Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

Abstract

Carbon‐free aluminum electrolysis is crucial for achieving the low‐carbon development and carbon neutrality in the future aluminum industry. NiFe2O4‐based cermet is the potential candidate of inert anode, benefiting from the satisfactory corrosion resistance and high‐temperature conductivity. Herein, complex‐shaped 25(Cu–20Ni)/(NiFe2O4–10NiO) cermets were fabricated via a plastic shaping method using the polyformaldehyde (POM)‐based granular feedstock. The feedstock showed uniform microstructure with evenly dispersed powders wrapped in polymers, which exhibited shear‐thinning behavior during molding. Roles of the feedstock with different powder loadings in the morphology and bending strength of the cermets were investigated. High‐precision gear parts exhibited no deformation, a high relative density over 98%. Investigation of different powder loadings revealed that parts prepared with a 56 vol% loading demonstrate the excellent performance, and possessed an impressive flexural strength of 178.4 MPa. This achievement provided a foundation for the future utilization of complex‐shaped inert anode material components in industrial applications.