Production of Nickel Flakes
Nickel Flakes is produced through several metallurgical processes that start with nickel containing ores. The primary nickel-bearing ores are sulfides, such as pentlandite and pyrrhotite, laterites and oxides. These ores undergo various purification steps to extract pure nickel. The purified nickel is further processed to produce Nickel Flakes.
The common production routes involve pyrometallurgical or hydrometallurgical processes. In the pyrometallurgical Nickel Powder, the nickel-containing ores are subjected to high-temperature treatments like smelting or roasting to separate nickel metal. The nickel metal is further refined using electrorefining or Mond process. This purified nickel is commonly used to manufacture alloys. However, to produce Nickel Flakes, water or gas atomization techniques are applied on the molten nickel to produce fine particles.
In hydrometallurgical production, ore leaching using acids solubilizes nickel ions which are purified by solvent extraction. The purified nickel solution is precipitated as nickel salts like nickel sulfate or carbonate. These salts undergo thermal decomposition at high temperatures under inert gas environment to produce pure Nickel Flakes. The atomization technique may also be used at this stage to produce finer Nickel Flakes. Overall, the production method adopted depends on the ore type and the required properties of Nickel Flakes.
Properties of Nickel Powder
Nickel Flakes has different physical, mechanical and chemical properties based on its production process and particle size. Some of the key properties include:
- Particle size: Commonly ranges between 1-100 microns. Finer powders below 10 microns are also produced.
- Purity: Production process determines purity which is generally above 98%. Impurities include carbon, sulfur, iron etc.
- Structure: Depending on production route, the powder can be spherical, irregular or dendritic in shape.
- Density: Nickel has a density of around 8.9 g/cm3. Powder densities vary with particle packing.
- Color: Nickel Flakes has a silvery-white color resembling pure nickel.
- Melting point: Above 1450°C
- Mechanical properties: High strength, ductility, corrosion and heat resistance. However, properties reduce with decrease in particle size.
- Chemical properties: Resistant to corrosion and oxidation up to 250°C in air. Can be catalyzed for hydrogenation reactions.
Applications of Nickel Powder
Due to its unique properties, Nickel Flakes finds applications in many industries as discussed below:
Magnetic Materials
Nickel Flakes is frequently used to develop magnetically soft and hard materials. When alloyed with iron, it produces magnets with high saturation magnetization. Such alloys find extensive use in electronic components, transformers etc.
3D Printing
Finer Nickel Flakess below 20 microns are increasingly used as a feedstock in 3D printing of complex geometry parts using techniques like laser sintering and binder jetting. This enables cost-effective manufacturing of nickel alloy components.
Catalysis
The catalytic properties of nickel make it ideal for hydrogenation, reforming and shift conversion reactions. Nickel Flakes supported over carriers improves surface area and catalytic activity.
Batteries
Nickel Flakes is commonly used as an active material in nickel-metal hydride rechargeable batteries. It improves battery capacity and cyclic performance.
Ceramics
When mixed with ceramic slurries, Nickel Flakess develop conductive nickel coatings on ceramic substrates used in varistors, thermistors and multilayer ceramic capacitors.
Superalloys
Nickel-based superalloys containing refined Nickel Flakess have high strength even at elevated temperatures up to 1000°C. They find extensive applications in jet engines and gas turbines.
Electroplating
It is used as an anode material for electroplating of nickel and its alloys onto various metal components to provide corrosion resistance and decorative finishes.
Nickel Powder production involves different metallurgical routes that influence its properties. Its unique attributes expand applications across various domains like batteries, magnets, 3D printing and superalloys owing to the superior corrosion resistance, mechanical strength and thermal stability offered by nickel.
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Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)