Nickel powder is a commercially pure metallic powder composed primarily of nickel. Chemically, nickel is a transition metal that has a melting point of 1453°C and a density of approximately 8.9 g/cm3. In powder form, the particle size can range from sub-micron to several hundred microns depending on the production method and intended application. The purity of nickel powder also varies - it is commercially available at grades from 98% to over 99.9% nickel composition. Trace elements present may include iron, copper, chromium, and carbon among others depending on the purification process.
Nickel Powder maintains its metallic structure and conductive properties even at the fine powder scale. It oxidizes readily when exposed to air, forming a thin passivating nickel oxide layer on the particle surfaces. This passive film gives nickel powder its corrosion resistance properties. The metallic bonding structure also contributes to nickel's attributes like hardness, strength and magnetic properties as a powder. Overall, the composition and physical structure of nickel powder closely mimic that of bulk nickel metal.
Production Methods for Nickel Powder
There are a few key industrial processes used for commercially producing nickel powder:
Atomization: One of the most common methods, atomization involves melting bulk nickel and spraying it through nozzles to form finely divided droplets that solidify into powder particles during cooling. Gas atomization uses an inert gas stream while water atomization uses a water jet or stream. Particle size ranges from 10-100 microns.
Electrochemical deposition: In this process, an aqueous solution of nickel salts is subjected to an electric current. Nickel ions are reduced at the cathode to form a porous nickel deposit which can later be separated into a powder. Particle size is typically below 10 microns.
Carbonyl process: Nickel carbonyl gas, Ni(CO)4, is decomposed either thermally or chemically to produce highly divided nickel powder. It allows for production of sub-micron powders with controlled morphology. However, nickel carbonyl is highly toxic requiring specialized production and handling.
Mechanical milling: Bulk nickel can be processed using ball mills or other mechanical means to refine the particle size down to the sub-micron range. However, contamination risks are higher with this technique.
Regardless of the specific production method used, nickel powders are classified based on their average particle size which dictates their properties and applications. Production is also tailored to achieve desired characteristics like particle morphology, purity, and distribution.
Applications of Nickel Powder
The unique composition and properties of nickel powder make it suited for a variety of applications:
Catalysts: Due to its high chemical reactivity and surface area, nickel powder finds wide use as a catalyst or catalyst support material in petroleum refining, chemical synthesis and other industrial processes. Finely divided powder maximizes catalytic activity.
Battery industry: As an active material in rechargeable nickel-metal hydride batteries, nickel powder provides high energy density. It is also used as a plating material in alkaline batteries.
Powder metallurgy: Nickel powder can be consolidated and sintered to form fully dense nickel-based alloys and composites for applications demanding high strength, conductivity and corrosion resistance. Common examples include industrial pumps, valves etc. Finer powders allow for net-shape manufacturing.
Electronic components: Due to its magnetic characteristics, nickel powder finds use in applications like magnetic recording media, transformers. It is also alloyed with other metals in connectors, switches due to conductivity and oxide film properties.
3D printing: Nickel powder is increasingly being used as a feedstock material for binder jetting and other powder-bed 3D printing processes to manufacture functional metal parts with complex geometries.
Coatings: Electroplated or thermal sprayed coatings of nickel powder provide wear and corrosion protection on surfaces. The coatings impart hardness, lubricity and aesthetic properties.
While having many similarities to other metal powders, nickel powder holds unique competitive advantages due to the balanced combination of properties intrinsic to nickel as an elemental metal. Its versatility has led to myriad applications across industries from energy to electronics to manufacturing. Further developments in nanoscale powders are also expanding nickel powder's potential.
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