Preparation of Metal Matrix Nanocomposite Powder Using Electroless Plating

Metal matrix nanocomposites (MMNCs) are anticipated to offer significantly better performance than existing superalloys for additive manufacturing (AM). However, traditional methods of preparing MMNC powder, such as high-energy ball milling, usually involve high cost and high energy consumption. This paper reports experimental results on a novel method to prepare MMNC feedstock powder. Nickel/alumina MMNC powder was successfully produced using electroless plating, containing a high fraction (66 vol. %) of alumina nanoparticles. Then, the MMNC powder was compacted into a disk shape with a hydraulic press and sintered with a tube furnace. After sintering at 1400 °C for 4 hours, the MMNC had a density of 4.16 g/cm³. Scanning electron microscopy observation, and X-ray diffractometry and energy-dispersive X-ray spectroscopy analysis were conducted on the sintered Ni/Al₂O₃ disk. As the alumina nanoparticles were added to nickel, an increased microhardness of HV_0.5 189 was obtained.