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The performance of attractive Ni-based composites can be affected by changing their microstructures, e.g., introducing pores. Here, we report a novel, relatively low-cost process to fabricate Ni/Al2O3 composites with open porosity modified by the size of Al2O3 particles. The mixture of powders was subjected to thermal oxidation twice in air after a maximal temperature of 800 °C was reached in a stepwise manner and maintained for 120 min. The oxidation kinetics were determined thermogravimetrically. The open porosity was evaluated by an Archimedes’ principle-based method. Localization and quantification of NiO, newly formed on the Ni particle surface and acting as a mechanical bonding agent, were explored by scanning electron microscopy with energy dispersive X-ray spectroscopy and X-ray diffractometry. Larger ceramic particles prevented merging of NiO layers on adjacent Ni particles more efficiently; therefore, the open porosity increased from 21% to 24.2% when the Al2O3 particle diameter was increased from 5–20 µm to 32–45 µm. Because both Ni/Al2O3 composites exhibited similar flexural strength, the composite with larger Al2O3 particles and the higher open porosity could be a better candidate for infiltration by molten metal, or it can be directly used in a variety of filtration applications.

Impact of Al2O3 Particle Size on the Open Porosity of Ni/Al2O3 Composites Prepared by the Thermal Oxidation at Moderate Temperatures