Morphology Of Powders Research Articles

Influence of initial powders morphology on structural-dimensional characteristics of porous ceramic materials based on SiC/MgO–SiO2

Synthesis of porous ceramic materials based on fine SiC with sintering silicon oxide and magnesia binders at T = 800–1300 °C is considered. Special attention is paid to the influence of the shape and morphology of the initial powder particles on structural parameters and characteristics of porous ceramic materials. The SiC membranes sintered at 1000–1300 °C had average pore sizes of 0.5–1 μm, open porosity - up to 50 %, bending strength - up to 48.5 MPa and high water permeance - up to 7890 l⋅m−2⋅h−1⋅bar−1. The established filtration efficiency was ∼99 % in the case of screening out model particles of D50 = 0.5 μm in size with maintaining stable permeance and physico-mechanical characteristics after multiple filtration-regeneration cycles.Comprehension of the initial powders morphology impact on the synthesized porous ceramics parameters makes it possible to forecast and ensure the preset structural, dimensional and physico-mechanical parameters of the materials under study properly. This work can be used for practical low-cost production of highly efficient SiC membranes for micro- and ultrafiltration processes, as well as base for catalysts.

Adsorption of Pb2+ ions of natural red lava rock powder in aqueous media

Red lava rock is available in nature and is formed from volcanic eruptions. Volcanic rocks are composed of oxides of diverse metals and have considerable porosity. In this study, lava rock powder was ground to a specific size and dried to test its ability to adsorb heavy metals in water. The morphology of the stone powder was observed to show crystals of 100–300 nm in size clumping into particles of a few μm. The phase structure is mainly in the form of Ca(Mg,Al)(Si,Al)2O6; in addition, the phases CaAl2Si4O12.2H2O, Ca2MgSi2O7, and Ca3MgSi2O8 also exist. The material's maximum Pb2+ ion adsorption capacity reaches 32.05 mg/g at endogenous pH. The isotherm of Pb2+ adsorption on the material follows the Langmuir model, and the adsorption kinetics are pseudo-first-order kinetics.

Preparation and microwave absorption property of Ni/Al powder

As a functional composite material, nickel-coated aluminum powder has been widely used in conductive fillers, electromagnetic shielding materials and other fields due to its advantages of low density, high conductivity and low cost. In this paper, nickel-plated aluminum powder was prepared by a sodium hypophosphite system. The effects of different nickel coating amounts (the percentage of nickel-plating quality to nickel-plated aluminum powder quality) on the morphology, phase, compaction resistivity and electromagnetic parameters of nickel-plated aluminum powder coating were studied. The X-Ray Diffraction (XRD) results proved the successful preparation of nickel-coated aluminum powders with different nickel coating amounts. The Scanning Electron Microscope (SEM) images clearly show the coating effect under different nickel coating amounts. By plating nickel on the surface of aluminum powder, the surface characteristics of aluminum powder are changed, so as to adjust its conductivity, resistance, stability and other properties, thus affecting its electromagnetic performance and wave absorption performance. The results show that the comprehensive absorbing performance is excellent when the nickel coating amount is 40%. The reflection loss of the sample with a thickness of 2.0[Formula: see text]mm is less than [Formula: see text][Formula: see text]dB in the frequency range of 10.17–12.38[Formula: see text]GHz. When the frequency is 10.72[Formula: see text]GHz, the minimum reflection loss reaches [Formula: see text][Formula: see text]dB.

Ceramic fused filament fabrication (CF3) of alumina: Influence of powder particle morphology on processing and microstructure

This study investigates ceramic fused filament fabrication (CF3) 3D printing of alumina with an emphasis on the impact of particle morphology on feedstock preparation and printability. Spherical powder displayed superior flow with higher apparent density, tap density, and powder packing fraction compared to irregular powder. A 55 vol % powder loading was chosen to ensure good flowability during printing. Irregular powder-based feedstocks had 40X higher viscosity than spherical powder feedstocks at 400 s−1 shear rate, posing potential printing challenges. Slow printing speed maintained low feed-rates for consistent material flow. The debinding and sintering process produced macroscopically defect-free alumina components with relative densities above 89 % for both powder morphologies. The focus of the work is on comparing two different powder particle morphologies influencing feedstock behavior, printing fidelity, and sintered part properties.

Effect of carbon nanofibers fabricated from electrospun PAN precursors on the characteristics and densification of MgO–CaO ceramic systems

MgO–CaO composites are basic materials with high melting points, high chemical resistance to alkaline environments, clean steel production, environmental friendliness, and abundant sources. In the current work, carbon nanofibers (CNFs) with diameters between 150 and 270 nm were prepared at different temperatures (up to 1200 °C) by carbonization of electrospun polyacrylonitrile (PAN) precursors. Then, the MgO–CaO composites were prepared in two steps. First, 3 wt% CNFs carbonized at different temperatures were added to the composite to determine the optimal carbonization temperature. Subsequently, the physical properties (apparent porosity and bulk density) and mechanical properties (flexural strength (FS) and cold crushing strength (CCS)) of the MgO–CaO-CNF composites were investigated. X-ray diffraction (XRD), Raman spectroscopy, field emission scanning electron microscopy (FESEM), Energy-Dispersive X-ray spectroscopy (EDS), and thermogravimetric analysis (TGA) were used to analyze the composition, morphology, and structure of the CNFs powders and composite samples. Based on the results obtained, such as the percentage graphitization, length, average diameter, and morphology of the CNFs, 1000 °C was determined as the appropriate carbonization temperature for the next steps of this study. In a second step, the CNFs synthesized at 1000 °C were added to the MgO–CaO with different wt% (0, 0.5, 1, 1.5, 2, 2.5, and 3 wt%). It was found that by adding CNFs (up to 1.5 wt%) into the MgO-CaO composites, the physical properties increased due to the improvement of densification, and mechanical properties improved due to the activation of reinforcing mechanisms, the reduction of surface defects and the creation of a dense body. However, these properties decreased from 1.5 to 3 wt% due to the agglomeration and poor dispersion of the CNFs. Finally, the results illustrated that adding CNFs, even in small amounts, significantly improved the features of MgO-CaO compounds; the ideal content was 1.5 wt% CNFs.

Optimising Mg-Ca/PLA Composite Filaments for Additive Manufacturing: An Analysis of Particle Content, Size, and Morphology.

Low-temperature additive manufacturing of magnesium (Mg) alloy implants is considered a promising technique for biomedical applications due to Mg's inherent biocompatibility and 3D printing's capability for patient-specific design. This study explores the influence of powder volume content, size, and morphology on the mechanical properties and viscosity of polylactic acid (PLA) matrix composite filaments containing in-house-produced magnesium-calcium (Mg-Ca) particles, with a focus on their application towards low-temperature additive manufacturing. We investigated the effects of varying the Mg-Ca particle content in a PLA matrix, revealing a direct correlation between volume content and bending strength. Particle size analysis demonstrated that smaller particles (D50: 57 μm) achieved a bending strength of 63.7 MPa, whereas larger particles (D50: 105 μm) exhibited 49.6 MPa at 20 vol.%. Morphologically, the filament containing spherical particles at 20 vol.% showed a bending strength that was 11.5 MPa higher than that of the filament with irregular particles. These findings highlight the critical role of particle content, size, and shape in determining the mechanical and rheological properties of Mg-Ca/PLA composite filaments for use in material extrusion additive manufacturing.

Enhancing strength and toughness of GNS/Al nanocomposites via a hybridization strategy

Good strength-ductility balance in graphene nanosheet (GNS)-reinforced aluminum nanocomposites can be achieved through tailorable and facile agglomeration control. Our previous study showed that pre-modulating the Al powder morphology by adding hard silicon carbide nanoparticles (SiCnp) during the two-step ball milling process effectively promotes the uniform dispersion of GNSs. However, excess SiCnp content causes SiCnp aggregate and premature cracking of composites. Here, GNS-reinforced aluminum nanocomposites with different SiCnp content (0.3–1.5 vol%) were prepared, and the optimal SiCnp-to-GNS ratio was determined after optimizing the SiCnp content in a pre-studied composite preparation process. The effect of SiCnp on the microstructure and mechanical properties of the composites was systematically investigated. The cold welding deformation of Al flakes increased with the SiCnp content. Nonetheless, inadequate or excessive SiC content caused insufficient lamination or excessive cold-weld stacking of Al flakes, respectively. Al-0.9vol.%SiCnp powders possessed the highest specific surface area which resulted in high homogeneous dispersion of 3.0 vol% GNS during the second ball-milling stage. Consequently, the resulting hybrid reinforced (GNS + SiCnp)/Al composites showed simultaneous improvement in strength and plasticity, unlike Al-3.0vol.%GNS composites. This showed that introducing hard nanoparticles (i.e., the hybridization strategy) is a promising method to simultaneously enhance strength and plasticity of aluminum nanocomposites.

Determination of nano-graphene content for improved mechanical and tribological performance of Zn-based alloy matrix hybrid nanocomposites

The primary objective of this study is to explore the fabrication of a hybrid nanocomposite (HNC) composed of ZnAl40Cu2 alloy, graphene, and B4C particles, while also determining the optimal graphene reinforcement ratio for enhanced properties. Our methodology entails the production of HNC powders (HNPs) through mechanical milling, where we combine graphene nanoplatelets with B4C microparticles into ZnAl40Cu2 alloy powders. Throughout this process, we maintain a constant B4C content of 1.5 wt%, while varying the graphene content at 1.5 wt%, 3 wt%, and 4.5 wt%. Following the characterization of all produced powders, which includes an assessment of powder morphology, powder size distribution, and powder microhardness, we proceed to hot-press the HNPs to create bulk HNC samples. After consolidating the specimens, a comprehensive series of tests are carried out to determine microstructural, mechanical (hardness and tensile strength) and tribological properties. Our results reveal that the HNC specimen with graphene content of 3 wt% (referred to as A2) displays the most notable enhancements in properties. Specifically, A2 exhibits an impressive hardness of 163 HB, surpassing the hardness of the ZnAl40Cu2 matrix alloy, which measures at 133 HB. Furthermore, its ultimate tensile strength significantly outperforms the ZnAl40Cu2 matrix alloy, with a remarkable value of 223 MPa compared to 157 MPa. However, it is worth noting that the improvement in wear resistance for HNCs is most pronounced up to a certain threshold of graphene content, which is 3 wt%.

Influence of pressure and powder characteristics on the properties and microstructure of Colmonoy-5 alloy sintered by spark plasma sintering

This study investigates the microstructure and final properties of Colmonoy-5, a nickel-based hardfacing alloy, consolidated via spark plasma sintering (SPS) as an alternative to traditional welding deposition on stainless steel substrates. Two batches of Colmonoy-5 alloy powders with different particle sizes used for sample processing. Sintering occurred at 900 °C under pressures of either 50 MPa or 60 MPa for 15 min. The evaluation of the sintered samples included density measurement through Archimedes' method, morphology assessment via confocal microscopy, phase composition analysis by X-ray diffraction (XRD), microstructural examination using scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), and hardness testing by Vickers method. Findings indicate that SPS is an effective technique for producing Colmonoy-5, achieving satisfactory densification. The study also reveals that the initial morphology of the precursor powders can influence the size of phases precipitated within the nickel matrix. Sintering pressure of 50 MPa seems to be the most effective in processing Colmonoy-5 via SPS.

Preparation of high-density green body based on binder jetting 3D printing using spheroidized SiC powder

Silicon carbide (SiC) ceramic stands as a critical material in the realm of high-performance engineering ceramics. However, Crafting SiC ceramics with intricate structures and superior mechanical properties presents notable challenges in shaping, sintering, and processing. Binder jetting (BJ) additive manufacturing has the outstanding advantages of high forming efficiency and no thermal deformation, especially suitable for printing complex structure SiC components.; however, BJ printed green bodies often exhibit low density, resulting in high residual silicon content and diminished strength of the final components. In this work, we introduce a novel strategy to fabricate high-strength SiC components with complex geometries by improving the density of printed SiC green bodies. This method involves modifying the morphology of SiC powder through the molten salt method to increase the density of BJ 3D printed green bodies from 1.24 ± 0.13 g/cm³ to 2.01 ± 0.03 g/cm³, followed by a reactive melt infiltration process. The resulting RB-SiC ceramics display exceptional flexural strength, averaging 280.60 ± 33.05 MPa, and an elastic modulus of 294.67 ± 4.90 GPa. These values represent some of the highest for flexural strength and elastic modulus reported among 3D-printed SiC composites. With its robust mechanical performance and streamlined fabrication process, this strategy holds substantial promise for the production of structural SiC ceramics.

Bimodal microstructural characterization of Si powder using X-ray diffraction: the role of peak shape

X-ray diffraction (XRD) characterization of Si powder was carried out using synchrotron and laboratory sources. Microstructural (size-strain) analyses of XRD patterns were carried out using the Rietveld refinement method. Experimentally observed super-Lorentzian shapes of the XRD peaks of Si powder were examined using multimodal profile fitting and bimodal model was found to be adequate. The two components obtained using a bimodal approach are referred as narrow and broad profiles based on their estimated relative peak widths. Peak shapes of crystallite size-dependent parts of narrow and broad profiles were found to be almost Gaussian and Lorentzian in nature, respectively. The simultaneous presence of such peak shapes corresponding to a bimodal microstructure is uncommon in literature. Therefore, in order to explore the role of different natures of XRD peak shapes (size dependent) of the bimodal profiles of Si, detailed microstructural analysis was carried out using the complementary method of whole powder pattern modeling (WPPM) and found to be related to the variance of crystallites' size distribution. Additionally, the effect of instrument resolution (laboratory and synchrotron sources) on the microstructural parameters was also studied. Scanning and transmission electron microscopy were used to characterize the morphology of Si powder and correlate with the microstructural findings of XRD methods.

A novel powder sheet laser additive manufacturing method using irregular morphology feedstock

Irregular (i.e. non-spherical) morphology powder is more cost-efficient to produce than spherical shaped powder. However, its reduced levels of flowability limit the wide application ranges of laser beam powder bed fusion (LPBF). To address this issue, a novel powder sheet additive manufacturing concept (MAPS) is proposed. Herein, a pre-manufactured metal particle-polymer binder composite (i.e. powder sheet) feedstock is employed as a raw material. The printability of irregularly shaped powder particles in sheet (MAPS) format was physically investigated using a range of different process parameters. The manufacturing process was observed by high-speed imaging. Microstructural and chemical element characterisations of the irregularly shaped powder particle print were then compared against those prints which were conducted using sheet-based (MAPS) spherical powder morphologies. The results indicated that the geometric accuracy and density of irregular powder morphology sheet printing improved when using a negative defocus strategy of the laser beam. A negative defocusing strategy allowed for the melting mode of the material to be transformed from keyhole to a more favourable conduction state. High speed imaging revealed that more spatter and vapour plume were observed with the increase in the magnitude of the negative defocus. The multi-morphology 304 L stainless steel (SS304) samples were printed in a single printer using an efficient method for the first time, i.e. printing spherical SS304 material on top of irregular SS304. EDX results indicated an insignificant change of chemical elements between the spherical and irregular prints. EBSD results revealed that columnar grains could grow through the irregular-spherical transition zone and similar grain size can form between spherical and irregular prints. The results of this study provide insights into the optimum printing configurations for powder sheet additive manufacturing using a cost-effective solution of irregular morphology material.

Characterization of LiNi0.8Co0.15Al0.05O2 cathode material synthesized via co-precipitation method

Abstract LiNi0.8Co0.15Al0.05O2 cathode material was synthesized using the co-precipitation method, and the effect of synthesis conditions on powder properties was studied. The results indicate that adjusting the pH value and complexing agent concentration during the reaction process can effectively control the precipitation process. The obtained hydroxide precursor is petallike, and the morphology of the cathode material powder after high-temperature sintering is well-dispersed spherical particles. The changes in the sintering system can significantly affect the crystallization process and crystal structure of cathode materials. As the sintering temperature increases, the peak rate I (003)/I (104) significantly decreases, while the R value increases. With the prolongation of sintering time, I (003)/I (104) first increases and then decreases, and the R value first decreases and then increases. After sintering at 750°C × 12 h, the cathode material has the highest peak rate and the lowest R value, indicating the lowest degree of cation mixing, higher structural integrity and the highest electrochemical activity at this time.

Chip morphology’s effect on properties of PLA-based bamboo–plastic composites produced using hot-pressing

This study explored the effect of raw material morphology on the properties of bamboo–plastic composites produced using hot-pressing. To provide a reference for reducing the production cost and improve the product properties of the composites, polylactic acid (PLA)-based bamboo–plastic composites were prepared using bamboo chips with a shaved morphology (BS) and fiber morphology (BF) and PLA as the matrix material, via hot-pressing. The properties of the bamboo–plastic composites formed with BS and BF chips were studied and compared with those of composites with conventional granular morphology (BM) and powder morphology (BP). The results showed that when the content of the bamboo chips was at 50% (the same below), the mechanical properties of the BF/PLA composites were remarkably better than those of the other PLA-based composites. However, the BF/PLA composites showed a high degree of hydrophilicity, with a water contact angle of 70.0° and a water absorption of 10.8% at 288 h. More holes could be seen in the BF/PLA composites using a scanning electron microscope. Among the four types of PLA-based composites, better melt fluidity was found only in the BF/PLA composites, and the melting index was 65.3 g/min.

Quasi-Homogeneous Photocatalysis in Ultrastiff Microporous Polymer Aerogels.

The development of efficient and low-cost catalysts is essential for photocatalysis; however, the intrinsically low photocatalytic efficiency as well as the difficulty in using and recycling photocatalysts in powder morphology greatly limit their practical performance. Herein, we describe quasi-homogeneous photocatalysis to overcome these two limitations by constructing ultrastiff, hierarchically porous, and photoactive aerogels of conjugated microporous polymers (CMPs). The CMP aerogels exhibit low density but high stiffness beyond 105 m2 s-2, outperforming most low-density materials. Extraordinary stiffness ensures their use as robust scaffolds for scaled photocatalysis and recycling without damage at the macroscopic level. A challenging but desirable reaction for direct deaminative borylation is demonstrated using CMP aerogel-based quasi-homogeneous photocatalysis with gram-scale productivity and record-high efficiency under ambient conditions. Combined terahertz and transient absorption spectroscopic studies unveil the generation of high-mobility free carriers and long-lived excitonic species in the CMP aerogels, underlying the observed superior catalytic performance.

Production of iron triad-based colored spinels by the self-propagating high-temperature synthesis

Blue, green, and khaki spinels were produced by self-propagating high-temperature synthesis (SHS) using Co3O4–ZnO–Mg(NO3)2·6H2O–Al(OH)3–Al, Ni2O3–ZnO–Cr2O3–Al(OH)3–Al, and Co2O3–Fe2O3–Al(OH)3–Al mixtures. The composition of the synthesis products was characterized by X-ray diffraction and IR spectroscopy. The oxides Co3O4, Co2O3, ZnO, Ni2O3, Cr2O3, Fe2O3, and aluminum hydroxide Al(OH)3 were used for the synthesis. Fuel was provided by aluminum powder (ASD-4). The spinel-type ceramic pigments were synthesized using layer-by-layer combustion, which involves two parallel exothermic reactions: aluminum oxidation and aluminothermic reactions. The fast self-propagating reactions and high synthesis temperatures rapidly destroy the structure of Al(OH)3 hydroxide in the starting mixture, producing gaseous reaction products that prevent the sintering of the spinels. The surface morphology of pigment powders and their composition was studied using a Quanta 3D 200i, FEI Co. scanning electron microscope and a Philips SEM 515 scanning electron microscope equipped with a local energy dispersive X-ray analysis (EDAX). The particle size of the synthesized spinels was approximately 1–5 μm. Colored spinels powders obtained by the SHS process can be used as ceramic pigments.

A meshless computational framework for studying cold spray additive manufacturing including large numbers of powder particles with diverse characteristics

Cold spray (CS) has emerged as an appealing additive manufacturing (AM) technique for producing or repairing individual components or entire structures. Compared to fusion-based AM technologies, cold spray additive manufacturing (CSAM) offers distinct advantages in the fabrication of components, while avoiding some melting/solidification-related issues such as phase transformation and oxidation. It involves intricate processes that pose significant challenges for numerical modeling, particularly when simulating the entire process at a large scale. The smoothed particle hydrodynamics (SPH) method is highly suitable for handling large material deformations due to its Lagrangian and meshless nature. In this work, we develop an enhanced SPH method to conduct large-scale simulations of CSAM with different powder sizes, morphologies, and distributions. A modified material model has been incorporated to accurately capture the strain-rate hardening effects during the plastic stage. The computational scale is greatly improved by using a Message Passing Interface (MPI) based framework, enabling the simulation of approximately ten million SPH particles. To the authors’ knowledge, this study marks the first attempt to numerically reproduce the entire process of CSAM with real powder sizes and distributions. Experimental data measured for a wide range of powder velocities are used to validate the simulation results and assess the prediction accuracy. Subsequently, we comparatively study the bonding mechanisms of powders with the same or different sizes, while also identifying a four-stage coating process. The effects of powder morphology on the bonding process are thoroughly investigated. A large-scale CSAM process is finally reproduced to demonstrate the capability of the present meshless scheme, and mechanisms of pore formation are analyzed, providing valuable insights for practical engineering applications.

Floatable Cu2(OH)PO4/rGO Aerogel for Full Spectrum Driven Photocatalytic Degradation of Organic Pollutants.

Photocatalytic technology is an attractive option for environmental remediation because of its green and sustainable nature. However, the inefficient utilization of solar energy and powder morphology currently impede its practical application. Here, we designed a floatable photocatalyst by anchoring 0D Cu2(OH)PO4 (CHP) nanoparticles on 2D graphene to construct 0D/2D CHP/reduced graphene oxide (rGO) aerogels. The CHP/rGO aerogels have interconnected mesopores that provide a large surface area, promoting particle dispersion and increasing the number of active sites. Moreover, the optical response of the CHP/rGO aerogel has been significantly expanded to cover the full spectrum of the solar light. Notably, the 20%CHP/rGO aerogel displayed a high degradation rate (k = 0.178 min-1) taking methylene blue (MB) as a model pollutant under light irradiation (λ > 420 nm). The enhanced photocatalytic activity is ascribed to the rapid electron transfer in the CHP/rGO heterostructures, as supported by the DFT theoretical calculations. Our research highlights the utilization of full spectrum responsive photocatalysts for the elimination of organic pollutants from wastewater under solar light irradiation, as well as the potential for catalyst recovery using floatable aerogels to meet industrial requirements.

DEVELOPMENT OF MYCROCRYSTALLINE CELLULOSE ORIGINATE FROM SAGO (METROXYLON SAGU) STEM BARK BY HYDROLISIS METHODE USING NITRIC ACID

Objective: Microcrystalline cellulose (MCC) is an essential excipient in tablet formulation. Mostly MCC was obtained from wooden conifer stem fiber, therefore environment issues had been came up. Alternative sources for MCC which offer friendly conifer wood need to be explored. This study aimed to isolate and determine the characteristics of MCC originated from Sago (Metroxylon sago Rottb.) stem fibers as an promising alternative of MCC. Methods: MCC was prepared through pre-hydrolysis using an acetic acid solution, alkali heating using NaOH solution, and acid hydrolysis using nitric acid 0.3 N using three variations of heating temperature, namely 90, 95 and 100 °C. The characterization carried out were pharmaceutical grade, powder properties, FTIR analysis and powder morphology by SEM. Results: The yields obtained were 66.02; 65.53 and 65.08%, respectively. The characteristics of the MCC sample based on pharmaceutical grade quality were white to yellowish white powder, odorless, tasteless, insoluble in: ether, 96% alcohol, HCl 2N and NaOH 1N. The pH of the MCC suspension were 5.07-5.12, while moisture content were 3.67-4.17%, with loss on drying value as much as 0.37-0.4%, and ash content 1-2.17%. The value of permanganate number were 0.09-0.11, Hausner factor was between 1.05-1.25, and angle of repose were between 11.4-24.8°. Conclusion: Based on the results, it can be concluded that Sago is potent natural resource for MCC. The resulting MCC revealed physicochemical and characteristic of MCC, which almost similar to Avicel PH 102 as standard.

High activity retention Al–Bi–Zn-base composite powder with mild hydrogen generation

Al–10Bi–7Zn and Al–10Bi–7Zn–1.5X (X: Cu, Fe, Ni, in wt.%) composite powders were designed and prepared through phase diagram calculation and gas atomization method. The effects of Cu, Fe, and Ni on the hydrolysis of Al–Bi–Zn-base composite powders for hydrogen production were investigated respectively. The composition and morphology of powders were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM) with energy disperse spectroscopy (EDS) analyses. Hydrolysis performance test results indicate that the additions of Cu, Fe, or Ni can modify the hydrogen production rate and enhance oxidation resistance in Al–10Bi–7Zn ternary alloy composite powder. In the quaternary composite powder system, Al–10Bi–7Zn–1.5Ni (wt.%) exhibits the best performance with the hydrogen generation yield of 75.3% (954.1 mL/g) within 500 min when reacting with distilled water at 60 °C and maintains a hydrogen yield of 57.9% (733.7 mL/g) within 1500 min after being stored (30 °C, relative humidity of 60%) for 7 d. In addition, the mechanism investigation suggested that the additions of Cu, Fe, or Ni in Al–Bi–Zn-base composite powders can stabilize the Al matrix to retain the high activity of powders resulting from inhibiting the cracking of composite powders in the air.