Mn Loading Research Articles

Impact of Inverse Manganese Promotion on Silica-Supported Cobalt Catalysts for Long-Chain Hydrocarbons via Fischer–Tropsch Synthesis

One of the challenges in Fischer–Tropsch synthesis (FTS) is the high reduction temperatures, which cause sintering and the formation of silicates. These lead to pore blockages and the coverage of active metals, particularly in conventional catalyst promotion. To address the challenge, this article investigates the effects of the preparation method, specifically the inverse promotion of SiO2-supported Co catalysts with manganese (Mn), and their reduction in H2 for FTS. The catalysts were prepared using stepwise incipient wetness impregnation of a cobalt nitrate precursor into a promoted silica support. The properties of the catalysts were characterized using XRD, XPS, TPR, and BET techniques. The structure–performance relationship of the inversely promoted catalysts in FTS was studied using a fixed-bed reactor to obtain the best performing catalysts for heavy hydrocarbons (C5+). XRD and XPS results indicated that Co3O4 is the dominant cobalt phase in oxidized catalysts. It was found that with increase in Mn loading, the reduction temperature increased in the following sequence 10%Co/SiO2 < 10%Co/0.25%Mn-SiO2 < 10%Co/0.5%Mn-SiO2 < 10%Co/3.0%Mn-SiO2. The catalyst with the lowest Mn loading, 10%Co/0.25%Mn-SiO2, exhibited higher C5+ selectivity, which can be attributed to less MSI and higher reducibility. This catalyst showed the lowest CH4 selectivity possibly due to lower H2 uptake and higher CO chemisorption.

Chemical Imaging of Carbide Formation and Its Effect on Alcohol Selectivity in Fischer Tropsch Synthesis on Mn-Doped Co/TiO2 Pellets.

X-ray diffraction/scattering computed tomography (XRS-CT) was used to create two-dimensional images, with 20 μm resolution, of passivated Co/TiO2/Mn Fischer-Tropsch catalyst extrudates postreaction after 300 h on stream under industrially relevant conditions. This combination of scattering techniques provided insights into both the spatial variation of the different cobalt phases and the influence that increasing Mn loading has on this. It also demonstrated the presence of a wax coating throughout the extrudate and its capacity to preserve the Co/Mn species in their state in the reactor. Correlating these findings with catalytic performance highlights the crucial phases and active sites within Fischer-Tropsch catalysts required for understanding the tunability of the product distribution between saturated hydrocarbons or oxygenate and olefin products. In particular, a Mn loading of 3 wt % led to an optimum equilibrium between the amount of hexagonal close-packed Co and Co2C phases resulting in maximum oxygenate selectivity. XRS-CT revealed Co2C to be located on the extrudates' periphery, while metallic Co phases were more prevalent toward the center, possibly due to a lower [CO] ratio there. Reduction at 450 °C of a 10 wt % Mn sample resulted in MnTiO3 formation, which inhibited carbide formation and alcohol selectivity. It is suggested that small MnO particles promote Co carburization by decreasing the CO dissociation barrier, and the Co2C phase promotes CO nondissociative adsorption leading to increased oxygenate selectivity. This study highlights the influence of Mn on the catalyst structure and function and the importance of studying catalysts under industrially relevant reaction times.

50 years of mining-induced environmental changes: topography, hydrology, and vegetation health in Kazreti, Georgia

Globally, prioritizing short-term economic gains from mineral extraction has led to a critical dilemma: a planet rich in resources struggles with environmental degradation and a diminishing ability to sustain future generations. Open-pit mining exemplifies this paradox, causing significant environmental damage. In Georgia, this extractive industry presents environmental problems. Despite these known consequences, the long-term impacts of mining activities remain understudied. This study addressed this gap by analyzing the effects of open-pit mining on terrain morphology, and water dynamics in the Kazreti region over a 50-year period (1970–2020) and vegetation health over 35-year period (1987–2022). By integrating water quality assessment, spatial analysis and remote sensing, we revealed the significant human-induced changes to the region’s ecosystem. Spatial analysis results suggested that over 156.7 million cubic meters of bedrock have been fragmented by mining in southern East Georgia, with 125.5 million cubic meters deposited in valleys. Consequently, discernible shifts in the trajectories of water flow were observed based on the hydrological model. Additionally, a comparative analysis of NDVI and EVI values revealed a decline in vegetation health near mining zones, while remote forest areas remained stable. June typically showed healthier vegetation due to cooler temperatures and optimal growing conditions, while August presented lower vegetation health due to increased heat stress. Water quality revealed significant loadings of Cu (58–1855 μg l−1), Zn (54–2582 μg l−1), Mn (1–2167 μg l−1), and Cd (0.1–4.5 μg l−1), in local river systems, which are higher than the Georgian official guideline values (Cu - 1000, Zn - 1000, Mn—100, Cd—1 μg l−1). This study highlighted the need for a broader long-term monitoring strategy to assess the migration of these contaminants within the food web and the consequent socio-economic impact.

Photochargeable Mn-Based Metal-Organic Framework and Decoupled Photocatalysis.

Designing multifunctional materials that mimic the light-dark decoupling of natural photosynthesis is a key challenge in the field of energy conversion. Herein, we introduce MnBr-253, a precious metal-free metal-organic framework (MOF) built on Al nodes, bipyridine linkers and MnBr(CO)3(bipyridine) complexes. Upon irradiation, MnBr-253 colloids demonstrate an electron photocharging capacity of ~42 C ⋅ g-1 MOF, with state-of-the-art photocharging rate (1.28 C ⋅ s-1 ⋅ g-1 MOF) and incident photon-to-electron conversion efficiency of ~9.4 % at 450 nm. Spectroscopic and computational studies support effective electron accumulation at the Mn complex while high porosity and Mn loading account for the notable electron storage performance. The charged MnBr-253 powders were successfully applied for hydrogen evolution under dark conditions thus emulating the light-decoupled reactivity of photosynthesis.

Introducing attapulgite to prepare manganese-based monolithic catalyst for catalytic combustion of toluene

A series of attapulgite-loaded manganese oxides cordierite monolithic catalysts with different KMnO4/Mn(NO3)2 molar ratios (3:1, 1:1, and 1:3 for KMnO4/Mn(NO3)2, respectively) were prepared by a hydrothermal-ball mill impregnation method. According to the analysis of the characterization findings, the main active species of the catalyst was Mn4+ species. By incorporating acid-treated attapulgite (HATP) and adjusting the molar ratio of KMnO4/Mn(NO3)2, the content of Mn4+ and surface-adsorbed oxygen species on the catalyst surface increased, subsequently enhancing catalytic activity at low temperatures. Experimental results revealed that the Mn/HATP/cordierite catalyst with a KMnO4 to Mn(NO3)2 molar ratio of 3:1, Mn loading amount of 30 wt%, and active coating deposition of 250 g/L exhibited the highest catalytic activity, achieving a 90 % conversion of toluene at 298 °C (T90 = 298 °C, GHSV = 10000 h−1). These findings will provide valuable support for the design of highly efficient monolithic catalysts for toluene removal.

Mn loading on montmorillonite surfaces for Cd stabilization: Insights from density functional theory calculations and surface complexation modeling

The latest works have been devoted to the stabilization mensuration for heavy metals and indicate that clay minerals can promote Cd(II) precipitation by favoring the retention of Mn(II). The assessment however has been tempered due to lacking the information about the molecular-level surface complexation structure and Cd nucleation process on clay surfaces. In this study, microscopic mechanisms for adsorption and stabilization of Cd at montmorillonite interfaces with or without Mn loading were leveraged by combining surface complexation model (SCM) evaluations and density functional theory (DFT) calculations. Mn(II) substitution resulted in increases in surface acidity equilibrium constant (pKa) by about 1 unit and complexation constant (lgK(SOCd+)) of Cd(II) by about 0.15 units at clay surface, and Mn(II) adion can provide extra active sites (i.e., OH− groups) for complexing Cd(II) via hydrolysis. DFT calculations revealed Mn(II) and Cd(II) adions bind on base surfaces by isomorphic substitutions through weak long-range interactions, whereas on edge surfaces by surface complexation with strong but short-range connections. Adsorption energy calculations and electrostatic distribution showed heterogenous nucleation with subsequent cations on clay surfaces was thermodynamically favored, the stabilization process underwent the steps of the adsorption-hydrolysis-precipitation. The derived results provide a quantitative basis for understanding the precipitation and heterogenous nucleation of cations on clay surfaces in surficial environments.

Inhibition of Mn(II) oxidation performance in the presence of high residual Mn(II) concentrations

Bioreactors rich in Mn-oxidizing bacteria hold the potential for removing toxic Mn(II) and generating valuable bio-manganese oxides. Various environmental factors, such as pH, temperature, initial Mn(II) concentration, and dissolved oxygen, could affect microbial Mn(II) oxidation activity. However, limited information is available concerning the effect of residual Mn(II) concentrations on the optimization of bioreactor operations for efficient Mn(II) oxidation. This study aims to explore the influence of residual Mn(II) on the biological Mn(II) oxidation performance in the reactors, employing two identical reactors (R-1 and R-2) operating at varying Mn(II) loading rates. Interestingly, during Phase 2, despite both reactors receiving an equivalent Mn(II) loading rate, R-1 exhibited no residual Mn(II) and demonstrated a higher Mn(II) oxidation rate than R-2, which had a high residual Mn(II) concentration. The maximum Mn(II) oxidation rate in R-1 and R-2 was 0.91 and 0.61 kg m-3 d-1, respectively. The results unequivocally reveal that high concentrations of residual Mn(II) exert a substantial inhibitory effect on Mn(II) oxidation activity. This inhibition can be attributed to the diminished tolerance of specific Mn-oxidizing bacteria, such as Hyphomicrobium, to elevated Mn(II) levels. These findings underscore the critical importance of maintaining low residual Mn(II) concentrations within the reactors. This study carries practical implications for the effective operation of Mn(II) removal systems using bioreactors, highlighting the need to mitigate high residual Mn(II) concentrations for optimized performance.

2D-Mn2C12: An Optimal Electrocatalyst with Nonbonding Multiple Single Centers for CO2-to-CH4 Conversion.

The CO2 reduction reaction (CO2RR) is a promising method that can both mitigate the greenhouse effect and generate valuable chemicals. The 2D-M2C12 with high-density transition metal single atoms is a potential catalyst for various catalytic reactions. Using an effective strategy, we screened 1s-Mn2C12 as the most promising electrocatalyst for the CO2RR in the newly reported 2D-M2C12 family. A low applied potential of -0.17 V was reported for the CO2-to-CH4 conversion. The relative weak adsorption of H atom and H2O in the potential range of -0.2 to -0.8 V, ensures the preferential adsorption of CO2 and the following production of CH4. The different loading amounts of Mn atoms on γ-graphyne (GY) were also investigated. The Mn atoms prefer doping in the nonadjacent triangular pores instead of the adjacent ones due to the repulsive forces between d-orbitals when the Mn loading is less than 32.3 wt % (5Mn). As the Mn concentration further increases, adjacent Mn atoms begin to appear, and the Mn@GY becomes metallic or half-metallic. The presence of four adjacent Mn atoms increases the d-band center of Mn@GY, particularly the dz2 center involved in CO2 adsorption, thereby enhancing the adsorption capacity for CO2. These findings indicate that 1s-Mn2C12 with high Mn atomic loadings is an excellent CO2RR electrocatalyst, and it provides new insights for designing efficient CO2RR electrocatalyst.

Manganese-Catalyzed 5-Endo-trig Oxygenative Cyclization of α,β-Unsaturated Oximes under Air and Ambient Conditions for the Synthesis of 4,5-Dihydroisoxazoles.

The stereoselective 5-endo-trig oxygenative cyclization of α,β-unsaturated oximes was achieved using molecular oxygen (O2) and a manganese catalyst. Several 4-hydroxy-4,5-dihydroisoxazoles were obtained in high yields by directly incorporating O2 from the atmosphere (eliminating the necessity for a pure oxygen environment) and using an unprecedentedly low loading of Mn(acac)3 (as little as 0.020 mol %) without additional additives. Because of its desirable features, such as operational simplicity, inexpensive catalyst, mild reaction conditions (open flask conditions at room temperature), and broad substrate compatibility, this novel reaction provides an attractive synthetic approach to producing 4-hydroxy-4,5-dihydroisoxazoles.

Porous durian shell biochar modified by KMnO4 (Mn-DSB) as a highly selective adsorbent for Be(II).

The mining of uranium-beryllium ores has resulted in substantial beryllium (Be) contamination. In this study, agricultural waste durian shells were utilized as raw materials to prepare biochar, which was further modified to enhance its adsorption capacity (Mn-DSB). The results effectively demonstrated Mn loading onto the DSB surface. Batch experiments were conducted to identify the optimal adsorption conditions of Mn-DSB for beryllium. At a temperature of 35 °C and pH 6, beryllium's maximum adsorption capacity (Qe) was 42.08 mg·g-1. The materials' internal structure was analyzed before and after adsorption via multiple techniques. Mn-DSB manifested potent selectivity towards beryllium in multicomponent mixed solutions, binary systems, and uranium-beryllium wastewater, as the beryllium removal rate exceeded 90%. The study investigated the recyclability of Mn-DSB and found that after five reuse cycles, the adsorption and desorption efficiencies were 90% and 85%, respectively. The strong ligand complexation (N-H, CO32-, -OH) and ion exchange mechanisms (with Mn7+ ions) of Mn-DSB explained its high adsorption capacity. Therefore, this study demonstrates the potential of Mn-DSB for treating uranium-beryllium tailing wastewater.

Photothermal catalytic CO2 oxidative dehydrogenation of propane over Co-Mn bimetallic oxides supported on MCM-41 molecular sieve

Compared with conventional thermal catalysis reaction, the photothermal CO2-assisted oxidative dehydrogenation of propane (CO2-ODHP) to produce propylene and CO is an environmentally friendly and sustainable method that operates at lower temperatures. In the present work, we have developed a series of Co-Mn/MCM-41 catalysts and utilized them in the photothermal CO2-ODHP reaction. Among these catalysts, the sample with Co and Mn loadings of 3 % resulted in activities of 225.7 μmol gcat−1 h−1 of propylene and 272.0 μmol gcat−1 h−1 of CO at 250 °C. Characterization results revealed that the electron transfer and interplay between Co and Mn oxides enhance the photoelectronic response and reduce impedance, facilitating the electron transfer process. Besides, the Co and Mn bimetallic species could enhance photothermal conversion efficiency and further enhance the local temperature during the reaction. The present work introduces a novel strategy for building supported bimetallic oxides in achieving CO2-ODHP via the photothermal route and is also expected to provide an optional catalyst required satisfactions including efficient electron transfer and photothermal conversion for other photothermal reactions.

Nonthermal plasma coupled with Mn/N-doped carbon catalysts for highly efficient removal of toluene

In order to ensure the excellent performance of a nonthermal plasma (NTP)-catalysis system, a highly efficient catalyst is generally required. In this study, nitrogen-enriched hollow hybrid carbon (N-C) catalysts were designed, synthesized through facile pyrolysis of a zeolitic imidazolate framework precursor, and used as a support on which to disperse Mn species. Notably, the coupling of NTP with the Mn/N-C catalysts resulted in strong activity. Mn loading of 6 % was found to remove almost all toluene (98 % efficiency) and to have COx selectivity (82.1 %) when the specific energy density (SED) value was 252 J·L−1; when the SED value was 102 J·L−1, the energy yield was 10.6 g·kWh−1. The performances of the developed Mn/N-C catalysts were related to their highly dispersed nature and strong ability to activate oxygen and dissociate O3. Hereafter, the toluene decomposition pathway is described. The present findings demonstrate the potential applications of porous N-C-supported metal oxide catalysts in the removal of volatile organic compounds through a catalyzed NTP process.

Manganese accumulation in red blood cells as a biomarker of manganese exposure and neurotoxicity

Although overexposure to manganese (Mn) is known to cause neurotoxic damage, effective exposure markers for assessing Mn loading in Mn-exposed workers are lacking. Here, we construct a Mn-exposed rat model to perform correlation analysis between Mn-induced neurological damage and Mn levels in various biological samples. We combine this analysis with epidemiological investigation to assess whether Mn concentrations in red blood cells (MnRBCs) and urine (MnU) can be used as valid exposure markers. The results show that Mn exposure resulted in neurotoxic damage in rats and that MnRBCs correlated well with neurological damage, showing potential as a novel Mn exposure biomarker. These findings provide a basis for health monitoring of Mn-exposed workers and the development of more appropriate biological exposure limits.

Preparation and Application of Slag‐Based Catalyst for Steelmaking

This study focuses on utilizing ground granulated blast furnace slag (GGBS) from a steel plant as the main raw material, with water and calcium‐based montmorillonite as binders, with manganese and alkali metal nitrates (Na, K, Mg, Ca). A series of supported denitration catalysts are prepared using the equal volume impregnation method. These catalysts are then employed in the selective catalytic reduction process to investigate their impact on denitration effectiveness. Furthermore, the mechanism of low‐temperature denitration in selective catalytic reduction is analyzed by combining catalyst activity tests and characterization techniques. The activity of catalysts is assessed through Fourier transform infrared spectrometer (FT‐IR), X‐Ray diffraction (XRD), and search engine marketing (SEM) characterization tests, along with examining its denitration and sulfur resistance capabilities to determine the denitration mechanism. Experimental results indicate that Mn–Mg/GGBS exhibit the most efficient low‐temperature denitrification effect, and it demonstrates certain sulfur resistance with a 5% Mn loading and a 3% second active component. Introducing Ce as the third active component further enhances the sulfur resistance of Mn–Mg–Ce/GGBS when loaded at 1%.

Insight into recycling spent power ternary cathode materials: Towards preparation of Mn-based catalyst for efficient toluene removal

Both the resource utilization of spent power ternary lithium-ion batteries (LIBs) and degradation of volatile organic compounds (VOCs) by thermal catalytic oxidation are environmental concerns. In this study, a novel perspective is presented: the Mn-based composite metal oxide catalysts were synthesized via impregnation of spent ternary cathode materials for the thermocatalytic oxidative degradation of toluene gas. The results demonstrated that the optimal conditions for catalyst synthesis were a 2% Mn loading, a Co/Mn molar ratio of 0.4, and calcination at 500 ℃ for 6 h. The effectiveness of catalysts is determined by two inherent factors: the specific surface area and the presence of active sites on the surface. The degradation of toluene remained stable across various reaction environments, with the predominant degradation mechanism being Marks-Van-Kreven (MVK) model. The toluene undergoes oxygenation on the catalyst in this pathway, resulting in the formation of H2O, CO2, and intermediates containing benzene rings; and simultaneously, the catalyst is regenerated. The present study offers a valuable reference for the resource utilization of spent ternary LIBs and advances the development of catalysts for efficient degradation of VOCs.

Damage evolution in spark plasma sintered boron carbide under scratch and indentation loading conditions

Spark plasma sintered boron carbide (B4C) has been tested for damage evolution characteristics. Three distinct failure regions were identified during the scratch process of B4C, based on the observed transitions in the induced tangential force pattern and fracturing. B4C exhibited significant elastic recovery effect (50%) under both scratch (1–50 N) and indentations (5–100 mN) loading conditions. The sequence of transition from the nucleation of cracking and its propagation resulting to amorphization were identified. Scratch grooves were characterized with partial bow type Hertzian cracking, radial cracking and an onset of chipping (up to 75 N) and extensive spallation and fragmentation (76–100 N). The spallation regions were characterized with numerous randomly oriented slip lines suggesting failure dominated by the shear deformation. Raman spectra from spallation regions reveal peaks corresponding to amorphous B4C, inferring the occurrence of amorphization concentrated at the localized shear bands. At higher loads (>75 N), grain boundary fractures were observed in addition to simple cleavage fracture, which contributes for deteriorating material performance, by extensive cracking. The hardness and elastic modulus of B4C measured by nanoindentation were 44 GPa ± 6.6 GPa and 560 GPa ± 47 GPa, respectively.

Efficient activation of peroxymonosulfate with zirconia-supported manganese and cobalt catalysts for oxidation of ibuprofen

This study assessed the efficacy of ZrO2-based catalysts with different Mn(II) and Co(II) metal loadings for catalytic degradation of ibuprofen using peroxymonosulfate anion as oxidant. The support was prepared via co-precipitation, and metal ion deposition was achieved through incipient wetness impregnation. Catalysts were characterized by atomic absorption spectrometry, X-ray diffraction, Fourier-Transform infrared spectroscopy, and scanning electronic microscopy. Optimal experimental conditions resulted in complete ibuprofen degradation in 30 min, with 63.3% mineralization. The best-performing catalyst was reusable up to three times. Both sulfate and hydroxyl radicals were generated in the oxidant activation process.

Atomically-dispersed manganese anchored on B,N co-doped carbon for the sensitive electrochemical detection of levodopa

Metal single-atom catalysts offer the dual advantages of high electrochemical activity and near 100 % metal atom utilization, leading to their potential use in low-cost electrochemical sensor development. Herein, a novel electrocatalyst comprising atomically-dispersed Mn on B,N co-doped bamboo-derived carbon (MnSAs-BN-BC) was synthesized via a facile pyrolysis procedure. A high dispersion of Mn single atoms in MnSAs-BN-BC was confirmed by aberration-corrected transmission electron microscopy and elemental mapping. The Mn loading in the MnSAs-BN-BC determined by inductively coupled plasma mass spectrometry was 255 mg kg−1. MnSAs-BN-BC displayed outstanding electrocatalytic performance for levodopa (LD) oxidation, allowing a robust electrochemical sensing platform for LD detection to be established. The MnSAs-BN-BC/GCE sensing platform offered a wide LD detection range (concentrations from 2 to 683 µM) and a very low limit of detection (LOD) of 0.45 µM, outperforming almost all electrochemical sensors reported to date for LD sensing. The MnSAs-BN-BC/GCE platform also featured outstanding repeatability, reproducibility, selectivity, and stability. The as-developed sensing platform was successfully applied to LD quantification in commercial tablets with satisfactory recoveries (85.2–102.4 %), with the analytical precision of method validated against a traditional UV–vis spectrophotometry method. Density functional theory (DFT) calculations showed that Mn single atom sites lowered the reaction energy barrier for LD oxidation, with the favorable d-band center position of Mn single atom sites in MnSAs-BN-BC contributing to the enhanced LD sensing performance. This work encourages the use of single-atom metal catalysts in design of high-performance electrochemical sensors for the rapid detection of LD.

Development of a multi-layered waterproof breathable fabric for full-weather apparel

In this research, a laminate was produced by assembling five textile layers. These layers were a coated double-sided knitted structure, a non-woven fabric, a hydrophilic membrane that was thermally assembled to a surface veil, and an open-work knitted fabric. The laminated textile's breathability, windproofness, and waterproofness were evaluated. The multi-layered fabric was windproof, and its water vapor permeability was 347.297 g?m-2?s-1 (CV= 8.902%). Its resistance to water penetration was equal to 117.68 Schmerber (CV = 7.81%). The assembled fabric's mechanical properties were also evaluated. Young?s modulus values were equal to 2 MPa (CV= 8.613%) and 1.6 MPa (CV= 8.349%) for both fabric directions. Its flexural rigidity was 5056.659 mg?cm and its surface total deformation was lower than 450 ?m when measured under 20, 40, 60, and 80 mN loads. Based on the results obtained, it was concluded that the developed multi-layered fabric could be used to produce raincoats and jackets to protect the wearer from light rain and drizzle.

Nanomechanical analysis of friction welded similar PEEK/aluminum nanocomposites: Effect of metal particle reinforcement

AbstractAluminum (Al), poly(etheretherketone) (PEEK) thermoplastics, and their individual composites have widely been used in many industries, including aerospace and biomedical fields. However, the joining process of those composites has not been explored much to date. In this context, the friction welding process (FWP) could be used as an alternative since it has the ability to join high‐strength components with minimal distortion. Therefore, the present study aimed to develop PEEK/Al nanocomposites with varying Al concentrations of 10, 20, 30, and 40 vol% using powder metallurgical technique and further joined the similar composition composites by FWP. Then, the effect of reinforced particle concentrations on the physical, morphological, structural, thermal, and micromechanical behaviors of the joined nanocomposites has been characterized by microscopy, X‐ray diffraction, differential scanning calorimetry, and nanoindentation tests. The concentrations of the reinforcement were found to have a significant effect on the crystallinity, melting temperature, glass transition temperature, and thereby micromechanical properties. The results were analyzed and correlated precisely for all the welded nanocomposites systematically. The interdiffusion mechanism was found to be involved in improving the mechanical properties of the present nanocomposites. The highest elastic modulus (13.91 GPa) or nanohardness (0.31 GPa) was obtained for the rotatory part of the PEEK/Al40 nanocomposites at 80 mN load. But, the applied load of 40 mN was the best loading condition due to the uniform change in modulus and nanohardness of all the nanocomposites. Therefore, the present alternative joining method of the PEEK/Al nanocomposites might be used for aerospace components.Highlights Development of PEEK/aluminum with 10, 20, 30 and 40 vol% Al nanocomposites. Friction welding of similar composite material, PEEK/Al‐PEEK/Al nanocomposites. Microstructural, thermal, and nanomechanical analyses. Effect of metal particle reinforcement on the friction welded nanocomposites. FW PEEK/Al40 nanocomposite is found to be the best.