A microstructural investigation of gas atomized Raney type Al-27.5 at.% Ni catalyst precursor alloys

Quantitative image analysis has been used to investigate the phase composition of gas atomized powders of a Raney type Ni catalyst precursor alloys of composition Al-27.5 at.% Ni in the powder size range 150–212 μm. We find that there are considerable variations in phase composition both between powders from the same batch and as a function distance from the particle surface within individual particles. Such variations may have significant implications for the future production and uptake of such catalysts, including the necessity for post-production crushing of gas atomized powders. Models are proposed to account for both variations. - Highlights: • The phase composition of powder Raney-Ni catalysts has been investigated. • Image analysis is used to quantify differences between and within particles. • Phase composition can vary by up to 10% between the particle surface and centre. • Differences of up to 10% in the mean composition are also found between particles