The core–shell Al/Fe composite powders were synthesised by electroless plating. The effects of concentration of FeSO4·7H2O, pre-treatment method of aluminium powders, and secondary plating on the preparation of core–shell Al/Fe composite powders were studied. The composite powders were analysed by the X-ray diffraction, a scanning electron microscope, and an energy-dispersive spectrometer. The results indicate that the content of iron in the composite powders could be effectively controlled by adjusting the concentration of FeSO4·7H2O in the plating solution. The pre-treatment of the raw aluminium powders is also a key factor to form a uniform iron layer on the surface of aluminium particles. Furthermore, the density and iron content of the composite powders prepared by secondary plating have been improved.
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