Alumina Spherical Powder

Alumina Spherical Powder is a high-purity ceramic material with excellent flowability, high packing density, and uniform particle shape. It offers good thermal conductivity, electrical insulation, and wear resistance. Common applications include thermal spray coatings, ceramic fillers for electronics, catalyst supports, and 3D printing feedstocks.NexusX Advanced Materials, as a premier manufacturer and supplier of high-quality. Alumina (Al2O3) products, focuses on producing high-precision aluminum nitride silicon structural compenents through advanced technologies for diverse application fields.

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Alumina Spherical Powder Data Sheet

Purity:	99.9%-99.99%
Morphology:	spherical
Series:	BAK Series, Top Cut Series, BAH Series and BAM Series

Alumina Spherical Powder Descriptions

Alumina Spherical Powder consists of high-purity aluminum oxide particles with a smooth, round morphology that ensures excellent flowability and high packing density. Its unique spherical shape reduces inter-particle friction, enabling uniform dispersion in coatings, composites, and 3D printing materials. The powder offers high thermal conductivity, strong electrical insulation, superior wear resistance, and chemical stability at elevated temperatures. It is widely used in thermal spray coatings, ceramic fillers for electronic packaging, catalyst carriers, and powder bed fusion additive manufacturing processes.

Specifications of BAK Series Alumina Spherical Powder

he BAK series is manufactured by calcining ordinary irregular Al2O3 using a high-temperature melting and spheroidizing injection method, followed by purification, sieving, and other processes. Due to its excellent thermal conductivity and flowability, the BAK series is widely used as a thermally conductive interface material, a thermally conductive engineering plastic, and a thermally conductive filler for aluminum-based copper-clad laminates.

Properties		Unit	BAK-1	BAK-2	BAK-5	BAK-10	BAK-15	BAK-20	BAK-30	BAK-40	BAK-70	BAK-90	BAK-120
Particle size	D10	μm	0.58	0.69	2.54	4.18	7.03	10.5	16.88	23.77	44.32	55.23	90.95
	D50	μm	1.03	2.18	5.52	10.03	15.11	20.8	30.52	41.54	71.54	87.96	122.39
	D90	μm	2.14	5.24	9.09	18.46	24.06	37.24	48.87	66.44	106.5	134.92	172.72
Specific surface area		m2/g	1.69	1.27	0.36	0.17	0.14	0.11	0.1	0.07	0.05	0.06	0.06
Electricity Conductivity		μS/cm	6.07	5.40	5.65	4.05	1.83	6.87	7.95	4.65	6.18	8.15	2.6
pH value		—	7.53	7.79	7.7	7.41	7.37	7.62	7.39	7.31	7.42	7.3	7.44
Humidity		%	0.05	0.03	0.03	0.03	0.03	0.03	0.03	0.03	0.05	0.03	0.03
Actual density		g/cm3	3.71	3.71	3.74	3.76	3.86	3.79	3.75	3.81	3.87	3.88	3.81
Spheroidization rate		%	96	98	98	98	96	96	98	96	96	95	96
Chemical composition	Al2O3	%	99.93	99.94	99.93	99.94	99.93	99.94	99.94	99.94	99.94	99.94	99.94
	SiO2	ppm	445	374	424	358	430	352	333	349	342	330	359
	Fe2O3	ppm	152	120	176	136	158	144	161	148	158	164	133
	Na2O	ppm	103	107	100	106	112	104	106	103	100	106	108

Specifications of the Top Cut Alumina Spherical Powder Series

The Top Cut series is an optimized version of the BAK series, characterized by high sphericity, a high filling rate, high thermal conductivity, and a narrow particle size distribution. It is widely used in applications such as epoxy molding compounds, thermal interface materials, thermally conductive engineering plastics, and thermally conductive substrates.

Product	Particle size (μm)				Specific surface area	Electricity Conductivity	PH	Humidity	Actual density	Spheroidization rate
Product	D10	D50	D90	D97	㎡ /g	μS/cm	–	%	g/cm³	%
BAK-5-25C	3.25	5.77	10.36	15.6	0.38	2.64	6.79	0.03	3.7	96
BAK-10-35C	4.52	9.32	18.11	22.1	0.22	5.81	7.33	0.02	3.82	96
BAK-15-45C	9.28	16.81	27.68	33.88	0.12	3.77	6.8	0.03	3.78	97
BAK-30-75C	16.16	31.78	52.47	60.87	0.09	3.77	7.05	0.03	3.8	96
BAK-40-75C	21.98	39.63	63.49	75.93	0.09	4.68	6.82	0.03	3.79	96
BAK-70-120C	51.54	73.37	98.43	111.7	0.06	5.31	6.97	0.02	3.79	95

Specifications of BAH Series Alumina Spherical Powder

The BAH series is a blended and modified product primarily used as thermal interface materials (e.g., thermally conductive silicone pads, thermally conductive greases, thermally conductive encapsulation compounds, thermally conductive tapes, phase-change materials, etc.) and thermally conductive engineering plastics (e.g., LED light covers, switch housings, electronic product enclosures, and heat dissipation components for electrical products). We can supply various types of modified products to meet the specific needs of each application.

Properties		Unit	BAH-2H4	BAH-5H4	BAH-10H4	BAH-20H4	BAH-40H4	BAH-70H4	BAH-90H4	BAH-120H4
Particle size	D10	μm	0.71	2.33	4.18	11.96	24.92	44.28	53.44	94.33
	D50	μm	2.15	5.59	10.03	21.56	42.49	71.45	88.27	122.18
	D90	μm	4.24	9.38	18.46	36.81	65.99	106.5	133.24	168.18
Specific surface area		m2/g	0.65	0.17	0.09	0.07	0.05	0.02	0.01	0.01
Electricity Conductivity		μS/cm	1.76	1.15	1.05	0.94	1.72	1.78	2.87	1.93
pH value		—	7.13	7.23	6.79	6.75	7.00	6.98	6.78	7.13
Humidity		%	0.04	0.04	0.04	0.04	0.03	0.04	0.04	0.04
Actual density		g/cm3	3.62	3.78	3.78	3.81	3.77	3.83	3.83	3.79
Spheroidization rate		%	96	96	96	96	96	96	95	95
Chemical composition	Al2O3	%	99.12	99.51	99.53	99.63	99.73	99.72	99.71	99.73
	SiO2	ppm	432	453	312	387	396	376	384	359
	Fe2O3	ppm	175	165	134	153	173	164	176	181
	Na2O	ppm	105	103	116	115	172	107	113	106

Specifications of BAM Series Alumina Spherical Powder

The BAM series is manufactured by blending the BAK series with particles of varying sizes to enhance thermal conduction efficiency. BAM offers superior filling capacity, a more optimized particle distribution, and effectively improves the heat transfer efficiency of thermal conduction channels.

Product	Particle size (μm)			Specific surface area	Electricity Conductivity	PH	Humidity	Actual density	Spheroidization rate	Al2O3	SiO2	Fe2O3	Na2O
Product	D10	D50	D90	㎡ /g	μS/cm	–	%	g/cm³	%	%	ppm	ppm	ppm
BAM-5M5	1.5	5.73	11.08	0.36	4.23	7.58	0.03	3.76	96	99.93	415	174	111
BAM-10M6	1,492	8.91	17.88	0.26	3.74	7.59	0.03	3.8	96	99.94	333	163	104

Alumina Spherical Powder Advantages

Excellent Flowability – Spherical shape minimizes inter-particle friction, ensuring smooth and consistent powder feeding in spraying and 3D printing processes.
High Packing Density – Uniform round particles pack more densely than irregular shapes, reducing voids and improving final product strength.
High Thermal Conductivity – Enables efficient heat dissipation, making it ideal for thermal management applications such as electronic packaging and thermal interface materials.
Good Electrical Insulation – Provides reliable dielectric properties for use in electronic and electrical components.
Superior Wear Resistance – Hard alumina particles offer excellent protection against abrasion and erosion in coatings and linings.
Chemical Inertness – Resistant to most acids, alkalis, and high-temperature oxidation, ensuring long-term stability in harsh environments.
Uniform Particle Size Distribution – Ensures consistent performance and predictable results in powder bed fusion, thermal spray, and composite manufacturing.
Reduced Equipment Wear – Smooth spherical surfaces cause less abrasion to nozzles, feeders, and other processing equipment compared to angular or irregular powders.

Alumina Spherical Powder Applications

Thermal Spray Coatings – Used in plasma and HVOF spraying to produce wear-resistant, corrosion-resistant, and thermal barrier coatings on metals and ceramics.
Electronic Packaging Fillers – Mixed with epoxy or silicone resins as thermally conductive but electrically insulating fillers for heat dissipation in power modules, LEDs, and IC substrates.
Additive Manufacturing (3D Printing) – Serves as a feedstock for powder bed fusion (e.g., SLS, binder jetting) to produce complex ceramic components with high density and smooth surfaces.
Catalyst Supports – Due to its high surface area and thermal stability, it is used as a carrier for catalysts in petrochemical and exhaust treatment systems.
Ceramic Injection Molding Feedstock – Combined with binders to mold precision ceramic parts such as insulators, nozzles, and medical devices.
Polishing and Lapping Abrasives – Spherical alumina provides uniform material removal for fine polishing of metals, glass, and semiconductor wafers.
Refractory and High-Temperature Linings – Used in castables and ramming mixes for kilns, furnaces, and incinerators requiring high thermal shock resistance.
Composite Reinforcements – Incorporated into polymers, metals, or ceramics to improve hardness, thermal conductivity, and dimensional stability.
Battery Separator Coatings – Applied as a thin ceramic coating on lithium-ion battery separators to enhance thermal shutdown resistance and mechanical strength.
Cosmetics and Personal Care – Used in foundations, powders, and sunscreens as an oil-absorbing, non-abrasive, and smooth-texture additive.

Alumina Spherical Powder Packaging

Alumina Spherical Powder is typically packaged in sealed, moisture-proof plastic bags, then placed in sturdy drum containers or fiber cartons to prevent contamination and ensure safe transport.

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FAQ

What is Alumina Spherical Powder used for?

Alumina Spherical Powder is primarily used as a thermally conductive filler in electronic packaging, a feedstock for thermal spray coatings, a raw material for ceramic 3D printing, a catalyst support, and a polishing abrasive.

What are the main advantages of Alumina Spherical Powder over irregular alumina powder?

Alumina Spherical Powder offers better flowability, higher packing density, lower equipment wear, and more uniform dispersion compared to irregular angular powders.

What particle sizes are available for Alumina Spherical Powder?

Alumina Spherical Powder is commonly available in size ranges from submicron (e.g., 0.5 µm) to hundreds of microns (e.g., 10–100 µm), with narrow or customized distributions for specific processes.

Does Alumina Spherical Powder cause wear on processing equipment?

Compared to angular powders, Alumina Spherical Powder significantly reduces wear on nozzles, feeders, and mixers due to its smooth surface and rounded shape, which minimizes abrasive friction.

Is Alumina Spherical Powder suitable for lithium‑ion battery separators?

Yes, Alumina Spherical Powder is commonly used as a ceramic coating on battery separators to improve thermal stability, mechanical strength, and electrolyte wettability while maintaining electrical insulation.

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