Cobalt Powder Properties and Safe Application Guide

When it comes to cobalt powder, we usually subdivide it into reduced cobalt powder, electrolytic cobalt powder and atomized cobalt powder. In my years of observation and practice, I found that due to its unique physical and chemical properties, cobalt powder has been widely penetrated into lithium-ion batteries, aerospace, 3D printing and cemented carbide and other high-tech fields, playing an indispensable role. In this blog post, I intend to talk in depth about the various types of cobalt powder and its core characteristics, analyze its key role in different applications, and share some experiences and suggestions on how to evaluate and select reliable suppliers, carry out quality control, and ensure safe operation and storage. After all, these are topics that cannot be avoided in our daily work.

1. Types and Key Characteristics of Cobalt Powder

The preparation methods of cobalt powder are various, and the common ones on the market are mainly reduced cobalt powder, electrolytic cobalt powder and atomized cobalt powder. From my experience, these powders have significant differences in purity, particle size, morphology and specific surface area, and these differences determine their performance in specific applications. Typically, cobalt powder is produced by chemical reduction, atomization, chemical vapor deposition or electrolysis of cobalt salts.

• Reduced Cobalt Powder: This powder is usually obtained by hydrogen reduction of cobalt oxide. It has a wide particle size distribution and relatively high activity, and is widely used in the field of cemented carbide and magnetic materials. Morphologically, it usually presents an irregular, or grape-like structure, which is determined by its technological characteristics.
• Electrolytic Cobalt Powder: As the name suggests, it is precipitated by electrolytic cobalt salt solution. To tell the truth, the purity of this kind of cobalt powder is quite high, and the morphology is mostly dendrite or flake. For those areas where purity requirements are extremely stringent, such as superhard materials and advanced alloys, electrolytic cobalt powder is often the first choice, and the effect is really not to be said.
• Atomized Cobalt Powder: This powder is formed by solidification of molten cobalt liquid under the action of inert gas or water atomization. Its particle size distribution is very uniform, the morphology is also more spherical or sub-spherical, liquidity is very good. Because of these characteristics, atomized cobalt powder is particularly prominent in the field of 3D printing (additive manufacturing) and powder metallurgy, which can be said to be very popular.

In my opinion, choosing which type of cobalt powder really requires us to consider the specific requirements of the specific application in terms of purity, particle size, morphology, density and fluidity. For example, battery cathode materials pay special attention to high-purity, specific morphology of cobalt powder, so as to optimize its electrochemical performance; and 3D printing, prefer those spherical and good liquidity of cobalt powder, because this directly affects the accuracy and efficiency of printing.

2. Applications of cobalt powder

1. Applications in lithium-ion batteries
In the context of the global energy transition, the demand for cobalt powder in the lithium-ion battery industry has continued to grow. Cobalt powder plays an important role as a key precursor in the manufacture of various lithium-ion battery cathode materials (such as lithium cobalt oxide (LCO), nickel cobalt manganese (NCM), and nickel cobalt aluminum (NCA)). It can significantly improve the energy density, cycle life and safety of the battery. According to my experience, when choosing, the purchaser must pay close attention to the purity, impurity content, particle size distribution and compatibility with nickel, manganese and other elements of cobalt powder, which is directly related to the final performance of the cathode material.

2. Fundamentals of Aerospace and High Temperature Alloys
Cobalt powder is an integral component of superalloys that are used to make high-performance aero-engine components, gas turbines, and other high-temperature structural parts. Its presence gives the alloy excellent high temperature strength, creep resistance and corrosion resistance. For example, cobalt can significantly improve the thermal fatigue and creep resistance of nickel-based superalloys, which is a lifeline for jet engine components that operate at extremely high temperatures. Therefore, when our engineers choose cobalt powder, they will definitely put its ultra-high purity, stable chemical composition and sintering performance in the powder metallurgy process in the first place. After all, the stringent requirements in the aerospace field are well known.

3. In 3D printing (additive manufacturing)
Having said that, with the rapid development of 3D printing technology in the field of metal component manufacturing, atomized cobalt powder, especially spherical powder, has become an excellent choice for laser powder bed melting (LPBF) and other processes due to its excellent fluidity, high bulk density and uniform particle size distribution. Through 3D printing, we can manufacture cobalt-based alloy parts with complex geometries and excellent mechanical properties, which are widely used in medical implants, custom tools and high-performance industrial components. According to the data I have at hand, additive manufacturing applications currently account for 33.54 percent of the cobalt alloy powder market and are leading the market with a compound annual growth rate (CAGR) of 6.34 percent, which is really not to be underestimated.

4. As a binder in cemented carbide
In cemented carbides, such as tungsten carbide-cobalt alloys, cobalt powder plays a crucial role as a binder. It can firmly combine hard tungsten carbide particles together, giving cemented carbide high hardness, high strength and excellent wear resistance. It can be said that its bonding effect is very important for the performance of cutting tools, molds and wear-resistant parts. Reduced cobalt powder, due to its good sintering activity and bonding properties, is widely used in this field and is a well-deserved “star material”.

3. Procurement of cobalt powder

How to Evaluate and Select Reliable Cobalt Powder Suppliers
In my opinion, it is really important to choose a reliable cobalt powder supplier. As a purchaser, I have a few suggestions that you must pay attention:

• Product Quality and Certification: Can the supplier provide a detailed certificate of analysis (COA) to ensure that the purity, particle size distribution, impurity content and other indicators of cobalt powder meet our requirements? In addition, there is no ISO, REACH and other relevant certification, which are hard indicators to measure its professionalism.
• Production Capacity and Technical Strength: Understand the supplier’s production scale, research and development capabilities, and whether they can provide customized services. After all, sometimes our needs are unique, aren’t they?
• Supply Chain Stability: To ensure that suppliers have a stable source of raw materials and a reliable logistics network, so as to calmly cope with market fluctuations and ensure the continuity of our production.
• Environmental and Social Responsibility: This is increasingly important. It is important for us to understand the environmental protection initiatives of our suppliers and their corporate social responsibility practices, especially the ethical issues related to cobalt mining, which are related to the company’s reputation and reflect the sense of responsibility of our industry.

4. Safe Handling of Cobalt Powder

Although cobalt powder is widely used in industrial applications, we must not ignore its potential health and environmental risks. My experience tells me that strict compliance with safe operating procedures is the most basic requirement to ensure personnel health and corporate compliance.

1. Safe Operating Procedures
Standard Operating Procedures (SOPs) must be established and strictly followed when handling cobalt powder.

• Ventilation: The operation must be carried out in a local exhaust or well-ventilated area, so as to effectively control the concentration of dust in the air, which is the most basic protection.
• Dust Control: the use of wet operation, vacuum and other measures to minimize the generation of dust. In particular, when handling combustible dust, be sure to use a non-sparking vacuum cleaner, this is the bottom line of safety.Standard Operating Procedures (SOPs) must be established and strictly followed when handling cobalt powder.

2. Storage, Transportation, and Emergency Response for Cobalt Powder

• Storage: Cobalt powder should be stored in a dry, cool, well-ventilated place, away from humidity and high temperature. Containers must be tightly sealed and clearly marked with hazard warning signs. In addition, to avoid contact with oxidants, alkalis and acids, these are common sense, but it is easy to be ignored.
• Transportation: When transporting, be sure to follow international and national dangerous goods transportation regulations, use appropriate packaging and labeling to ensure safety during transportation.
• Emergency response:
  • Spill: In the event of a leak, evacuate irrelevant personnel immediately and wear appropriate personal protective equipment (PPE). Cover and collect spills with non-combustible materials (e. g. sand, inert absorbent), taking special care to avoid dust flying. The collected waste must be treated as hazardous waste.
  • Fire: Cobalt powder itself is not easy to burn, but the dust cloud may cause an explosion under certain conditions. When extinguishing fire, you should use a dry powder fire extinguisher or inert gas (such as nitrogen, carbon dioxide) to extinguish the fire; remember, avoid direct water, which may cause dust diffusion and backfire.
  • First Aid: Contact a poison control center or doctor immediately if respiratory symptoms occur. In case of skin contact, rinse immediately with plenty of water. These are the things that are racing against time in an emergency.

Author: Li Ming, Ph.D

Li Ming, a seasoned materials engineer and industry expert with over 15 years of experience in advanced materials. Holding a Ph.D. in Materials Science and Engineering, I’ve dedicated my career to the research, development, and application of cobalt and cobalt powder materials in global research institutions and industrial enterprises. My expertise spans physicochemical properties, preparation technologies, and their impact on performance in high-tech sectors like Li-ion batteries, aerospace, cemented carbides, and additive manufacturing. Committed to providing rigorous, objective, and practical insights, I aim to empower professionals to navigate the complexities of cobalt powder, ensuring both maximum application value and operational safety.