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The use of reducing agents such as sodium borohydride have been used in a wide variety of chemical reactions from organic compounds synthesis to metal production. In order to reduce metal ions into the metallic state, the solution electrochemical potential must be sufficiently low to allow the metal to accept electrons from the reducing agent. One information source that gives important information regarding the conditions necessary for spontaneous aqueous nickel metal reduction is the electroless nickel plating literature. Although nickel is not the only desired metal, it provides an important starting point in metal reduction, and it is useful because of its resistance to corrosion. The electroless nickel plating literature indicates that sodium hypophosphite, sodium borohydride, and hydrazine are all used as reductants. Sodium hypophosphite is usually used at 30--95 C in a bath containing dissolved nickel sulfate and other additives such as oxalic acid and ammonium chloride. Sodium borohydride is usually used with sodium hydroxide in a similar temperature range. Hydrazine is also used with sodium hydroxide in a similar temperature range. However, in order to make the transition from electroless nickel deposition to spontaneous metal powder production requires different conditions. In this research program, a number of different conditions were examined to determine optimum conditions for the production of metal and metal alloy powders in aqueous solutions

Methods for preparation of extremely fine superalloy powders and fabrication to superalloy parts. Final report, October 1, 1995--February 15, 1998