A Guide to Nickel Alloys: Exploring Properties, Applications ...

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What is Nickel?

Nickel is a metallic element known for its versatility and strength in the world of chemistry. The following properties make nickel a versatile and indispensable material, driving innovation and progress across a wide range of sectors

&#;Nickel has strong corrosion resistance and its magnetic qualities are integral to the functioning of numerous electronic devices and equipment. Its corrosion resistance ensures longevity in corrosive environments like chemical processing and marine settings.

&#;The strength of nickel plays a critical role in components used in applications demanding structural integrity, notably in aerospace and power generation.

&#;Nickel possesses magnetic properties, making it essential in electronic devices and equipment. This electrical conductivity adds to its utility, making it crucial in electrical connectors and components.

&#;Its exceptional heat resistance makes it ideal for high-temperature applications like gas turbines and nuclear reactors.

Nickel&#;s Melting Point and Physical Properties

Nickel&#;s melting point is a defining feature that holds significant implications in high-temperature applications. With a melting point of approximately 1,455 degrees Celsius (2,651 degrees Fahrenheit), nickel exhibits remarkable stability at elevated temperatures. This property makes it an indispensable element in alloys designed for applications such as gas turbines, aerospace components and industrial furnaces.

Nickel boasts a relatively low density, controlled thermal expansion and excellent thermal conductivity. These characteristics contribute to its effectiveness in heat-resistant materials and heat exchange systems. Understanding how nickel&#;s unique properties align with the demands of high-temperature environments is essential for engineers and researchers seeking to enhance the performance and efficiency of various industrial processes.

Nickel Uses

Nickel alloys represent a versatile and invaluable category of materials, characterised by their unique compositions and exceptional properties. These alloys, primarily composed of nickel but often alloyed with elements like chromium, iron and molybdenum, exhibit a remarkable range of characteristics.

Strength

The strength of nickel alloys is a dynamic quality influenced by their composition and heat treatment. Below are six nickel alloys celebrated for their remarkable strength in various applications:

Inconel® 718: Distinguished for its extraordinary strength, particularly at elevated temperatures, Inconel® 718 stands as a go-to choice in the aerospace and gas turbine industries.

Hastelloy® X: This nickel-chromium-iron-molybdenum alloy has exceptional strength and impressive resistance to oxidation, rendering it ideal for high-temperature environments.

Waspaloy® Prized for its high tensile strength, creep resistance and corrosion resistance, Waspaloy(R) finds widespread use in aerospace and gas turbine engine components.

Incoloy® 800H/HT: These nickel-iron-chromium alloys exhibit outstanding strength and steadfast stability at elevated temperatures, making them indispensable in the petrochemical and nuclear sectors.

Monel® K-500: Monel® K-500 showcases both high tensile strength and impeccable resistance to corrosion, making it a preferred choice for marine and chemical processing equipment.

Rene 41: As a precipitation-hardening nickel alloy, Rene 41 is renowned for its exceptional strength and resistance to creep, often seen in critical aerospace components.

It is essential to recognise that the selection of a specific nickel alloy hinges on the particular requirement of an application, extending beyond strength to encompass factors like corrosion resistance, heat tolerance and more.

Corrosion-Resistant Nickel Alloys

The following nickel alloys are preferred choices in industries where corrosion resistance is paramount, such as chemical processing, oil and gas, and marine applications. Each alloy&#;s unique composition and properties cater to specific corrosive conditions, ensuring the longevity and reliability of critical components.

Monel® 400: This nickel-copper alloy is known for its remarkable resistance to various corrosive elements, including seawater and chemical processing.

Hastelloy® C-276: As a versatile nickel-molybdenum-chromium alloy, Hastelloy C-276 is celebrated for its outstanding resistance to a wide range of aggressive chemicals and acidic solutions.

Inconel(R) 625: Exhibiting excellent corrosion resistance in both high-temperature and acidic environments, Inconel 625 is suitable for applications such as chemical processing and marine engineering.

Alloy 20: Also known as Carpenter 20, Alloy 20 offers superior resistance to corrosion caused by sulfuric acid, as well as other corrosive chemicals and environments.

Incoloy® 825: This nickel-iron-chromium alloy with added copper and molybdenum, provides excellent resistance to corrosive media such as sulfuric and phosphoric acids.

Hastelloy® B-3: With exceptional resistance to hydrochloric acid at all concentrations and temperatures, Hastelloy B-3 is invaluable in chemical processing.

For more details on corrosion-resistant alloys and their applications, refer to our article on various types of corrosion-resistant metals and their uses.

Heat Resistance for High-Temperature Applications

The following alloys are critical in industries where exposure to extreme heat and temperature fluctuations is a constant challenge, such as aerospace, power generation and petrochemical sectors. Their specific properties ensure reliable performance under extreme conditions, making them essential materials for advanced engineering and technology.

Inconel® 600: Inconel® 600 is celebrated for its outstanding resistance to high-temperature corrosion and oxidation. It&#;s widely used in furnace components, heat-treating equipment and aerospace applications.

Hastelloy® X: With its exceptional strength and resistance to oxidation, Hastelloy X excels in high-temperature environments, making it a popular choice in gas turbine engines and industrial furnace applications.

Haynes® 230: This nickel-chromium-tungsten-molybdenym alloy with excellent high-temperature strength and stability is frequently employed in applications like gas turbines and industrial heating equipment.

Incoloy® 800/800H: These nickel-iron-chromium alloys offer impressive resistance to high-temperature environments, making them suitable for heat exchangers, petrochemical processing and nuclear power plants.

Rene 41: Rene 41 is a precipitation-hardening nickel alloy that combines exceptional strength with heat resistance, making it ideal for aerospace components exposed to high temperatures.

Nimonic® 75: Nimonic® 75 is known for its excellent creep resistance and ability to withstand high temperatures. It&#;s used in gas turbine components and high-temperature applications.

Exploring Nickel Alloys: The Science Behind Nickel Alloys

Nickel alloys are carefully designed to harness the exceptional properties of nickel while blending them with other elements to achieve desired performance characteristics. This alloying process involves precise ratios and controlled heat treatments, which optimise the alloy&#;s strength, corrosion resistance, heat resistance or other specific attributes.

The science behind nickel alloys revolves around tailoring their microstructures at the atomic level, enabling them to withstand extreme conditions in various industries. Engineers and scientists continually push the boundaries of materials science to develop nickel alloys with ever-improving properties, making them vital for applications ranging from aerospace to petrochemicals. Understanding the intricacies of nickel alloy composition and microstructure is crucial to unlock their full potential and meet the ever-evolving demands of modern technology.

Applications Across Industries

The role of nickel in alloys is pivotal; it acts as a catalyst, enhancing their properties and overall performance. As a result, nickel alloys find applications in an array of industries, including aerospace, automotive and energy production, showcasing the invaluable contributions of nickel to our modern world. Here is a comprehensive list of applications and industries where nickel alloys play a crucial role:

Aerospace: Nickel alloys are used in aircraft components, engine parts and aerospace equipment due to their high strength, corrosion resistance and heat resistance.

Chemical Processing: Nickel alloys are employed in chemical reactors, pipelines and equipment for their resistance to corrosive chemicals and acids. In chemical manufacturing, nickel alloys are used for reactor vessels, heat exchangers and pipes.

Petrochemical: In the petrochemical industry, nickel alloys are used for valves, heat exchangers, and piping systems to withstand aggressive environments.

Marine: Marine applications include shipbuilding, offshore platforms and seawater handling equipment due to nickel alloys&#; resistance to seawater corrosion.

Power Generation: In power plants, nickel alloys are used in turbines, heat exchangers and boiler components that operate at high temperatures.

Oil and Gas: Nickel alloys find application in drilling tools, wellhead components and downhole equipment due to their resistance to sour gas and high-pressure environments. In mining applications, nickel alloys are used in tools, drilling equipment and conveyor systems due to their wear resistance.

Nuclear: Nickel alloys are deployed in nuclear reactors and spent fuel storage due to their resistance to radiation and high-temperature stability.

Automotive: Employed in exhaust systems, turbochargers and engine components, nickel alloys can improve performance and durability.

Electronics/ Electrical: Nickel alloys are found in electrical connectors and components due to their excellent electrical conductivity. They are employed in electrical heating elements, resistors and conductive wires.

Medical: Within the medical field, nickel alloys are used for implants, surgical instruments, and dental appliances due to their biocompatibility and corrosion resistance.

Food processing: Nickel alloys are utilised in food processing equipment and packaging machinery for their hygiene and corrosion resistance.

Textile: In the textile industry, nickel alloys are deployed in machinery parts for their resistance to abrasion and corrosion.

Electroplating: Nickel alloys are employed in electroplating to provide a corrosion-resistant and attractive finish on various products.

Construction: In construction, nickel alloys find application in architectural facades, roofing and structural components.

Renewable Energy: Within wind turbines and solar panels, nickel alloys are used for their corrosion resistance and durability.

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Characteristics Effects of Alloying Elements

The characteristics and effects of alloying elements such as chromium, molybdenum, titanium and others are pivotal in the realm of materials science and engineering.

Chromium enhances corrosion resistance and forms a protective oxide layer on the surface of alloys like stainless steel.

Molybdenum contributes to increased strength, particularly at elevated temperatures, making it a key element in high-temperature applications such as aerospace components and chemical processing equipment.

Titanium is renowned for its low density and high strength and finds extensive use in aerospace, medical implants and sporting equipment.

Each alloying element imparts specific properties to the base metal, allowing engineers and researchers to tailor materials for diverse applications. Understanding the characteristics and effects of these elements is fundamental to designing and developing materials with desired attributes, whether it&#;s corrosion resistance, strength or heat resistance.

Solid Solution Strengthening: Nickel as a Matrix Precipitation

Solid solution strengthening, with nickel serving as a matrix for precipitation, is a cornerstone of materials engineering. The process involves the incorporation of alloying elements into a nickel matrix:

Carefully selected alloying elements like copper, aluminium or titanium are added to nickel to create a solid solution.

As these elements dissolve into the nickel matrix, they form a homogeneous alloy, effectively blocking dislocation movement within the crystal lattice.

This results in increased strength and hardness, as the presence of these alloying elements hinders the movement within the crystal structure. This material has been made to be exceptionally durable and resistant to deformation.

In industries such as aerospace, where high-strength materials are a necessity, nickel matrix precipitation hardening plays a pivotal role. By optimising the alloy composition and heat treatment, engineers can tailor the material to meet the precise requirements of demanding applications. Understanding the science behind solid solution strengthening with nickel as the matrix is crucial for enhancing performance and longevity in various high-stress environments.

Advantages of Nickel Alloys

The following benefits demonstrate the importance and versatility of nickel alloys across various industries, where their unique properties contribute to enhanced performance and durability:

Corrosion resistance: Nickel alloys are highly resistant to corrosion, making them ideal for applications in corrosive environments such as chemical processing and marine industries.
High Strength: With their excellent strength, especially at elevated temperatures, nickel alloys can ensure structural integrity in demanding conditions.
Heat Resistance: Nickel alloys can withstand high temperatures without losing their mechanical properties, making them suitable for use in aerospace, power generation and high-temperature processing industries.
Heat Resistance: Suitable for use in aerospace, power generation and high-temperature processing industries, nickel alloys can withstand high temperatures without losing their mechanical properties.
Versatility: Nickel alloys can be tailored to specific requirements by adjusting their composition, making them versatile for various applications.
Low Thermal Expansion: With their low thermal expansion coefficients, nickel alloys can maintain their shape and dimensions at different temperatures- reducing the risk of warping or distortion.
High Electrical Conductivity: Some nickel alloys have exceptional electrical conductivity, making them suitable for electrical and electronic applications.
Wear Resistance: Nickel alloys are highly wear-resistant, making them suitable for use in mining, manufacturing and construction equipment.
Biocompatibility: Certain nickel alloys are biocompatible, making them suitable for medical implants and surgical instruments.
Magnetic properties: Nickel alloys can be magnetised, making them useful in various magnetic applications.
Longevity: Their resistance to corrosion and wear ensures a longer lifespan for components and structures.
Weight Reduction: In industries like aerospace, nickel alloys can help reduce weight while maintaining strength, contributing to fuel efficiency and performance.
Chemical compatibility: Nickel alloys are compatible with a wide range of chemicals, making them suitable for chemical processing equipment.
Recyclability: Nickel alloys are recyclable, promoting sustainability and reducing the need for new raw materials.
Low Maintenance: Components made from nickel alloys often require minimal maintenance, reducing downtime and maintenance costs.

Navigating the World of Nickel Alloys

Nickel alloys are renowned for their versatility and use in applications across a spectrum of industries, from aerospace to chemical processing. These alloys exhibit exceptional corrosion resistance, strength and heat resistance, making them vital for demanding environments. For expert advice and assistance in choosing the correct nickel alloy, contact NeoNickel today.

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Monel, Incoloy, Inconel and Nimonic are registered trademarks of Special Metals Corporation.
Hastelloy and Haynes are registered trademarks of Haynes International Inc.
Waspaloy is a registered trademark of United Technologies Corp.

What is Nickel?

Nickel, with the symbol Ni and the atomic number 28, is a chemical element. Nickel is a silvery-white, brilliant metallic element that occurs naturally. It is the sixth most prevalent element on the planet and is abundant in the crust and core. Nickel, like iron, is a common element in meteorites and is also found in trace amounts in plants, animals, and oceans.

Despite being the fifth most prevalent element on (and in) our planet, pure nickel reacts with oxygen and is thus rarely found on the surface. Nickel is particularly stable when combined with iron, which explains its presence in iron-bearing ores and its practical use in stainless steel production.

Nickel is extremely strong and corrosion-resistant, making it ideal for reinforcing metal alloys. It&#;s also ductile and malleable, which means its numerous alloys may be formed into wire, rods, tubes, and sheets.

History of Nickel

In , Baron Axel Fredrik Cronstedt isolated pure nickel for the first time, but it had been known for a long time. Chinese texts from circa BC mention &#;white copper,&#; which was almost certainly a nickel-silver alloy.

The metal was dubbed kupfernickel, &#;the devil&#;s copper,&#; by fifteenth-century German miners who believed they could extract copper from nickel ores in Saxony. Due to their futile attempts to extract copper from the ore and likely due to the health effects caused by the ore&#;s high arsenic content.

James Riley gave a talk to the Iron and Steel Institute of Great Britain in about how nickel may be used to improve traditional steel. Riley&#;s talk sparked interest in nickel&#;s good alloying qualities, and it also corresponded with the discovery of huge nickel reserves in New Caledonia and Canada.

In the early twentieth century, the discovery of ore resources in Russia and South Africa made large-scale nickel production viable. World War I and World War II soon followed, resulting in major increases in steel consumption and, as a result, nickels demand.

Alloys of Nickel

Most metals, including copper, chromium, iron, and molybdenum, will easily alloy with nickel. The addition of nickel to other metals changes the properties of the alloy, which can be utilized to achieve desirable attributes like improved corrosion or oxidation resistance, increased high-temperature performance, or reduced coefficients of thermal expansion.

Following are the alloys of nickel:

1. Nickel-Iron Alloys

Nickel-iron alloys are used in applications where a low thermal expansion rate is desirable. The coefficient of thermal expansion of Invar is about a tenth of that of carbon steel.

Nickel-iron alloys are helpful in precise measurement equipment and thermostat rods because of their high dimensional stability. Other nickel-iron alloys with a higher nickel percentage are used in soft-magnetic applications such as transformers, inductors, and memory storage devices.

2. Nickel-Copper Alloys

Nickel-Copper Alloys are nickel-base alloys with a substantial alloying element of copper (Cu) of 29-33 percent. Mono-phase solid solution of copper and nickel. Heat-treatable nickel-copper alloys with 3% aluminum (Al) and 0.6 percent titanium (Ti) as additional alloying elements can be enhanced by precipitation hardening.

Nickel-Copper Alloys have excellent acid and alkali corrosion resistance, high mechanical strength, good flexibility, and a low coefficient of thermal expansion. The alloys have low machinability. Chemical processing equipment, valve stems, springs, pumps, shafts, fittings, heat exchangers, screw machine products, and marine equipment use nickel-copper alloys.

3. Nickel-Chromium Alloys

Corrosion resistance, high-temperature strength, and electrical resistance are desirable properties of nickel-chromium alloys. NiCr 70/30, for example, has a melting point of oC and an electrical resistivity of 1.18-m. Nikrothal 70, Resistohm 70, and X30H70. Nickel-chromium alloys are heating elements in toasters and other electrical resistance warmers. 

4. Nickel-Molybdenum Alloys

Nickel-molybdenum alloys are chemically resistant to strong acids and other reducers such as hydrochloric acid, hydrogen chloride, sulfuric acid, and phosphoric acid. An alloy, such as Alloy B-2, has a molybdenum concentration of 29-30% and a nickel concentration of 66-74 percent in its chemical makeup. Applications include pumps and valves, gaskets, pressure vessels, heat exchangers, and pipe work.

5. Nickel-Chromium-Iron Alloys

Nickel-chromium-iron alloys combine these elements to generate alloys that resist oxidation and high-temperature corrosion. Alloy 800, also known as Incoloy 800, Ferrochronin 800, Nickelvac 800, and Nicrofer , is used in furnace components such as petrochemical furnace cracker tubes and as a sheathing material for electrical heating elements. 

These alloys are also prized for their high-temperature creep and rupture properties. These alloys are typically 30-35 percent nickel, 19-23 percent chrome, and a minimum of 39.5 percent iron. Due to their high iron concentration, these alloys have been categorized as stainless steel.

6. Nickel-Chromium-Cobalt Alloys

Nickel alloys with chromium and molybdenum are added to increase creep rupture strength. Alloy 617, for example, has a composition of 20-24 percent chromium, 10-15 percent cobalt, and 8-10 percent molybdenum, with a minimum nickel concentration of 44.5 percent supplied under the brand names Inconel 617 and Nicole 617.

Industrial furnace components, gas turbines, nitric acid catalyst grid supports, and fossil fuel production facilities require these alloys.

7. Nickel-Chromium-Molybdenum Alloys

Alloy C-276 (N) is the most well-known of these corrosion-resistant alloys. They have a high resistance to reducing acids like hydrochloric and sulphuric acid. Several variations based on this composition have changed the Cr and Mo amounts and, in some cases, added Cu or W to increase corrosion resistance in more oxidizing or reducing environments. Alloy C-22 (N), Alloy 59 (N), Alloy C- (UNS N), and Alloy 686 (N) are some of the alloys available.

8. Nickel-Titanium Alloys

Shape retention and shape memory qualities are seen in nickel-titanium alloys. By making a shape out of this alloy at a higher temperature and then deforming it from that produced shape at a lower temperature, the alloy will remember its original shape and reform it when heated to this so-called transition temperature. 

The transition temperature can be changed by manipulating the alloy&#;s composition. These alloys have a super elastic feature that can be used as a shock absorber for stone constructions, among other things.

Ores of Nickel

1. Sulfides

Sulfides containing nickel, copper, and iron are found in Canadian ores. Pentlandite (Ni, Fe)9S8  is the most important nickel mineral, followed by pyrrhotite (FeS to Fe7S8), in which some of the iron is replaced by nickel. The primary copper mineral in these ores is chalcopyrite (CuFeS2) and cubanite (CuFe2S3).

There is also some gold, silver, and the six platinum-group metals, and their recovery is crucial. Cobalt, selenium, tellurium, and sulfur can all be extracted from ores.

2. Laterites

Laterites are ore that forms due to peridotite weathering with a minor fraction of nickel. In subtropical climates, weathering eliminates most of the host rock, but the contained nickel dissolves and percolates downstream, potentially reaching a high concentration to make mining profitable. 

Manufacturing of Nickel

Nickel is recovered principally from the nickel sulfides pentlandite, pyrrhotite, and millerite, containing approximately 1% nickel, and the iron-bearing lateritic ores limonite and garnierite, which contain around 4% nickel.

The nickel separation process is largely dependent on the ore type. Nickel sulfides, such as those found in the Canadian Shield and Siberia, are typically found deep below, making extraction difficult and costly.

However, the separation method for these ores is significantly less expensive than for lateritic ores like those found in New Caledonia. Furthermore, nickel sulfides frequently contain impurities of other precious elements that can be extracted economically.

Nickel matte and nickel oxide can be made from sulfide ores by froth flotation, hydrometallurgical, or magnetic methods. The Sherritt-Gordon Treat is routinely used to process further these intermediate products, which typically contain 40-70 percent nickel.

The Mond (or Carbonyl) Process is most popular and efficient technique for treating nickel sulfide is the Mond (or Carbonyl) Process. The sulfide is treated with hydrogen and fed into a volatilization kiln in this procedure. At around 60 0C, it reacts with carbon monoxide to generate nickel carbonyl gas. 

The nickel carbonyl gas decomposes on the surface of pre-heated nickel pellets that circulate through a heat chamber until they reach the necessary size. This procedure can be used to make nickel powder at greater temperatures.

Because of their high iron content, lateritic ores are frequently smelted using pro-metallic techniques. Because lateritic ores have high moisture content (35-40%), they must be dried in a rotary kiln furnace. It generates nickel oxide, which is reduced in electric furnaces at temperatures ranging from ( 0C - 0C and volatilized to produce Class I nickel metal and nickel sulfate.

Properties of Nickel

• Nickel is ferromagnetic, meaning it magnetizes easily at ambient temperature. 
• It is both malleable and ductile.
• Nickel has an atomic number of 28.
• Nickel&#;s resistance to heat, oxidation, and corrosion is one of its finest qualities.
• It is silver-white with a golden color.
• Nickel has a melting point of °C, and a boiling temperature of about °C nickel reacts with oxygen in its pure state.

Uses of Nickel

This natural element is now used in various applications, making it one of the most important metals. Some of the nickel&#;s important uses are listed below:

• Stainless steel uses over 65% of all nickel produced. 
• Nickel-metal hydride and rechargeable nickel-cadmium batteries are two types of batteries that contain the nickel element.
•  Hand-held power tools, camcorders, scanner radios, guitar strings, laptops, and cellular and cordless telephones are just a few examples of daily devices that contain nickel. 
• Desalination plants typically use a copper-nickel alloy to convert seawater to freshwater. 
•  Nickel is a good material for making wires because of its malleability and flexibility. 
• In gas turbines and parts of jet engines, superalloys made by combining nickel with iron or cobalt are employed.
• The nickel dimethylglyoxime compound is used as a colorant in cosmetics, paints, and some polymers.
• Nickel is also used for electroplating other metals using this natural material.

Advantages of Nickel

Nickel is classified as a transition metal. Because of its slow oxidation rate at normal temperatures, it is hard, malleable, and corrosion-resistant. It&#;s also magnetic at ambient temperature and has a high melting point.

Disadvantages of Nickel

If too much nickel enters the human body, it has negative consequences like many other metals on the planet. For starters, inhaling certain nickel compounds while mining can cause miners to develop life-threatening allergies.

Fibrosis, lung cancer, and other diseases are more common in these employees. When high nickel concentrations accumulate in the air, soil, food, or water supply, humans are in danger of poisoning.

Conclusion

Nickel is a strong, shiny, silvery-white metal common in our daily lives, appearing in everything from television remote batteries to stainless steel kitchen sinks. Although many nickel alloys, including stainless steel, are safe to work with, additional care must be taken to protect the safety of people working with some other nickel compounds, including metallic nickel, because they have been linked to cancer.

References: 

1. Chemistry of Nickel &#; Chemistry LibreTexts. (, October 2). Chemistry LibreTexts; chem.libretexts.org. https://chem.libretexts.org/Bookshelves/Inorganic_Chemistry/Supplemental_Modules_and_Websites_(Inorganic_Chemistry)/Descriptive_Chemistry/Elements_Organized_by_Block/3_d-Block_Elements/Group_10%3A_Transition_Metals/Chemistry_of_Nickel
2. Types of Nickel Alloys and their Properties. (n.d.). Types of Nickel Alloys and Their Properties; www.thomasnet.com. Retrieved May 21, , from
3. A Look at Nickel Metal: It&#;s Properties, History, and Production & Uses. (, July 28). ThoughtCo; www.thoughtco.com. https://www.thoughtco.com/metal-profile-nickel-
4. Uses of Nickel | Supply, Demand, Production, Resources. (n.d.). Uses of Nickel | Supply, Demand, Production, Resources; geology.com. Retrieved May 21, , from https://geology.com/usgs/uses-of-nickel/
5. Pedersen, T., & @Live Science. (, September 23). Facts About Nickel | Live Science. Livescience.Com; www.livescience.com. https://www.livescience.com/-nickel.html
6. Nickel | Definition, Properties, Symbol, Uses, & Facts. (n.d.). Encyclopedia Britannica; www.britannica.com. Retrieved May 21, , from https://www.britannica.com/science/nickel-chemical-element

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