Nickel powder is a highly useful industrial metal that has numerous applications across many industries. The unique properties of nickel powder make it well suited for a variety of purposes.
Chemical and Physical Properties
Nickel powder has several notable chemical and physical characteristics that drive its widespread use. Chemically, nickel is a transition metal that is corrosion resistant. It has good conductive properties and is resistant to oxidation even at high temperatures.
Physically, Nickel Powder is a silvery-white metal that is ferromagnetic, though not as strongly as iron. Its melting point is relatively high at 1453°C. Nickel also has a high boiling point of 2651°C. These high temperature tolerances allow nickel powder to retain its strength and durability even under heat.
Nickel powders can be produced through various reduction and atomization processes to achieve different particle sizes ranging from nanometers to centimeters depending on the application. The powder characteristics like particle size distribution, density and shape can be controlled during manufacturing.
Battery Manufacturing
A major commercial use of nickel powder is in the production of rechargeable batteries like nickel-cadmium (NiCd) and nickel-metal hydride (NiMH) batteries. Nickel provides the positive electrode (cathode) in these battery types.
The rechargeable nature and high energy density of NiCd and NiMH batteries mean they see widespread use in consumer electronics, power tools, electric vehicles and more. Nickel's resistance to corrosion over many charge/discharge cycles is key to the longevity of these battery types.
Different nickel powder particle characteristics are required depending on the manufacturing process and desired battery specifications. For example, spherical nickel powders tend to facilitate the sintering processes used to make battery electrodes.
Aerospace Applications
Nickel alloys produced using nickel powder also see extensive use in the aerospace industry due to nickel's impressive strength and corrosion resistance properties even in extreme environments. Titanium-nickel alloys like Inconel are very successful aerospace materials.
Parts for jet engines like turbine discs, combustion chambers and valves regularly use nickel superalloys due to their ability to withstand high temperatures and stresses. Spacecraft often employ nickel alloys in applications like fuel tanks that must perform reliably for long periods.
Other Transportation
Other transportation applications beyond aerospace also leverage nickel powder attributes. Stainless steel typically contains 8-10% nickel content which boosts its corrosion resistance for automotive exhaust systems and other under-hood components.
Nickel plating provides decorative and protective coatings on equipment and vehicle parts. The electrical conductivity of nickel comes into play for things like motor brushes and electrical contacts.
Catalytic Converters
Perhaps the highest profile automotive use of nickel powder is catalytic converters. These emissions control devices harness the catalytic properties of palladium and platinum, which are dispersed onto a high surface area nickel powder substrate.
Oxidation and reduction reactions facilitated by the noble metal catalyst particles convert harmful pollutants like carbon monoxide, hydrocarbons and nitrogen oxides in engine exhaust into less toxic emissions like carbon dioxide and water vapor.
Industrial Processes
Beyond consumer and transportation applications, industrial manufacturing leverages several nickel powder characteristics. As a versatile catalyst, nickel is employed for processes like hydrocarbon refining and production of other chemicals.
As one example, nickel is integral to industrial hydrogenation - adding hydrogen to unsaturated organic compounds - which creates materials like oils and fats. Its resistance to corrosion also benefits equipment in harsh chemical plant environments.
Magnetic Applications
The magnetic properties of nickel undergo precise control and manipulation when used as soft magnetic materials in things like transformers, inductors and sensors. Nickel iron alloys exhibit much higher magnetic permeability than pure iron, improving device performance.
Printed circuit boards may employ conductive nickel pastes for interconnections. Other electromagnetic applications include microwave devices and the read/write heads in computer hard drives.
Regulations and Sustainability
Like many industrial materials, manufactured nickel powder is regulated to ensure safe production, transportation, use and disposal. Trade groups provide guidance on issues like minimizing workplace exposure and proper waste handling.
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