Development of high–performance polymer–nickel composites by casting

Additive manufacturing (AM) has emerged as a key technique for the fabrication of high–performance polymer–metal composites (PMCs) in tribological field, which combines the exceptional properties of multiple polymers and achieves the precise structural control. In this study, a new type polymer–nickel composites (PNCs) with superior mechanical properties and wear resistance was developed through the casting method, which overcomes the limitations of PMCs for the high–performance structural applications. The interpenetrating networks composed of thermoplastic elastomers (TPE) and nickel powder are distributed throughout the cast PNCs, ensuring the high strength, ductility and interlayer bonding force. The results demonstrate that the PNCs have high mechanical properties and wear resistance under the heavy–load conditions, showing wide potential in tribological application. Furthermore, the PNCs present the comprehensive performance close to or even exceeding that by the injection molding process, which provides the new insights and technical pathways for the cast PNCs.