Ni Powders Research Articles

Use of Laser Metal Deposition Technology in Additive Manufacturing of Ni Powder Materials

Abstract The process parameters of the Laser Metal Deposition technology in the production of simple components made of NiCuBSi type metal powder were verified in this paper. A laser head with a coaxial powder supply and argon gas was used in the production. The powder was welded to a S235J2G3 steel plate. The used parameters (heat input 0.25 kJ.mm−1) enabled the production of samples with a minimum porosity (1.2 %) and without the defects (cold joints, pores) between the weld layers.

Synthesis and Characterization of High Entropy Alloy 23Fe-21Cr-18Ni-20Ti-18Mn for Electrochemical Sensor Applications.

High entropy alloys (HEA) are one of the modern-era alloys accelerating with greater velocity because of their excellent properties and different applications. In the present paper, we have successfully fabricated HEA (23Fe-21Cr-18Ni-20Ti-18Mn) powders by ball milling the elemental Fe, Cr, Ni, Ti, and Mn powders for 15 h. The advancement of the milling process and phase transformation of HEAs were studied by using X-ray diffraction (XRD) and scanning electron microscope (SEM). The crystallite size and the lattice strain of the HEA were calculated by using the Williamson-Hall (W-H) equation and the values were found to be 7 nm and 0.0176%, respectively. Similarly, the true lattice parameter was calculated using the Nelson-Riley (N-R) extrapolation method, and the value was found to be 3.544 Å. We have successfully investigated the electrochemical response of 15 h ball milled 23Fe-21Cr-18Ni-20Ti-18Mn HEA powders to determine the ascorbic acid (AA) using cyclic voltammetry. We have modified the carbon paste electrode with ball milled HEA of concentrations 0, 2, 4, 6, 8, and 10 mg, and among them, 8 mg HEA modified carbon paste electrode (HEA-MCPE) depicted the highest current sensitivity. We reported the effect of modifier concentration, analyte concentration, scan rate, and pH on the oxidation peak of AA. The electrochemical active surface area of carbon paste and MCPE was calculated using the Nernst equation and the values were found to be 0.0014 cm2 and 0.0027 cm2, respectively. The fabricated HEA-MCPE showed excellent current sensitivity, stability, anti-fouling, and selectivity.

Study of the structural and magnetic properties at high temperature of Ni-Co-Mn-Al Heusler alloy prepared by an unconventional route

ABSTRACT Ni, Co, Mn, and Al elemental powders have been ball milled in a planetary mill for various periods, up to 32 h. The obtained powder was characterized with XRD, SEM-EDS, DSC, high-temperature-XRD, and VSM techniques to study morphology, composition, thermal transitions, structural and magnetic changes occurring at high temperatures. At the end of the milling process, a particle mixture consisting of agglomerated grains with a rounded shape and an average size of about 60 µm was formed. XRD patterns of the as-milled powders revealed the presence of a nanocrystalline solid solution mixture with (L10) and (B2) structures. HT-In-situ XRD characterizations confirmed the complete formation of the B2 ordered structure from 573 K. The austenitic Heusler phase B2 remains stable during one hour of isothermal holding and its proportions increase between 648 and 773 K. Under the heating effect, crystallites size grows up greatly with increasing holding temperature, nevertheless the micro-strains decrease sharply from 0.98% at room temperature to 0.31% at 773 K. Magnetic features of the milled alloy enhance further during the heating process, making it magnetically soft with the most intriguing values of Ms, Mr, and Hc between 648 and 773 K. This is owing to the complete development of the homogeneous and ordered Heusler B2 phase and the significant increase in crystallite size with the relaxation of residual stresses resulting from the direct effects of temperature.

Determination of Atomic-Scale Density of Materials from Total Scattering Profiles

Atomic-scale density (microscopic density) for non-crystalline materials is sometimes hard to obtain when the sample contains microscopic grains and/or pores. This is also the case for crystalline materials that contain atomic scale defects. We propose a method for the determination of the microscopic density of an amorphous sample from total scattering data. Theoretically, the microscopic density can be calculated from the slope of the pair distribution function G(r) in the short-distance region from zero to the nearest neighbor. However, the observed G(r) in this region is greatly affected by unphysical modulation of the experimental scattering data and the derived structure factor S(Q). As a result, the estimated microscopic density has a large uncertainty. The proposed method removes the unphysical modulation of S(Q) and obtains a G(r) that satisfies theoretical conditions only using the coherent scattering intensity and the first neighbor distance. We have applied the present method to SiO2 glass, crystalline Ni powders, and a set of data from germinate glasses whose densities have been reported. The results of the present method are consistent with the reported values within ±5%.

Electrochemical hydrogenation of Ti–Ni powder mechanochemically alloyed with titanium

The paper reports the results of the study aimed to increase the Ti2Ni phase content in Ti–Ni powder by mechanochemical alloying with titanium and subsequent heat treatment. The interaction of the alloyed Ti–Ni powder with hydrogen was investigated. It is shown that before mechanochemical alloying the phase composition of Ti–Ni powder included three phases: TiNi (B2, B19’), Ti2Ni, and Ni3Ti. After mechanochemical alloying followed by heat treatment, Ti–Ni powder contained TiNi (B2, B19’) and Ti2Ni phases, where the latter phase was of different genesis. Ti2Ni (I) phase was present in Ti–Ni powder before mechanochemical alloying; its unit cell size after alloying with titanium remained unchanged and was equal to 1.1283 ± 5 × 10−4 nm Ti2Ni (II) phase was formed during mechanochemical alloying; its lattice parameter decreased as the Ti content in Ti–Ni powder during alloying increased. Electrochemical hydrogenation of the Ti–Ni (85 wt%) – Ti (15 wt%) powder mixture increased the cell size of both Ti2Ni (I) and Ti2Ni (II), which indicates the interaction of hydrogen with both Ti2Ni phases. The Ti2Ni (I) cell volume increased by 0.3% due to solid solution formation, and the Ti2Ni (II) cell volume increased by 17.6% due to hydride formation. The Ti2Ni (II) phase formed by mechanochemical alloying is more prone to interact with hydrogen with the formation of Ti2NiHx hydride than with the Ti2Ni (I) phase present in Ti–Ni powder before alloying. The number of hydrogen atoms in chemical formulas of Ti2Ni (II)-based hydride was determined. Hydrogenation of the Ti–Ni (85 wt%) – Ti (15 wt%) powder mixture for 90 min caused formation of Ti2NiH1.9 hydride; 360 min hydrogenation yielded Ti2NiH2.8 hydride.

Microstructure evolution and tensile properties tailoring of graphene nanoplatelets/nickel composites fabricated by two-step 3D vibration milling

Uniformly dispersing graphene nanoplatelets (GNPs) with well-preserved structure into matrix is essential for pursuing high-performance nickel (Ni) based composites reinforced by GNPs. In this study, a two-step 3D vibration milling strategy was proposed to prepare GNPs/Ni composites with evenly-dispersed and slightly damaged GNPs. During step I milling, GNPs were exfoliated by Ni powders from graphite balls and initially distributed on powder surfaces synchronously. Followed by step II milling with zirconia balls, the uniform dispersion and thinner thickness of exfoliated GNPs were promoted, while the increased damage to GNPs was induced at higher vibration frequencies. The improved milling frequency boosted deformation of Ni powders and resulted in fine-grained matrix. The GNPs/Ni composites milled at 15 Hz in step II demonstrated a combination between homogeneously distributed GNPs with less defects and refined grains, thus actualizing the superior tensile strength (592 MPa) and ductility (30.6%). Therefore, it is feasible to tailor the microstructure and achieve exceptional mechanical properties for GNPs reinforced metal matrix composites by adjusting proper frequency in the two-step 3D vibration milling strategy.

The Influence of Discharge Mode on Morphology of Al–Ni Nanoparticles Prepared by Underwater Electrical Wire Explosion

We report the results of experiments investigating the influence of discharge mode on morphology of Al–Ni bimetallic nanoparticles prepared by underwater electrical explosion (UEE) of intertwined Al/Ni wire. The experiments were conducted using a pulsed power generator with the stored energy of [Formula: see text][Formula: see text]J (underheat mode) and [Formula: see text][Formula: see text]J (overheat mode), delivering to the intertwined Al/Ni wire a [Formula: see text][Formula: see text]kA current rising during [Formula: see text]s. By analyzing electrical signals, we conclude that there exists a competitive process between Al wire and Ni wire, and the latter always lags behind the former in various stages, duo to the difference of electrical resistivity. Using transmission electron microscope (TEM) and energy dispersive spectroscopy (EDS), the morphology and element composition of nanopowders obtained at underheat mode and overheat mode were studied. The results reveal that core-shell structured Al–Ni nanoparticles can be easily obtained at underheat mode, due to the mismatched specific surface energy and matching lattice type between aluminum and nickel. Besides, the Al–Ni powder prepared by underwater electrical wire explosion (UEWE) has a smaller particle size (less than 100[Formula: see text]nm) and more consistent particle size distribution compared with traditional preparation methods. These results show that UEWE is very attractive for the preparation of Al–Ni nanopowders, which is helpful in improving the specific surface area of Raney–Ni catalyst.

Ni composites reinforced with ultrafine and uniform TiCx and Cr3C2 particles in situ: Enhanced properties and a well-matched interface

Ni composites were reinforced with ultrafine and uniform TiCx and Cr3C2 particles in situ via reactive pressure sintering using 15 vol%Ti2AlC, 15 vol%Cr2AlC, Ni powders. An improved powder preparation process through high-energy ball milling and freeze drying was adopted. Ultrafine TiCx or Cr3C2 particles (about 200 nm) were combined with about 320 nm Ni grains within a uniform microstructure. Considering the matrix grains, intragranular nanoscale TiCx and Cr3C2 were found in Ni grains, with a dispersed distribution of γ′-Ni3(Al,Ti) nanospheres. The interface between Ni and TiCx was semicoherent, whereas Cr3C2 and Ni had a well-matched interface. Ni composites dispersedly strengthened by in situ uniformly distributed TiCx and Cr3C2 with a high ceramic fraction of about 15 vol% possess noticeable 1.378 GPa yield strength. This strategy can be used to design ultrafine, uniform, high-performance composites for structural application.

THE INFLUENCE OF ULTRASOUND ACTIVATION ON MICROSTRUCTURE AND HARDNESS OF POROUS Ni-Ti SHAPE MEMORY ALLOYS

A Ni-Ti shape memory alloy with a porous structure is obtained by the method of self-propagating high-temperature synthesis (SHS) and investigated the possibility of changing its microstructure and hardness. The research aimed to study the changes in the microstructure and hardness of the Ni-Ti shape memory alloy with a porous structure when the Ni and Ti metal powders are preliminarily subjected to ultrasound activation for different periods. The microstructure of the alloy surfaces was studied with using a Hitachi scanning electron microscope (SEM), and the hardness was measured with a Brinell electronic hardness tester. The results of the experiments showed that the porosity and hardness of the Ni-Ti alloy enlarged with an increase in the time of ultrasound activation of the components. The innovative aspect of this study is that prior to the synthesis of powder elements with a purity of Ni 99.9% and Ti 99.9% with an average particle size of 40 μm, they were previously subjected separately to ultrasound activation at different periods.

Fabrication of Pressure Conductive Silicone Rubber Socket Device by Shape-Controlled Nickel Powders Produced by High-Energy Ball Milling.

The pressure conductive silicone rubber socket (PCR) is one of the promising test socket devices in high-speed testing environments. In this study, we report highly dense PCR device channels comprised of high aspect-ratio flake-shaped Ni powders. The shape-controlled Ni powders are prepared by the high-energy milling process. The scanning electron microscopy (SEM) and particle size analyzer (PSA) results of the synthesized powder samples showed well-defined flake type Ni powder morphology, and the powder sizes are distributed in the range of ~24–49 μm. The cross-sectional SEM study of the fabricated PCR revealed that the channels consisting of flake Ni powder are uniformly, densely distributed, and connected as face-to-face contact. The resistance of the PCR channels comprised of flake-shaped Ni powders showed ~23% lower resistance values than the spherical-shaped Ni powders-based channels, which could be due to the face-to-face contact of the powders in the channels. The magnetic properties study for the flake-type Ni powder showed a high remanence (~2.2 emu/g) and coercivity (~5.24 mT), owing to the shape anisotropy factor. Finally, the fabricated highly dense and conductive channels of the silicone rubber socket device by shape-controlled Ni powder could be a potential test socket device.

Laser powder bed fusion (LPBF) of NiTi alloy using elemental powders: the influence of remelting on printability and microstructure

PurposeThe purpose of this paper is to investigate the effect of remelting each layer on the homogeneity of nickel-titanium (NiTi) parts fabricated from elemental nickel and titanium powders using laser powder bed fusion (LPBF). In addition, the influence of manufacturing parameters and different melting strategies, including multiple cycles of remelting, on printability and macro defects, such as pore and crack formation, have been investigated.Design/methodology/approachAn LPBF process was used to manufacture NiTi alloy from elementally blended powders and was evaluated with the use of a remelting scanning strategy to improve the homogeneity of fabricated specimens. Furthermore, both single melt and up to two remeltings were used.FindingsThe results indicate that remelting can be beneficial for density improvement as well as chemical and phase composition homogenization. Backscattered electron mode in scanning electron microscope showed a reduction in the presence of unmixed Ni and Ti elemental powders in response to increasing the number of remelts. The microhardness values of NiTi parts for the different numbers of melts studied were similar and ranged from 487 to 495 HV. Nevertheless, it was observed that measurement error decreases as the number of remelts increases, suggesting an increase in chemical and phase composition homogeneity. However, X-ray diffraction analysis revealed the presence of multiple phases regardless of the number of melt runs.Originality/valueFor the first time, to the best of the authors’ knowledge, elementally blended NiTi powders were fabricated via LPBF using remelting scanning strategies.

Study of microstructure and properties of in-situ alloyed AlCoCrFeNi(Y) high-entropy alloy by laser directed energy deposition method

In this study, the equimolar AlCoCrFeNi(Y) high entropy alloy (HEA) was obtained through in-situ alloying by laser directed energy deposition (DED) method. The in-situ alloying route was designed to be economical and flexible such that a commercial cobalt-rich powder for thermal spray applications was used as the base powder, supplemented with additional elemental Al, Fe, Cr and Ni powders. For the obtained AlCoCrFeNi(Y) HEA, two phases of cubic crystal structures were identified which are Pm3¯m (221) ordered B2 and Im3¯m (229) disordered A2 BCC structures. Morphology of the resultant material was dominated by dendritic microstructure. Elongated grains with an average area of 327.1 μm2 growing in zigzag pattern along the deposition direction were observed. The average microhardness was measured to be 635.6 HV0.5. More importantly, the presence of twin boundaries was identified by the peaks in grain misorientation angle distribution at 39° and 60°. The crystallographic study also discovered fiber texture with 45° twist from <100> direction. In addition, the findings about microstructure, texture and microhardness of AlCoCrFeNi(Y) sample were compared with the results obtained by literature studies on similar HEAs, and the differences were analysed and discussed.

Effects of Sulfur and Phosphorus on Binder Decomposition Behavior of Nickel Powder

Fine Ni particles are utilized as internal electrode materials for multilayer ceramic capacitors. Despite extensive research, the effects of the surface properties (additional elements) remain unclear. To the best of our knowledge, the present study is the first to demonstrate the effects of the addition of sulfur (S) and phosphorus (P) on surface modification and binder decomposition during the production of fine Ni particles. Scanning electron microscopy, X-ray diffractometry, thermogravimetry-differential thermal analysis, hydrogen temperature-programmed reduction, temperature-programmed decomposition, and X-ray photoelectron spectroscopy were performed to analyze non-doped Ni, S-doped Ni and P-doped Ni powder. S existed as S–O or Ni–S on the particle surface in the S-doped Ni powder, whereas P existed solely as P–O on the particle surface in the P-doped Ni powder. When formed into a paste with these powders, the decomposition temperature of the binder is lower than that of the binder alone owing to the catalytic effect of the unmodified surface of Ni in non-doped Ni. However, the catalyst poisoning effect of S in S-doped Ni and the coating effect of P–O in P-doped Ni suppressed the lowering of the binder decomposition temperature due to the catalysis of the Ni surface. The results of the present study are expected to inspire future research on the optimization of the manufacturing process of multilayer ceramic capacitors.

Fabrication of Al-Ni-Al2O3 metal matrix composite coating on AA1100 wrought aluminium alloy by Gas Tungsten Arc (GTA) coating technique

The present paper describes about the Al-Ni-Al2O3 composite coating, which was developed on AA1100 aluminium alloy by gas tungsten arc (GTA) cladding method. The coating was developed by use of different composition of Al, Ni and Al2O3 mixed powders. Scanning electron microscopy (SEM) with energy dispersive x-ray (EDS) and x-ray diffractometry (XRD) were used to examine the microstructure and phase formation of the coating. Vickers microhardness and dry sliding wear test were used to study the mechanical and tribological properties of the coated layer under various normal loading conditions. It was observed that the increase in percentage composition of Al2O3 improved the metallurgical and mechanical properties of the coated layer. It was found that due to the development of Al2O3 reinforced intermetallic matrix composite the hardness and wear resistance of coated layer increased as compare to the AA11000 aluminium alloy substrate. It was also found that due to these phases the coefficient of friction of coated layer was lower than the substrate and the wear resistance of coated layer was higher than that of the substrate. The maximum hardness of coated layer was found to be nearly 26 times higher than that of the AA1100 aluminium alloy substrate. Also, the wear resistance of coated layer was nearly five to eight times higher than that of the AA1100 aluminium alloy substrate.

Process optimization and thermodynamic modeling of weld zone in nickel powder-added dissimilar pulsed-laser NiTi/ASS joint

Dissimilar joining of NiTi alloys to stainless steel has attracted abundant consideration. In this research, pure nickel powder diluted in PVA adhesive was added to the joint area with different concentrations to eliminate or minimize the brittle intermetallic compounds. Also, thermodynamic concepts of phase stability employing the quaternary CALPHAD method were used to calculate the weld zone's phase stability. The results indicated that laser welding combined with 30% nickel powder addition did not have a noteworthy effect on detracting the content of Fe2Ti in the weld zone. In contrast, adding nickel powder with a concentration of 50% reformed the chemical composition and changed the Fe2Ti primary solidifying phase to more ductile phases of Ni3Ti and γ. The results of equilibrium thermodynamic calculations also predicted that Ni3Ti, γ, and B2-(Fe,Ni)Ti phases are possible to form in this condition. In laser welding with 70% nickel powder, unmixed nickel areas and gas porosities were observed in the weld zone. The superlative mechanical properties were obtained for the samples with 50% nickel powder addition. The microhardness results revealed a diminution of the weld zone's average hardness from 667 HV (without nickel powder addition) to 325 HV (50% nickel powder addition). Evaluation of joint strength revealed the twofold increase in 50% nickel powder added joints compared with conventional samples; the fracture strength and fracture strain reached 310 MPa and 2.9%, respectively. Therefore, Ni powder addition is an effective process for improving the mechanical properties of dissimilar joints of these two alloys.

Microstructural evolution and mechanical properties of TiC-containing WC-based cemented carbides prepared by pressureless melt infiltration

WC-based cemented carbides with different amounts of TiC (0.9, 1.2, 1.5, 1.8 and 2.1 wt%) were synthesized by pressureless melt infiltration at 1200 °C for 90 min in vacuum furnace using Cu–10Ni–5Mn–3Sn binder alloy and cast WC, Ni and TiC powders. The microstructural evolution, new phase formation, and related mechanical properties of melt infiltrated alloys were investigated. Results revealed that partially-cast WC and TiC decomposed and formed Ni2W4C, W, (Ti,W)C1-x and annular-structured solid solution when the content of TiC was in the range of 1.2–2.1 wt%, whereas Ni2W4C and W were not observed in the alloy with 0.9 wt% TiC. Annular-structured solid solution was characterized by high carbon with relatively small amounts of W and/or Ti. An increase in TiC content promoted the formation and growth of Ni2W4C and (Ti,W)C1-x phases. However, the annular structure with a continuous network developed into discontinuous net-like distribution and gradually disappeared. Addition of an appropriate amount of TiC improved the Rockwell hardness (HRA) and transverse rupture strength (TRS); however, the impact toughness always decreased with the addition of more amount of TiC. The alloys with 1.8 wt% TiC, 1.5 wt% TiC, and 0.9 wt% TiC exhibited the best mechanical properties with Rockwell hardness of 93.6 HRA, TRS of 1823.4 MPa, and impact toughness of 6.33 J cm−2, respectively.

Fabrication of Ni-Rich 58NiTi and 60NiTi from Elementally Blended Ni and Ti Powders by a Laser Powder Bed Fusion Technique: Their Printing, Homogenization and Densification.

Compared to the equiatomic or near-equiatomic NiTinol alloys, Ni-rich NiTi alloys are suitable to be employed in structural applications as they exhibit higher hardness and are dimensionally stable. This research aimed to process two different grades of Ni-rich NiTi alloys, 58NiTi and 60NiTi, from Ni–Ti powder mixtures having about 58 wt.% and 60 wt.% Ni, respectively. This was performed by a laser powder bed fusion technique. At the first stage of this research, the printability of the used powder mixtures was investigated by applying different sets of printing parameters. Two appropriate sets were then selected to print the samples. Microstructural study of the printed parts revealed the existence of inhomogeneity in the microstructures. In addition, depending on the applied set of parameters, some amounts of cracks and pores were also present in the microstructure of these parts. Postprinting hot isostatic pressing procedures, performed at different temperatures, were developed to cause the reaction of phases, homogenize the parts, and possibly eliminate the existing flaws from the samples. Effects of these applied treatments on the microstructure, phase composition, density, dimensional integrity, and hardness of parts were sequentially studied. In essence, 58NiTi and 60NiTi parts having phase compositions complying with those of the equilibrium phase diagram were obtained in this research. However, the mentioned cracks and pores, formed in the microstructure of as-printed parts, could not be fully removed by postprocessing treatments.

Synthesis, and characterization of metallic glassy Cu–Zr–Ni powders decorated with big cube Zr2Ni nanoparticles for potential antibiofilm coating applications

Biofilms, are significant component that contributes to the development of chronic infections, especially when medical devices are involved. This issue offers a huge challenge for the medical community since standard antibiotics are only capable of eradicating biofilms to a very limited degree. The prevention of biofilm formation have led to the development of a variety of coating methods and new materials. These methods are intended to coat surfaces in such a way as to inhibit the formation of biofilm. Metallic glassy alloys, in particular, alloys that include copper and titanium metals have gained popularity as desirable antibacterial coating. Meanwhile, there has been a rise in the use of the cold spray coating technique due to the fact that it is a proper approach for processing temperature-sensitive materials. The present study was carried out in part with the intention of developing a new antibiofilm metallic glassy consisting of ternary Cu–Zr–Ni using mechanical alloying technique. The spherical powders that comprised the end-product were utilized as feedstock materials for cold spray coatings to stainless steel surfaces at low temperature. When compared to stainless steel, substrates coated with metallic glassy were able to significantly reduce the formation of biofilm by at least one log.

A Tungsten Heavy Alloy with Enhanced Performance Prepared by Spark Plasma Sintering from Fine Spherical Tungsten Powders

Traditional tungsten heavy alloys (WHAs), with a coarse liquid‐phase sintered microstructure, have moderate strength and excellent ductility. Grain refinement is one of the effective methods to improve the strength of these WHAs. The routine spark plasma sintering (SPS) method can refine W grains; however, the obtained typical solid‐state sintered microstructure is detrimental to the performance. Adapted SPS methods such as cyclic SPS and transient liquid‐phase SPS, proposed in the previous study, are capable of modifying W grain morphology to further enhance the performance of parts. They are, however, complex processes, especially when it comes to mass production. In this research, 93W–5.6Ni–1.4Fe heavy alloys (93WHAs) with similar liquid‐phase sintered microstructure are prepared via SPS at solid‐state sintering temperature using fine spherical W powders as raw materials. The influences of the W powder shape and powder mixing condition on the microstructural and mechanical properties of the prepared 93WHAs are investigated. An improved microstructure is obtained in the 93WHA prepared using spherical W powders blended with nano Ni and Fe powders as raw materials, as compared to using the irregular W powders. The alloy thus shows elevated mechanical properties, due to the improved matrix phase distribution and the W grain morphology.

Investigation on mechanical properties of ZTA+ Cr3C2 + Ni reinforced EN31 steel-based composite material: Micromechanical finite-element analysis

The present investigation deals with the development of EN31 steel-based metal matrix composite material under the ultrasonic vibration effect by providing 20 kHz frequency. In the process of the development of composite material, primary and secondary reinforcement has been taken as zirconia toughened alumina (ZTA) and Cr3C2 (chromium (II) carbide), respectively. The Ni has also been taken as dissolving reinforcement material and its weight percentage (wt.%) is kept constant at 2.5%. The variation in ZTA weight percentage was selected between 1.25% and 10%. Furthermore, the weight percentage of Cr3C2 has been kept constant (2.5 wt.%) throughout the development of different composite samples. The microstructural investigation indicated the fair distribution of reinforcement particles up to the 3.75 wt.% of ZTA, developed with the ultrasonic vibration effect. Furthermore, the addition of 2.5 wt.% of nickel in the EN31 steel has improved the wettability of ZTA and Cr3C2 particles. The best values of hardness (254.22 BHN) and tensile strength (892.15 MPa) were achieved with the composition of EN31/3.75 wt.% ZTA/2.5 wt.% Cr3C2/2.5 wt.% Ni composite material sample. Furthermore, the tensile strength and hardness of EN31 steel matrix material were improved by about 45.065% and 100.36% respectively. The addition of ZTA and Cr3C2 decreases the ductility of EN31 steel matrix material. The addition of 2.5wt.% Ni powder with ZTA+ Cr3C2 improved the ductility of EN31 steel. The results revealed that the mechanical properties (tensile strength, hardness, and ductility) of the developed composite material were further improved after performing the heat treatment process. Furthermore, an approach has been made to investigate the micro-mechanical deformation of EN31/3.75 wt.% ZTA/2.5 wt.% Cr3C2 metal matrix composite representative volume element (size: 225 × 225 × 225 nm) with finite-element analysis (FEA). The maximum stress (895.60 MPa) is generated at matrix–particle interfaces, which is the main reason for failure. The percentage difference between FEA and experimental results was less than 10%.