The melting, casting, and welding of the raney nickel alloy (42 pct ni-58 pct al), a methanation catalyst useful in coal gasification, were investigated. Melting was done in graphite crucibles by heating aluminum and adding nickel using a cryolite slag cover. Casting conditions were found to be optimum when the melt temperature ranged from 1,125 deg to 1,200 deg c and the mold temperature ranged from ambient to 250 deg c. Suitable mold materials were found to be quartz, heat-resistant glassware, olivine, and zircon. Welding of the alloy can be accomplished using tungsten inert gas process. Tensile strength of the alloy, in the as-cast condition, was found to be 2,000 lb/sq in with an impact strength of less than 1 ft-lb. The coefficient of thermal expansion was determined to be 18.4 X 10-6/deg c after heat treatment.