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The focus of this study is to explore the potential use of Fe₄₀Ni₆₀/Polyamide 6 (PA6) nanocomposites in engineering applications by providing understanding of how the nanocrystalline (nc) metallic particles are altering physical properties of the polymer and the corresponding reinforcing mechanisms. This is the first study using nc Fe-Ni alloy, which has unique various properties, as a filler for polymers. nc Fe₄₀Ni₆₀ particles were chemically synthesized. The composites with various nanofiller loadings were made by compounding the materials, either by melt mixing (MM) or via solution mixing (SM), and injection molding. The results show that SM composites have remarkable mechanical and thermomechanical properties, but MM ones exhibit deteriorated properties. In addition, morphological and crystalline structure analyses indicate that there is good interfacial interaction between nanofiller and polymer …