In this paper, two kinds of advanced powder processing techniques Metal Injection Molding (MIM) and Direct Laser Forming (DLF) are introduced to fabricate complex shaped Ti alloy parts which are widely used for med- ical and aerospace applications. The MIM process is used to strengthen Ti-6Al-4V alloy compacts by addition of fine Mo, Fe or Cr powders. Enhanced tensile strength of 1030 MPa with 15.1% elongation was obtained by an addition of 4 mass%Cr because of the microstructural modification and also the solution strengthening in beta phase. However, their fatigue strength was lower compared to wrought materials, but was improved by HIP. Subsequently, the effect of feed- ing layer height (FLH) on the characteristics of the DLF compacts was investigated. In the case of 100 µm FLH, sur- face roughness was improved and nearly full density (99.8%) was obtained. Also, tensile strength of 1080 MPa was obtained, which is higher than the ASTM value.

A new PIM in-process joining technique has been developed for more complicated and functional PIM components by application of the exuded wax from the green compacts during solvent debinding step. At first, various stainless steels and iron compacts with rectangular shape were combined, and the joining behaviors and properties were investigated by shear and tensile test, and microscopic observation. Subsequently, perfect joined three pieces of thin and hollow compacts were obtained for the combination of same and different stainless steels, and it was difficult to join the iron and stainless steel compacts in hydrogen atmosphere because of the different starting temperature of shrinkage. However, pretty good joined iron and stainless steel compacts were obtained by consideration of particle size and vacuum atmosphere. Finally, for the combination of ferro-silicon and austenitic stainless steel compacts, high functionality (magnetic (1.60Tes1a) & non-magnetic) and perfect joint were obtained.