Nickel-based powders Characteristics, Preparation and Diverse Applications
Nickel-based alloy powders are advanced materials primarily composed of nickel or nickel alloy powders, fortified with alloying elements such as chromium (Cr), molybdenum (Mo), niobium (Nb), titanium (Ti), and sometimes reinforced with ceramic particles. These materials leverage nickel’s inherent properties—including excellent toughness, corrosion resistance, and high-temperature stability—to deliver high strength, hardness, superior oxidation resistance at elevated temperatures, thermal fatigue resistance, and creep resistance. These attributes enable stable performance under extreme conditions, such as high temperatures, complex stress fields, and harsh corrosive environments.
Widely utilized in critical components like aircraft engine turbine disks and blades, nickel-based powders also find applications in high-temperature furnace parts, catalytic converters, precision electronic components, and other sectors across energy, petrochemicals, and electronics. As a cornerstone material technology, they drive advancements in modern high-end manufacturing.
This category includes a variety of formulations, such as Ni-Cr heat-resistant alloys (e.g., 20% Cr addition). These alloys exhibit near-zero oxidation at high temperatures, making them ideal for heat-, corrosion-, and oxidation-resistant coatings. Their dense microstructure and strong adhesion to substrates serve as excellent transitional layers between ceramic/soft metal coatings and base metals, enhancing resistance to high-temperature gas erosion and improving interfacial bonding strength.
By incorporating iron into Ni-Cr alloys, this category sacrifices marginal high-temperature oxidation resistance compared to Ni-Cr systems but retains similar performance in other aspects. Its cost-effectiveness makes it suitable for repairing corrosion-resistant components and as a transitional coating material.
Enriched with boron (B), chromium, and carbon, these alloys combine high hardness with moderate toughness. The resulting coatings offer robust wear, corrosion, and heat resistance, making them ideal for anti-corrosion repairs of shafts, pistons, and similar components.
Ni-Al powders are primarily used as bond coats. Each particle consists of fine nickel and aluminum powders. During thermal spraying, the powder is heated above 600°C, triggering an exothermic reaction between nickel and aluminum to form intermetallic compounds. Simultaneously, aluminum oxidation releases additional heat, promoting nickel diffusion into the substrate and significantly enhancing coating adhesion. The rough surface of Ni-Al coatings provides an optimal foundation for subsequent coating layers. With thermal expansion coefficients closely matching those of most steels, Ni-Al serves as an ideal intermediate coating material.
