Nickel powder is a refined form of nickel that is produced by various processes to create fine particles of the metal that have a wide range of commercial and industrial uses. Some key qualities and uses of nickel powder are discussed below.
Production Methods
There are a few main industrial processes for producing Nickel Powder including chemical reduction, electrolysis and thermal decomposition. Chemical reduction involves reacting nickel salts with reducing agents like hydrogen or carbon monoxide to separate out pure nickel. Electrolysis uses an electric current to plate nickel out of its salts in aqueous solution. Thermal decomposition heats nickel compounds to extremely high temperatures to break them down into nickel and other byproducts. The powder is then further processed through sieving or atomization to refine the particle size for specific applications.
Physical and Chemical Properties
Nickel powder has a silvery-white color similar to bulk nickel metal. However, as a powder the material has much higher surface area which impacts some of its properties. It is moderately hard with a Mohs rating of 4. Some key attributes include high strength and ductility even at small sizes. It also retains excellent corrosion resistance. Chemically, nickel powder is non-toxic and resistant to oxidation and acids. Its melting point is approximately 1453°C or 2641°F.
Applications in Batteries and Fuel Cells
Due to its stability, nickel powders play a major role in battery technologies where they are used to produce electrodes, especially for rechargeable batteries like nickel-cadmium and nickel–metal hydride batteries. Finely divided nickel powder acts as an electroactive material that participates in charge transfer during the battery's discharge-charge cycles. Nickel powder is also used in fuel cells where it serves as a catalyst particularly for oxidizing hydrogen fuel in proton-exchange membrane fuel cells.
Uses in Electronics Manufacturing
The manufacturing of various electronic components relies heavily on nickel powder. It is commonly used as a conductive filler or binder material in silver pastes for die attachment and bonding of semiconductor chips. This helps provide electrically conductive joints. Nickel powders are also widely utilized in the production of contacts and connectors found in electrical devices. The material acts as a corrosion resistant coating or underlayer in multi-layer circuit boards.
Powder Metallurgy Applications
Powder metallurgy (PM) is a fabrication technique that involves compacting and forming metal powders into near-net shapes. Nickel powders are well suited for PM owing to their ability to sinter and bond together at high temperatures. Common PM applications of nickel powders include producing porous electrodes, filters, precision parts for jet engines, medical implants and more. The finely divided powders allow for complex internal structures and geometries to be shaped economically.
Magnetic and Catalytic Uses
Pure nickel powders display some magnetic properties that are useful in various technological applications. They are employed as electromagnetic shielding materials and in the manufacture of devices like ignition coils. Additionally, nickel powders serve as effective catalysts due to their large surface areas. In the petroleum industry, nickel catalysts promote cracking reactions to produce gasoline and other hydrocarbon fuels from crude oil.
Environmental and Safety Standards
As with all industrial materials, nickel powders necessitate responsible handling procedures and safety compliance standards. They must be stored in properly sealed containers to prevent dust release. Nickel does not pose the inhalation risks of other powdered metals but European Union regulations have classified it as a potential respiratory sensitizer if inhaled. In industrial use, facilities must have adequate ventilation and personal protective equipment for workers. Due to its toxicity, effluent water containing nickel must be treated before discharge.
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