High-entropy alloys (HEAs) have been reported to have better properties than conventional materials; however, they are more expensive due to the high cost of their main components. Therefore, research is needed to reduce manufacturing costs. In this study, CoCrFeMnNi HEAs were prepared using metal injection molding (MIM), which is a powder metallurgy process that involves less material waste than machining process. Although the MIM-processed samples were in the face-centered cubic (FCC) phase, porosity remained after sintering at 1200°C, 1250°C, and 1275°C. In this study, the hot isostatic pressing (HIP) process, which considers both temperature (1150°C) and pressure (150 MPa), was adopted to improve the quality of the MIM samples. Although the hardness of the HIP-treated samples decreased slightly and the Mn composition was significantly reduced, the process effectively eliminated many pores that remained after the 1275°C MIM process. The HIP process can improve the quality of the alloy.

The emergence of ferrous-medium entropy alloys (FeMEAs) with excellent tensile properties represents a potential direction for designing alloys based on metastable engineering. In this study, an FeMEA is successfully fabricated using laser powder bed fusion (LPBF), a metal additive manufacturing technology. Tensile tests are conducted on the LPBF-processed FeMEA at room temperature and cryogenic temperatures (77 K). At 77 K, the LPBF-processed FeMEA exhibits high yield strength and excellent ultimate tensile strength through active deformation-induced martensitic transformation. Furthermore, due to the low stability of the face-centered cubic (FCC) phase of the LPBFprocessed FeMEA based on nano-scale solute heterogeneity, stress-induced martensitic transformation occurs, accompanied by the appearance of a yield point phenomenon during cryogenic tensile deformation. This study elucidates the origin of the yield point phenomenon and deformation behavior of the FeMEA at 77 K.

Aluminum alloy-based additive manufacturing (AM) has emerged as a popular manufacturing process for the fabrication of complex parts in the automotive and aerospace industries. The addition of an inoculant to aluminum alloy powder has been demonstrated to effectively reduce cracking by promoting the formation of equiaxed grains. However, the optimization of the AM process parameters remains challenging owing to their variability. In this study, the response surface methodology (RSM) was used to predict the crack density of AM-processed Al alloy samples. RSM was performed by setting the process parameters and equiaxed grain ratio, which influence crack propagation, as independent variables and designating crack density as a response variable. The RSM-based quadratic polynomial models for crack-density prediction were found to be highly accurate. The relationship among the process parameters, crack density, and equiaxed grain fraction was also investigated using RSM. The findings of this study highlight the efficacy of RSM as a reliable approach for optimizing the properties of AM-processed parts with limited experimental data. These results can contribute to the development of robust AM processing strategies for the fabrication of highquality Al alloy components for various applications.

High-entropy alloys (HEAs) are attracting attention because of their excellent properties and functions; however, they are relatively expensive compared with commercial alloys. Therefore, various efforts have been made to reduce the cost of raw materials. In this study, MIM is attempted using coarse equiatomic CoCrFeMnNi HEA powders. The mixing ratio (powder:binder) for HEA feedstock preparation is explored using torque rheometer. The block-shaped green parts are fabricated through a metal injection molding process using feedstock. The thermal debinding conditions are explored by thermogravimetric analysis, and solvent and thermal debinding are performed. It is densified under various sintering conditions considering the melting point of the HEA. The final product, which contains a small amount of non-FCC phase, is manufactured at a sintering temperature of 1250oC.

The process optimization of directed energy deposition (DED) has become imperative in the manufacture of reliable products. However, an energy-density-based approach without a sufficient powder feed rate hinders the attainment of an appropriate processing window for DED-processed materials. Optimizing the processing of DEDprocessed Ti-6Al- 4V alloys using energy per unit area (Eeff) and powder deposition density (PDDeff) as parameters helps overcome this problem in the present work. The experimental results show a lack of fusion, complete melting, and overmelting regions, which can be differentiated using energy per unit mass as a measure. Moreover, the optimized processing window (Eeff = 44~47 J/mm2 and PDDeff = 0.002~0.0025 g/mm2) is located within the complete melting region. This result shows that the Eeff and PDDeff-based processing optimization methodology is effective for estimating the properties of DED-processed materials.

In this study, the layered structures of immiscible Fe and Cu metals were employed to investigate the interface evolution through solid-state mixing. The pure Fe and Cu powders were cold-consolidated by high-pressure torsion (HPT) to fabricate a layered Cu-Fe-Cu structure. The microstructural evolutions and flow of immiscible Fe and Cu metals were investigated following different iterations of HPT processing. The results indicate that the HPTprocessed sample following four iterations showed a sharp chemical boundary between the Fe and Cu layers. In addition, the Cu powders exhibited perfect consolidation through HPT processing. However, the Fe layer contained many microcracks. After 20 iterations of HPT, the shear strain generated by HPT produced interface instability, which caused the initial layered structure to disappear.

In this research, a new medium-entropy alloy with an equiatomic composition of FeCuNi was designed using a phase diagram (CALPHAD) technique. The FeCuNi MEA was produced from pure iron, copper, and nickel powders through mechanical alloying. The alloy powders were consolidated via a high-pressure torsion process to obtain a rigid bulk specimen. Subsequently, annealing treatment at different conditions was conducted on the four turn HPT-processed specimen. The microstructural analysis indicates that an ultrafine-grained microstructure is achieved after post-HPT annealing, and microstructural evolutions at various stages of processing were consistent with the thermodynamic calculations. The results indicate that the post-HPT-annealed microstructure consists of a dual-phase structure with two FCC phases: one rich in Cu and the other rich in Fe and Ni. The kernel average misorientation value decreases with the increase in the annealing time and temperature, indicating the recovery of HPT-induced dislocations.

Selective laser melting (SLM), a type of additive manufacturing (AM) technology, leads a global manufacturing trend by enabling the design of geometrically complex products with topology optimization for optimized performance. Using this method, three-dimensional (3D) computer-aided design (CAD) data components can be built up directly in a layer-by-layer fashion using a high-energy laser beam for the selective melting and rapid solidification of thin layers of metallic powders. Although there are considerable expectations that this novel process will overcome many traditional manufacturing process limits, some issues still exist in applying the SLM process to diverse metallic materials, particularly regarding the formation of porosity. This is a major processing-induced phenomenon, and frequently observed in almost all SLM-processed metallic components. In this study, we investigate the mechanical anisotropy of SLM-produced 316L stainless steel based on microstructural factors and highly-oriented porosity. Tensile tests are performed to investigate the microstructure and porosity effects on mechanical anisotropy in terms of both strength and ductility.

In this paper, a new Co10Fe10Mn35Ni35Zn10 high entropy alloy (HEA) is identified as a strong candidate for the single face-centered cubic (FCC) structure screened using the upgraded TCFE2000 thermodynamic CALPHAD database. The Co10Fe10Mn35Ni35Zn10 HEA is fabricated using the mechanical (MA) procedure and pressure-less sintering method. The Co10Fe10Mn35Ni35Zn10 HEA, which consists of elements with a large difference in melting point and atomic size, is successfully fabricated using powder metallurgy techniques. The MA behavior, microstructure, and mechanical properties of the Co10Fe10Mn35Ni35Zn10 HEA are systematically studied to understand the MA behavior and develop advanced techniques for fabricating HEA products. After MA, a single FCC phase is found. After sintering at 900℃, the microstructure has an FCC single phase with an average grain size of 18 μm. Finally, the Co10Fe10Mn35Ni35Zn10 HEA has a compressive yield strength of 302 MPa.

Harmonic structure materials are materials with a core–shell structure having a shell with a small grain size and a core with a relatively large grain size. They are in the spotlight because their mechanical properties reportedly feature strength similar to that of a sintered powder with a fine grain size and elongation similar to that of a sintered powder with a coarse grain size at the same time. In this study, the tensile properties, microstructure, and stretchflangeability of harmonic structure SUS304L made using powder metallurgy are investigated to check its suitability for automotive applications. The harmonic powders are made by mechanical milling and sintered using a spark plasma sintering method at 1173 K and a pressure of 50 MPa in a cylindrical die. The sintered powders of SUS304L having harmonic structure (harmonic SUS304L) exhibit excellent tensile properties compared with sintered powders of SUS304L having homogeneous microstructure. In addition, the harmonic SUS304L has excellent stretch-flangeability compared with commercial advanced high-strength steels (AHSSs) at a similar strength grade. Thus, the harmonic SUS304L is more suitable for automotive applications than conventional AHSSs because it exhibits both excellent tensile properties and stretch-flangeability.

In this study, nanocrystalline nickel powders were cold compacted by a dynamic compaction method usinga single-stage gas gun system. A bending test was conducted to measure the bonding strengths of the compacted regionsand microstructures of the specimen were analyzed using a scanning electron microscopy. The specimen was separatedinto two parts by a horizontal crack after compaction. Density test shows that the powder compaction occurred only inthe upper part of the specimen. Brittle fracture was occurred during the bending test of the compact sample. Dispersionof shock energy due to spalling highly affected the bonding status of the nanocrystalline nickel powder.

Bulk nanostructured copper was fabricated by a shock compaction method using the planar shock wavegenerated by a single gas gun system. Nano sized powders, average diameter of 100 nm, were compacted into the cap-sule and target die, which were designed to eliminate the effect of undesired shock wave, and then impacted with analuminum alloy target at 400 m/s. Microstructure and mechanical properties of the shock compact specimen were ana-lyzed using an optical microscope (OM), scanning electron microscope (SEM), and micro indentation. Hardness resultsshowed low values (approximately 45~80 Hv) similar or slightly higher than those of conventional coarse grained com-mercial purity copper. This result indicates the poor quality of bonding between particles. Images from OM and SEMalso confirmed that no strong bonding was achieved between them due to the insufficient energy and surface oxygenlayer of the powders.

In this study, porous titanium samples were manufactured by space holder methods using two kinds of urea and sodium chloride space holders. Three-dimensional pore structures were obtained by a computed-tomography (CT) tech- nique and utilized for finite element analysis in order to investigate the mechanical properties. The CT-based finite ele- ment analyses were in better agreement with the experimental results than unit cell model-based analyses. Both the experimental and CT-based results showed the same tendency that the elastic modulus decreased with increasing the porosities. The total porosity of the bulk body plays a key role in determining the elastic modulus of porous materials.

Recently, self-propagating high-temperature synthesis (SHS), related to metallic and ceramic powder inter- actions, has attracted huge interest from more and more researchers, because it can provide an attractive, energy-efficient approach to the synthesis of simple and complex materials. The adiabatic temperature Tad and apparent activation energy analysis of different thermit systems plays an important role in thermodynamic studies on combustion synthesis. After establishing and verifying a mathematic calculation program for predicting adiabatic temperatures, based on the thermo- dynamic theory of combustion synthesis systems, the adiabatic temperatures of the NiO/Al aluminothermic system dur- ing self-propagating high-temperature synthesis were investigated. The effect of a diluting agent additive fraction on combustion velocity was studied. According to the simulation and experimental results, the apparent activation energy was estimated using the Arrhenius diagram of ln(v/Tad)~1/Tad based on the combustion equation given by Merzhanov et al. When the temperature exceeds the boiling point of aluminum (2,790 K), the apparent activation energy of the NiO/ Al aluminothermic system is 64 ± 14 kJ/mol. In contrast, below 2,790 K, the apparent activation energy is 189 ± 15 kJ/ mol. The process of combustion contributed to the mass-transference of aluminum reactant of the burning compacts. The reliability of the simulation results was experimentally verified.