offering: Osprey® Ni-Based MCrAlY gas atomized powders

Sandvik’s Osprey brand is synonymous with high-quality metal powders produced via advanced gas atomization. Their Ni-Based MCrAlY powders are used in critical applications requiring superior high-temperature oxidation and corrosion resistance, particularly in the aerospace and power generation industries.

Innovation & Market Focus:

• Expertise in manufacturing highly spherical, satellite-free powders
• Integration of powder production with additive manufacturing solutions
• Strong commitment to digitalization and process control for consistent quality

Download FREE Sample Report:
Ni-Based MCrAlY Alloy Powder Market – View in Detailed Research Report

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6️⃣ 5. Praxair Surface Technologies (now part of Linde)

Headquarters: Indianapolis, Indiana, USA
Key Offering: NiCrAlY, NiCoCrAlY, and CoNiCrAlY alloy powders

Praxair Surface Technologies, now operating under Linde, has a long-standing reputation for providing advanced coating materials and services. Their MCrAlY powders are engineered for use in turbine blade and vane coatings, offering proven performance in extending component life under extreme thermal cycling conditions.

Innovation & Market Focus:

• Development of low-activity bond coats for longer-lasting TBC systems
• Extensive application expertise through its coating service centers
• Focus on powders that enable higher operating temperatures for improved engine efficiency

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5️⃣ 6. Metal Powder and Process Inc. (MPP)

Headquarters: Johnson City, Tennessee, USA
Key Offering: Custom Ni-Based MCrAlY and superalloy powders

MPP is a specialized manufacturer of fine metal and alloy powders using water and gas atomization processes. The company provides tailored MCrAlY powder solutions for thermal spray and hardfacing applications, serving a diverse clientele in aerospace, defense, and industrial sectors.

Innovation & Market Focus:

• Flexibility in producing small to medium batch sizes for R&D and specialized applications
• Strong capabilities in recycling and reprocessing of metal powders
• Commitment to agile manufacturing and customer-specific powder formulations

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4️⃣ 7. Höganäs AB

Headquarters: Höganäs, Sweden
Key Offering: Nickel-based alloy powders including MCrAlY variants

Höganäs is a world leader in metal powder solutions, primarily for the metallurgy industry, with expanding capabilities in advanced application areas. While its core is iron-based powders, its expertise in atomization allows it to produce high-quality nickel-alloy powders for demanding thermal spray and MIM (Metal Injection Molding) applications.

Innovation & Market Focus:

• Decades of experience in powder metallurgy and particle engineering
• Global production footprint ensuring reliable supply
• R&D focused on sustainable powder production methods

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3️⃣ 8. Parker Hannifin – Specialty Engineered Materials Group

Headquarters: Cleveland, Ohio, USA
Key Offering: High-purity nickel alloy and MCrAlY powders

Parker Hannifin’s Specialty Engineered Materials group provides advanced material solutions, including specialty metal powders. Their products are used in critical applications where material purity and performance are paramount, such as in the coating of components for aerospace and industrial turbines.

Innovation & Market Focus:

• Integration of materials science with component design and manufacturing
• Focus on high-purity powders with controlled oxygen and nitrogen content
• Supporting the entire value chain from raw material to finished coated part

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2️⃣ 9. Tekna Advanced Materials

Headquarters: Sherbrooke, Quebec, Canada
Key Offering: Spherical Ni-Based MCrAlY powders via plasma atomization

Tekna is a technology leader in the production of high-purity, spherical metal powders using its proprietary plasma atomization process. This method yields powders with excellent flow characteristics, ideal for both thermal spray coatings and additive manufacturing processes like laser powder bed fusion.

Innovation & Market Focus:

• Plasma atomization technology for superior powder sphericity and low porosity
• Strong focus on the additive manufacturing segment with certified powders
• Active R&D in recycling and reconditioning of used powders

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1️⃣ 10. Carpenter Technology

Headquarters: Philadelphia, Pennsylvania, USA
Key Offering: Custom-engineered Ni-Based superalloy and MCrAlY powders

Carpenter Technology is a recognized leader in the development, manufacture, and distribution of premium specialty alloys. Its powder products division offers high-performance MCrAlY powders, leveraging deep metallurgical expertise to serve the aerospace, defense, and energy markets with materials that withstand extreme environments.

Innovation & Market Focus:

• Extensive alloy development capabilities and metallurgical science
• Vertical integration from melting to finished powder product
• Strategic focus on next-generation materials for advanced propulsion systems

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Ni-Based MCrAlY Alloy Powder Market – View in Detailed Research Report

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🌍 Outlook: The Future of MCrAlY Powders Is Smarter and More Sustainable

The Ni-Based MCrAlY alloy powder market is experiencing a significant evolution. While traditional thermal spray applications continue to drive volume, the industry is increasingly influenced by digital manufacturing, material science breakthroughs, and sustainability imperatives.

📈 Key Trends Shaping the Market:

• Rising adoption of additive manufacturing for near-net-shape turbine components with integrated MCrAlY bond coats
• Development of novel MCrAlY compositions with improved phase stability and oxidation resistance for higher temperature operations
• Increasing demand for powder recycling and sustainable lifecycle management of coating materials
• Digitalization of the powder supply chain, including quality tracking via blockchain and AI-driven powder characterization

Get Full Report Here:
Ni-Based MCrAlY Alloy Powder Market – View in Detailed Research Report

The companies profiled above are not merely suppliers of metal powder—they are essential enablers of technological progress, providing the advanced materials that allow industries to operate at the limits of temperature and performance.