Sandvik launches metal powder for demanding space applications

The material combines high thermal conductivity with high strength and the ability to retain its properties at elevated temperatures.

"Osprey GRCop-42 is developed for advanced space propulsion applications, designed to withstand the harsh environments found in regeneratively cooled rocket engine components," said Luke Harris, sales director business unit AM, Powder Solutions, Sandvik. "To achieve stable, repeatable powder production, this alloy places exceptionally high requirements on melting practice, impurity control and process discipline."

This alloy is intended for additive manufacturing of components such as fuel injector faces and combustion chamber linings, where efficient heat transfer, tight tolerances and predictable material behavior are critical throughout qualification and production.

GRCop‑42 is widely regarded as one of the most challenging copper alloys to manufacture to specification. In addition to narrow limits on individual alloying elements, the material requires extremely tight control of the chromium‑to‑niobium ratio and very low impurity levels to ensure high thermal conductivity in service. Significant differences in melting temperature between copper and niobium further increase the complexity of production.

Through extensive metallurgical development and adaptations of its Vacuum Inert Gas Atomisation (VIGA) process, Sandvik has established controlled and repeatable production of GRCop‑42. The powder is atomized under inert gas using a highly automated production flow that protects the material from oxidation throughout the entire process, resulting in a metallurgically clean powder with consistent batch‑to‑batch characteristics.

Osprey GRCop‑42 is already supporting customer qualification and production programs, where repeatable powder quality, predictable performance and complete documentation are essential. This experience provides valuable feedback into process control and supports reliable supply for ongoing and future space manufacturing applications.

"GRCop‑42 is a material where production control is just as important as alloy design," stated Szymon Kubal, director of Technology Business unit AM, Powder Solutions, Sandvik. "Customers in the space sector need powder that performs predictably during qualification, printing and in service. Our focus has been to make this demanding alloy available with the consistency, documentation and traceability required for space programs."

Osprey GRCop‑42 is produced within the company’s AS9100‑certified quality system and supported by full cradle‑to‑gate traceability. Every step - from raw materials and melting practice to atomisation parameters and testing powder batches - is documented, helping customers reduce qualification risk, audit friction and schedule uncertainty.

Now fully integrated into the Sandvik product portfolio, Osprey GRCop‑42 is available in volumes suitable for both qualification activities and ongoing production, supported by the company’s long‑standing expertise in gas‑atomised metal powders and the well‑established Osprey trademark, trusted for premium quality and batch‑to‑batch consistency.

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