Abstract This study explores the potential application of the mechanical activation (MA) of nickel powder for incorporation into the composition of powder wire blends for the deposition of wear-resistant coatings. Nickel powder of PNE-1 grade was processed in a vibrational mill for various durations (4 to 16 min) with different combinations of grinding media. The influence of MA parameters on the bulk density and apparent particle size of nickel powder was investigated. The greatest effect was observed at the maximum processing time of 16 min, where electron microscopy revealed significant deformation and an increase in discoid particles, leading to enhanced energy accumulation. Nickel powder processed with a combination of 6 balls that are 20 mm in diameter and 8 balls that are 10 mm in diameter showed significant changes, though no major alteration in chemical composition was noted. XRMA indicated that the powder’s surface was partially covered with oxides, with a composition of 96.8–98.4% Ni and 0.8–1.7% O 2. Additionally, the effect of nickel powders after the treatment on the structure of deposited metal was determined, demonstrating alterations in the morphology and a slight increase in hardness. Furthermore, a convolutional neural network (CNN)-based approach was proposed to discern fragments within images depicting surface microstructures, both with and without MA. Keywords: mechano-activation; nickel; surfacing; powder wire; microstructure; hardness