Nickel-Coated Aluminum Powder (Ni@Al)
Ni@Al powder is a self-bonding thermal-spray bond-coat material: the exothermic reaction between the nickel shell and aluminum core during spraying gives strong adhesion to steel substrates for restoration and ceramic top-coat work.
4-20 wt% Al (bal. Ni)Coating Content
-90+45 µmParticle Size Range
Custom Made-to-OrderGrade, Size & Quantity
WorldwideExport Shipping
Nickel-Coated Aluminum Powder — Grades & Specifications
Nickel-Coated Aluminum Powder (Ni@Al) powder is supplied across a range of grades, particle sizes and coating ratios. The options below are typical; specify your target values in the request form and we will confirm availability, lead time and pricing.
| Material | Nickel-Coated Aluminum Powder (Ni@Al) |
|---|---|
| Category | Metal-Coated Powder |
| Core material | Aluminum (CAS 7429-90-5) |
| Coating / shell material | Nickel (CAS 7440-02-0) |
| Coating content | Standard exothermic bond-coat grades run balance Ni with 4.0-5.5 wt% Al; higher-aluminum grades run balance Ni with approximately 20 wt% Al |
| Particle size | Clad grades typically -90+45 um (sieve); gas-atomized grades typically -45+11 um |
| Morphology | Spheroidal; produced by mechanical cladding, chemical cladding or gas atomization depending on grade |
| Appearance | Metallic gray free-flowing powder |
| Max. Service Temperature | Clad grades are rated up to approximately 800°C (1470°F) and undergo an exothermic Ni-Al reaction during spraying that gives strong self-bonding to steel substrates without a separate bond coat |
| Typical applications | Thermal Spray Bond Coats, Worn Part Salvage & Build-Up, Turbine Component Restoration, Combustion & Plasma Spray Undercoats |
Applications by Industry
Thermal Spray Bond CoatsApplied beneath ceramic or abradable topcoats to promote adhesion via exothermic self-bonding.
Worn Part Salvage & Build-UpRestores dimensions on damaged or undersized machine components before finish machining.
Turbine Component RestorationRebuilds worn gas turbine and industrial machinery surfaces.
Combustion & Plasma Spray UndercoatsApplied via flame or plasma spray as a base layer for subsequent coatings.
Oxidation-Resistant Intermediate LayersProvides an oxidation-resistant transition layer between steel substrates and ceramic coatings.
Self-Bonding Steel CoatingsUsed where direct, primer-free bonding to steel substrates is required.
Particle Size & Mesh Conversion
Reference for converting between US mesh and microns/millimetres. Figures are nominal sieve openings and may vary slightly by standard.
| Mesh (US) | Micron (µm) | mm | Inch | Remarks |
|---|---|---|---|---|
| 3 | 6730 | 6.730 | 0.2650 | |
| 4 | 4760 | 4.760 | 0.1870 | |
| 5 | 4000 | 4.000 | 0.1570 | |
| 6 | 3360 | 3.360 | 0.1320 | |
| 7 | 2830 | 2.830 | 0.1110 | |
| 8 | 2380 | 2.380 | 0.0937 | |
| 10 | 2000 | 2.000 | 0.0787 | |
| 12 | 1680 | 1.680 | 0.0661 | |
| 14 | 1410 | 1.410 | 0.0555 | |
| 16 | 1190 | 1.190 | 0.0469 | |
| 18 | 1000 | 1.000 | 0.0394 | |
| 20 | 841 | 0.841 | 0.0331 | |
| 25 | 707 | 0.707 | 0.0278 | |
| 30 | 595 | 0.595 | 0.0234 | |
| 35 | 500 | 0.500 | 0.0197 | |
| 40 | 420 | 0.420 | 0.0165 | |
| 45 | 354 | 0.354 | 0.0138 | |
| 50 | 297 | 0.297 | 0.0117 | |
| 60 | 250 | 0.250 | 0.0098 | |
| 70 | 210 | 0.210 | 0.0083 | |
| 80 | 177 | 0.177 | 0.0070 | |
| 100 | 149 | 0.149 | 0.0059 | |
| 120 | 125 | 0.125 | 0.0049 | |
| 140 | 105 | 0.105 | 0.0041 | |
| — | 100 | 0.100 | 0.0039 | Sand |
| 170 | 88 | 0.088 | 0.0035 | |
| 200 | 74 | 0.074 | 0.0029 | |
| — | 70 | 0.070 | 0.0027 | |
| 230 | 63 | 0.063 | 0.0024 | Human hair |
| — | 55 | 0.055 | 0.00217 | |
| 270 | 53 | 0.053 | 0.0021 | |
| — | 50 | 0.050 | 0.00197 | |
| 325 | 44 | 0.044 | 0.0017 | |
| — | 40 | 0.040 | 0.00157 | |
| 400 | 37 | 0.037 | 0.0015 | |
| 550 | 25 | 0.025 | 0.00099 | |
| 625 | 20 | 0.020 | 0.00079 | |
| 1200 | 12 | 0.012 | 0.0005 | |
| 1250 | 10 | 0.010 | 0.000394 | |
| — | 7 | 0.007 | 0.000276 | |
| 2500 | 5 | 0.005 | 0.000197 | |
| 4800 | 3 | 0.003 | 0.000118 | |
| 5000 | 2.5 | 0.0025 | 0.000099 | Bacteria (approx.) |
| 12000 | 1 | 0.001 | 0.0000394 |
Information Required for Quotation
- Grade or type
- Particle size (micron or mesh)
- Coating content / core-shell ratio
- Quantity
- Application environment
- Required delivery country
Lead time depends on grade, particle size, quantity and processing requirements. Export availability can be reviewed based on destination country and material type. A Certificate of Analysis can be provided on request.
Request a Quote or Custom Order
Tell us your grade, particle size and quantity. We typically reply within one business day.
Frequently Asked Questions
What is the coating content of Nickel-Coated Aluminum Powder?
Standard exothermic bond-coat grades run balance Ni with 4.0-5.5 wt% Al; higher-aluminum grades run balance Ni with approximately 20 wt% Al Other coating ratios can be reviewed on request depending on your application and quantity.
What particle sizes can you supply?
Clad grades typically -90+45 um (sieve); gas-atomized grades typically -45+11 um Mesh-based requirements are also accepted; a mesh-to-micron conversion reference is provided on the page.
Can Nickel-Coated Aluminum Powder be made to custom specifications?
Yes. Nickel-Coated Aluminum Powder is produced to order — core/shell ratio, particle size, morphology and packaging can be customized to your specification. Select “Custom Order” in the request form and provide your target values.
What is the minimum order quantity (MOQ)?
Order quantity is flexible and small quantities and prototype requests are welcome. Please state your required quantity in the form for an accurate quotation.
Can you export and ship Nickel-Coated Aluminum Powder internationally?
Yes, export inquiries are welcome. Availability and shipping are reviewed based on destination country, grade and quantity.
Do you provide a Certificate of Analysis (COA) or technical data?
A Certificate of Analysis and technical data can be provided on request for supplied lots.
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Request a Quote for Nickel-Coated Aluminum Powder
Send us your grade, particle size, quantity and application. We will review availability, quotation and lead time. Small quantities, prototypes and custom made-to-order specifications are welcome.