Ni/Al Composite
80/20 and 50/50 Ni-clad Al with certified clad integrity. Turbine abradable spray grades, lightweight EMI fillers, Raney precursors. Custom ratios.
QUICK ANSWER
Nickel-coated aluminum powder is a composite material with aluminum cores uniformly clad in nickel shells (typically 50/50 or 80/20 Ni/Al by weight), produced by chemical plating. It combines aluminum's light weight with nickel's surface chemistry — serving thermal spray abradable and bond coatings, conductive fillers, and exothermic reaction applications where a true nickel-aluminum intermetallic bond forms on spraying.
The composite structure is the engineering: each particle carries its own nickel-aluminum couple, so when the powder hits a substrate in plasma or flame spraying, the nickel and aluminum react exothermically particle-by-particle, forming NiAl intermetallic phases that bond coatings with exceptional strength. This made Ni-clad-Al the classic self-bonding spray powder for decades (an evolution of the NiAl 95/5 family in Category 3). In conductive applications, the nickel shell gives aluminum's low density a solderable, oxidation-resistant surface — the lightweight answer for conductive adhesives and EMI gaskets in aerospace electronics.
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 shell (Ni) | 20-80 wt% (grade) | Continuous clad layer — surface chemistry, bonding, oxidation resistance |
| Aluminum core (Al) | Balance | Lightweight core — density and exothermic reaction partner |
| Coating integrity | > 95% coverage | Shell continuity — the key quality parameter |
| Free nickel | < 2 wt% | Unbonded nickel limit for consistent behavior |
| Particle size | 45-150 µm (spray), 5-45 µm (conductive) | Application-matched cuts |
Final limits can be aligned with the agreed purchase specification.
APPLICATIONS
Thermal spray is the traditional market: nickel-clad aluminum powders spray into self-bonding coatings and — at the 80/20 ratio — into machinable abradable seal coatings for gas turbine compressor sections, where rotating blade tips cut their own clearance channels into the soft coating. Every aero engine and industrial turbine uses abradable seals; overhaul shops re-spray them at every shop visit. The spray grades sell on coating bond-strength certification and lot-to-lot clad consistency.
Conductive and specialty applications are the growth market: nickel-coated aluminum fills conductive adhesives, gaskets, and sealants for aerospace EMI shielding (weight-critical where nickel-coated graphite is too fragile); serves as the precursor for Raney-type nickel-aluminum catalyst alloys; and feeds exothermic brazing and reaction-bonding research. Each buys specific clad ratios and size cuts, with coating-integrity certification as the universal quality demand.
SPECIALTY & COMPOSITE POWDERS
CUSTOM SUPPLY
We supply nickel-coated aluminum in 80/20 and 50/50 ratios across spray (45-150 µm) and conductive (5-45 µm) cuts, with certified clad integrity and free-nickel content per lot. Custom ratios, polymer-compatible surface treatments for adhesive formulation, and abradable-grade spray qualification support are available. Not export-controlled.
We supply nickel-coated aluminum in 80/20 and 50/50 ratios across spray (45-150 µm) and conductive (5-45 µm) cuts, with certified clad integrity and free-nickel content per lot.
Custom ratios, polymer-compatible surface treatments for adhesive formulation, and abradable-grade spray qualification support are available.
MATERIAL COMPARISON
| Comparison Point | This Product | NiAl 95/5 |
|---|---|---|
| Structure | Composite clad — Ni shell, Al core | Pre-alloyed or Ni-clad composite |
| Exothermic strength | Strong — intact Ni/Al couple | Strong (clad) / weak (alloyed) |
| Abradable capability | Yes (80/20 ratio) | No — bond coat only |
| Coating machinability | Excellent | Good |
| Cost | Moderate | Moderate |
| Best use | Abradable seals, strong bond coats | Universal bond coats |
TECHNICAL FAQ
Need a different chemistry, particle range, or processing route? Our material team can review the requirement and supply window.
80Ni/20Al in the 45-150 µm spray cut is the classic abradable composition — soft enough for blade tips to cut cleanly, bonded strongly enough to stay on the casing. We supply with coating qualification data for the common plasma and flame spray systems.
By microscopic coverage analysis — unclad aluminum spots oxidize and break the exothermic chain in spraying, or corrode in conductive service. We certify above 95 percent coverage per lot.
Yes — the nickel shell is chemically compatible with silicone systems, and the aluminum core cuts gasket weight versus pure nickel fillers. Our conductive grades ship with dispersion guidance.
Raney nickel is made by leaching aluminum from Ni-Al alloy — our 50/50 clad powder serves as a precursor route for catalyst producers, with the clad structure giving controlled leaching kinetics.
No. Nickel-aluminum composite powders ship without licensing requirements.
RELATED PRODUCTS
Compare neighboring grades from the same material family, then review the complete category for additional chemistry and particle options.
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REQUEST THIS GRADE
Share your target chemistry, particle size, process, annual volume, and destination. Our powder specialists will confirm the closest production grade and documentation package.
