Effects of processing conditions and fine powder loading on real and electroactive surface areas of porous nickel manufactured by lost carbonate sintering

ABSTRACT The effects of five key processing parameters on the real and electroactive surface areas of porous nickel samples produced by the Lost Carbonate Sintering (LCS) process have been investigated systematically. The specific real and electroactive surface areas of the LCS porous Ni samples are 500–1600 cm−1 and 80–115 cm−1. Pore size, compacting pressure and sintering temperature have no significant effect on the surface areas. Porosity has no effect on the gravimetric real surface area, but a higher porosity leads to a lower volumetric real surface area and a higher electroactive surface area. Metal particle size has a huge effect on the surface areas of the LCS porous metal. An intermediate amount of fine Ni powder results in the highest real surface area, approximately 70% higher than the samples produced with coarse Ni powder. Samples produced with fine Ni powder can increase the electroactive surface area by up to 100%.