What is Nickel Powder and application?

In short, it is a fine gray metal powder made of pure nickel, and its notable features lie in its excellent electrical conductivity, outstanding corrosion resistance and unique magnetism. Based on my experience, the production processes of nickel powder that we usually see are no more than carbonyl decomposition, atomization or electrolysis. These methods can produce products with different particle size ranges from a few nanometers to hundreds of micrometers. Although from a chemical perspective, it is merely the embodiment of the element symbol “Ni”, its true commercial value and application potential lie in its unparalleled versatility: It is not only an indispensable conductive component in electronic pastes (especially MLCCS), but also a key active material in rechargeable batteries (such as lithium-ion batteries), and at the same time plays a fundamental role as a strengthening agent in powder metallurgy and 3D printed superalloys.

Nickel metal powder basics

When it comes to the fundamental properties of nickel metal powder, I often say that this thing is essentially the “cornerstone” of industrial materials. In my opinion, the unique combination of its physical and chemical properties is truly the key to the realization of many high-end applications.

Physical and chemical properties

From a physicochemical perspective, the core of nickel powder lies in its retention of the inherent properties of bulk nickel, but it “amplifies” these characteristics through an extremely large surface area, which is crucial in many reactions and interface behaviors. Its melting point is 1,455°C (2,651°F), and it exhibits ferromagnetism at room temperature. But in my personal opinion, the most highly regarded property of it in chemistry and physics is still its outstanding antioxidant and anti-corrosion capabilities. It can remain stable even in high-temperature environments, which is particularly valuable in demanding application scenarios. Of course, when we insiders talk about “powder”, we don’t mean anything at random. We usually refer to those particles that have been carefully classified by strict size distribution (Fisher subsieve number) and specific surface area, as these parameters directly determine the performance and applicability of the material.

The reasons for the wide application of nickel powder

As for why the global demand for nickel powder has been continuously soaring, to put it bluntly, I think it’s because it has played the role of an “enabler”. Its core value lies in its ability to enable other materials and systems to perform better. For instance, in the diamond tool industry, it can firmly “grasp” diamond particles. In the field of electronics, it enables current to pass smoothly through tiny ceramic layers. In chemical engineering, it can also act as a catalyst, accelerating the reaction process without being consumed itself. So, for those students who have just entered this field or analysts who want to gain a deeper understanding of industry trends, truly understanding nickel powder is actually understanding a key cornerstone in the high-tech supply chain. I often emphasize this point at conferences.

Nickel powder manufacturing process

When it comes to the production process of nickel powder, I have to be honest. The saying “You get what you pay for” is most appropriate here – not all nickel powders are the same. In my opinion, the manufacturing method directly determines the particle shape, purity and cost of the powder, and these three points are the most crucial considerations for any purchaser.

Carbonyl method (high purity, unique morphology)

In my personal opinion, this method is simply the “gold standard” in the field of high-tech applications. Specifically, it involves reacting crude nickel with carbon monoxide to form volatile carbonyl nickel gas, which is then separated through thermal decomposition. What is made in this way is what we often call nickel carbonyl powder. It is famous not only for its extremely high purity (usually reaching over 99.8%), but also for its unique “spiny” or “chain-like” (filamentous) structure. This structure, how to put it, is just like Velcro. The particles can interlock and entangle with each other very well, thus showing an unparalleled advantage in conductivity, especially when creating conductive paths, the effect is simply a perfect match.

Atomization method (large batch, spherical particles)

If your application requires a large amount of powder, especially for those heavy industrial components, I would generally recommend that you consider nickel powder produced by atomization. Simply put, it involves melting nickel and then spraying it with high-pressure water or gas. During the cooling process, the molten metal droplets solidify into rough or spherical particles. This type of powder has a higher density and better fluidity. Therefore, when pressed into shape in powder metallurgy or subjected to thermal spraying, the effect is very ideal. It can be said to be a “versatile” product.

Electrolysis and hydrometallurgy

Both of these methods prepare powder by precipitating nickel from the solution. The morphology of the obtained powder is usually dendritic (like ferns) or irregular. I find that they mainly serve those specific niche markets. For instance, in applications where both cost and specific surface area need to be taken into account, they are quite competitive and can be regarded as a relatively economical choice.

Applications of nickel powder

So, where exactly can nickel powder be used? I often say that its application scenarios are far broader than we imagine. Now I will list a few of the main ones.

Electronic products and MLCC

This is probably one of the most “precise” application scenarios of nickel powder. Nickel powder is the key material used to make the internal electrodes in multilayer ceramic capacitors (MLCCS) – the hundreds or even thousands of those tiny components in your smartphone. Here, our requirements for the powder are extremely high. Usually, ultra-fine particles at the sub-micron level are needed, and they must not agglomerate. Based on my experience, once the quality of the powder is substandard, circuit failure is almost an inevitable result. Therefore, in this field, the control requirements for nickel powder have reached the extreme.

Energy storage and batteries

With the deepening of the electric vehicle (EV) revolution, the importance of nickel powder in my opinion is beyond doubt. It is widely used in the cathode materials of nickel-metal hydride (NiMH) batteries and lithium-ion batteries. The high specific surface area of powder can significantly accelerate chemical reactions, which means that batteries charge faster and have a higher energy density. In addition, we now also observe that porous nickel powder is being used as the base material for fuel cells, and the market potential in this area is equally huge.

Powder Metallurgy (PM) and 3D printing

In the powder metallurgy industry, we mix nickel powder with iron powder or steel powder to prepare sintered parts, such as gears in automotive gearboxes, which often have higher toughness and durability. In the emerging field of metal additive manufacturing (also known as 3D printing), spherical nickel alloy powders are being used to print complex aerospace components that can withstand extreme high temperatures. The technological content and application prospects are both very exciting.

Selection and Safety

When purchasing nickel powder, my first piece of advice to you is: You must define your specifications very clearly. Never simply ask for “nickel powder” in a general way; that won’t work. You need to clarify its morphology: Is it filamentous (for electrical conductivity) or spherical (for bulk density)? At the same time, verify its apparent density: this can tell you how much volume the same weight of powder occupies. More importantly, it is essential to verify the purity: it should be known that trace elements such as sulfur or carbon are very likely to destroy a batch of precious high-temperature alloys.
Finally, regarding safety, I would like to particularly emphasize one point. Fine nickel powder, especially those with a particle size of less than 10 micrometers, can cause respiratory hazards and even pose a potential risk of cancer if inhaled for a long time. Moreover, when it exists in the form of dust clouds, it is also flammable. Therefore, it cannot be overemphasized that professional operations must be equipped with appropriate ventilation equipment, personal protective equipment (PPE), and strictly follow all the guidelines on the Material Safety Data Sheet (MSDS).

Author： Mike

Senior Materials Application Engineer

With over 11 years of field experience in powder metallurgy (PM) and additive manufacturing, I specialize in bridging the gap between material science and shop-floor reality. My work focuses on helping manufacturers select the right metal powders to optimize conductivity, density, and performance in automotive and electronic applications.