Exothermic NiAl 95/5 bond coat powder, > 40 MPa bond strength. Clad and pre-alloyed forms for flame, plasma and arc spray. Universal first layer for coating systems.
QUICK ANSWER
NiAl 95/5 is a nickel-aluminum composite powder (95% nickel, 5% aluminum) used as the universal bond coat in thermal spray systems. Sprayed by flame, arc, or plasma, it undergoes an exothermic reaction during deposition that creates a self-bonding layer with bond strengths exceeding 40 MPa — the standard first layer under virtually every ceramic, carbide, or alloy topcoat, and a standalone oxidation-resistant coating in its own right.
Every spray shop in the world keeps NiAl 95/5 on the shelf because it solves the fundamental problem of thermal spray: getting the coating to stick. The nickel-aluminum exothermic reaction at the particle level produces localized metallurgical bonding even on grit-blasted steel, and the resulting layer is itself oxidation resistant to about 800 °C. It is sold in two forms — mechanically clad composite particles (nickel clad around aluminum cores) and pre-alloyed — with clad powder giving the stronger exothermic reaction for flame spraying.
MATERIAL DATA
Lot-level controls focus on the chemistry, particle characteristics, and process values that influence manufacturing consistency and finished-part performance.
| Element | Content | Performance Role |
|---|---|---|
| Nickel (Ni) | ~95 wt% | Oxidation-resistant matrix; carries the exothermic reaction and provides the tough bond layer |
| Aluminum (Al) | ~5 wt% | Reacts exothermically with nickel during spraying, generating self-bonding heat |
| Iron (Fe) | < 0.5 wt% | Impurity limit — excess iron degrades bond quality |
| Carbon (C) | < 0.1 wt% | Controlled low to keep the bond layer ductile |
| Others | < 0.5 wt% total | Purity control for consistent exothermic behavior |
Final limits can be aligned with the agreed purchase specification.
APPLICATIONS
As a bond coat, NiAl 95/5 is applied before almost every multi-layer thermal spray system: under alumina and zirconia ceramics, under carbide wear coatings, under stainless and bronze restoration layers. The workflow in any dimensional-restoration job — a worn shaft, a scored hydraulic rod, a corroded pump housing — starts with a NiAl bond layer after grit blasting, because it guarantees the expensive topcoat stays attached in service. Spray shops buy it by the pallet as a consumable tied directly to their job volume.
As a standalone coating, NiAl 95/5 serves where moderate oxidation resistance and a machinable, ductile layer are needed: exhaust system components, furnace fixtures, exhaust manifold protection, and as a salvage coating on mismachined aluminum and steel parts where its self-bonding nature lets it grip even marginal surface preparation. Arc-sprayed NiAl is also the standard bond coat under arc-sprayed zinc and aluminum anti-corrosion systems on steel infrastructure.
THERMAL SPRAY & HARDFACING POWDERS
CUSTOM SUPPLY
We supply both clad and pre-alloyed NiAl 95/5 in flame spray (45-106 µm), arc spray cored wire feedstock powder, and plasma (15-53 µm) cuts. Custom Ni/Al ratios (90/10 for higher exotherm, 80/20 for maximum oxidation resistance), and Mo-bearing variants (NiAlMo) for improved high-temperature bond strength are available. Standard 10 kg and 25 kg packaging with flow and chemistry certification. Not export-controlled.
We supply both clad and pre-alloyed NiAl 95/5 in flame spray (45-106 µm), arc spray cored wire feedstock powder, and plasma (15-53 µm) cuts.
Custom Ni/Al ratios (90/10 for higher exotherm, 80/20 for maximum oxidation resistance), and Mo-bearing variants (NiAlMo) for improved high-temperature bond strength are available.
Standard 10 kg and 25 kg packaging with flow and chemistry certification.
MATERIAL COMPARISON
| Comparison Point | This Product | Mo Bond Coat |
|---|---|---|
| Bond mechanism | Exothermic self-bonding — grips most metals | High melting point adhesion; excellent on steel |
| Oxidation resistance | Good to 800 °C | Poor — Mo oxidizes rapidly above 400 °C |
| Machinability | Good | Excellent |
| Cost | Moderate | Higher |
| Typical use | Universal bond coat, all processes | Plasma bond coats, bearing surfaces |
| Self-bonding to aluminum | Yes | Poor |
TECHNICAL FAQ
Need a different chemistry, particle range, or processing route? Our material team can review the requirement and supply window.
Almost always for ceramics and always on smooth or corrosion-contaminated substrates. The exceptions are soft metals like zinc and aluminum arc-sprayed onto well-blasted steel, which bond adequately without one.
For flame spraying, clad powder's strong exothermic reaction gives the best bond. For plasma and HVOF, pre-alloyed powder is preferred because clad particles can react prematurely in the hotter plasma plume.
50-150 µm is the standard window. Thinner risks incomplete coverage after blasting profile; thicker wastes money and can reduce system adhesion through residual stress.
Yes — its self-bonding exothermic reaction is one of the few options that bonds reliably to grit-blasted aluminum, making it the standard salvage and restoration coating for aluminum components.
No. Nickel-aluminum bond coat powders are unrestricted commercial products.
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