CNTs/Al-Li composite was first prepared by hot-pressed sintering from Al-Li alloy powder and CNTs solution, and then the hot compression tests were performed on MMS-100 thermal simulator at strain rate range of 0.01– 10 s− 1, deformation temperature range of 350–500 °C, and total deformation amount of 60%. True stress–strain curves were plotted, and constitutive equation as well as hot processing maps were successfully confirmed based on Arrhenius constitutive model and Prasad instability criterion. Results show that CNTs/Al-Li composite have a very poor hot deformation ability and narrow processing region, which is strain rate range of 0.1–1 s− 1 and deformation temperature range of 360–400 °C. Hot extrusion experiment was carried out and the processing parameters were selected according to the established hot processing map, and an improvement on strength and a good balance between strength and plasticity can be obtained, which is about 650 MPa for tensile strength and 9% for elongation.

Titanium is the ninth most abundant element in the Earth’s crust and is the fourth most abundant structural metal after aluminum, iron, and magnesium. It exhibits a higher specific strength than steel along with an excellent corrosion resistance, highlighting the promising potential of titanium as a structural metal. However, titanium is difficult to extract from its ore and is classified as a rare metal, despite its abundance. Therefore, the production of titanium is exceedingly low compared to that of common metals. Titanium is conventionally produced as a sponge by the Kroll process. For powder metallurgy (PM), hydrogenation-dehydrogenation (HDH) of the titanium sponge or gas atomization of the titanium bulk is required. Therefore, numerous studies have been conducted on smelting, which replaces the Kroll process and produces powder that can be used directly for PM. In this review, the Kroll process and new smelting technologies of titanium for PM, such as metallothermic, electrolytic, and hydrogen reduction of TiCl4 and TiO2 are discussed.

Carbon short fibers/copper composites with different carbon short fiber contents up to 15 wt.% as reinforcements are prepared to investigate the influence of the carbon short fiber surface coating on the microstructure, density, and electrical properties of the carbon short fibers/copper composites. The carbon short fibers were surface treated by acid functionalization followed by alkaline treatment before the coating process. It was observed from the results that coated type copper nanoparticles were deposited on the surface of the carbon short fibers. The surface treated carbon short fibers were coated by copper using the electroless deposition technique in the alkaline tartrate bath by using formaldehyde as a reducing agent of the copper sulfate. The produced coated carbon short fibers/copper composite powders were cold compacted at 600 MPa, and then sintered at 875 °C for 2 h under (hydrogen/nitrogen 1:3) atmosphere. A reference copper sample was also prepared by the same method to compare between the properties of pure copper and the carbon short fibers/copper composites. The phase composition, morphology, and microstructure of the prepared carbon short fibers/copper composite powders as well as the corresponding carbon short fibers/copper composites were investigated using X-ray diffraction analysis (XRD) and scanning electron microscope (SEM) equipped with an energy-dispersive spectrometer (EDS), respectively. The density and the electrical resistivity of the sintered composites were measured. It was observed from the results that the density was decreased; however, the electrical resistivity was increased by increasing the carbon short fibers wt.%.

The automotive industry has focused on the development of metallic materials with high specific strength, which can meet both fuel economy and safety goals. Here, a new class of ultrafine-grained high-Mn steels containing nano-scale oxides is developed using powder metallurgy. First, high-energy mechanical milling is performed to dissolve alloying elements in Fe and reduce the grain size to the nanometer regime. Second, the ball-milled powder is consolidated using spark plasma sintering. During spark plasma sintering, nanoscale manganese oxides are generated in Fe-15Mn steels, while other nanoscale oxides (e.g., aluminum, silicon, titanium) are produced in Fe-15Mn-3Al-3Si and Fe-15Mn-3Ti steels. Finally, the phases and resulting hardness of a variety of high-Mn steels are compared. As a result, the sintered pallets exhibit superior hardness when elements with higher oxygen affinity are added; these elements attract oxygen from Mn and form nanoscale oxides that can greatly improve the strength of high-Mn steels.

The composition of martensite transformation in NiAl alloy is determined using pure nickel and aluminum powder by vacuum hot press powder metallurgy, which is a composition of martensitic transformation, and the characteristics of martensitic transformation and microstructure of sintered NiAl alloys are investigated. The produced sintered alloys are presintered and hot pressed in vacuum; after homogenizing heat treatment at 1,273 K for 86.4 ks, they are water-cooled to produce NiAl sintered alloys having relative density of 99 % or more. As a result of observations of the microstructure of the sintered NiAl alloy specimens quenched in ice water after homogenization treatment at 1,273 K, it is found that specimens of all compositions consisted of two phases and voids. In addition, it is found that martensite transformation did not occur because surface fluctuation shapes did not appear inside the crystal grains with quenching at 1,273 K. As a result of examining the relationship between the density and composition after martensitic transformation of the sintered alloys, the density after transformation is found to have increased by about 1 % compared to before the transformation. As a result of examining the relationship between the hardness (Hv) at room temperature and the composition of the matrix phase and the martensite phase, the hardness of the martensite phase is found to be smaller than that of the matrix phase. As a result of examining the relationship between the temperature at which the shape recovery is completed by heating and the composition, the shape recovery temperature is found to decrease almost linearly as the Al concentration increases, and the gradient is about -160 K/ at% Al. After quenching the sintered NiAl alloys of the 37 at%Al into martensite, specimens fractured by three-point bending at room temperature are observed by SEM and, as a result, some grain boundary fractures are observed on the fracture surface, and mainly intergranular cleavage fractures.

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.

In this study, Bi-Sb-Te thermoelectric materials are produced by mechanical alloying (MA) and spark plasma sintering (SPS). To examine the influence of the milling atmosphere on the microstructure and thermo-electric (TE) properties, a p-type Bi-Sb-Te composite powder is mechanically alloyed in the presence of argon and air atmospheres. The oxygen content increases to 55% when the powder is milled in the air atmosphere, compared with argon. All grains are similar in size and uniformly, distributed in both atmospheric sintered samples. The Seebeck coefficient is higher, while the electrical conductivity is lower in the MA (Air) sample due to a low carrier concentration compared to the MA (Ar) sintered sample. The maximum figure of merit (ZT) is 0.91 and 0.82 at 350 K for the MA (Ar) and MA (Air) sintered samples, respectively. The slight enhancement in the ZT value is due to the decrease in the oxygen content during the MA (Ar) process. Moreover, the combination of mechanical alloying and SPS process shows a higher hardness and density values for the sintered samples.

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.

As well-known wrought stainless steel, sintered stainless steel (STS) has excellent high-temperature anticorrosion even at high temperature of 800ºC, and exhibits good corrosion resistance in air. However, when temperature increases above 900ºC, the corrosion resistance of STS begins to deteriorate and dramatically decreases. In this study, the effects of phase and composition of STS on high-temperature corrosion resistances are investigated for STS 316L, STS 304 and STS 434L above 800ºC. The morphology of the oxide layers are observed. The oxides phase and composition are identified using X-ray diffractometer and energy dispersive spectroscopy. The results demonstrate that the best corrosion resistance of STS could be improved to that of 434L. The poor corrosion resistance of the austenitic stainless steels is due to the fact that NiFe2O4 oxides forming poor adhesion between the matrix and oxide film increase the oxidation susceptibility of the material at high temperature.

The effects of processing parameters on the flow behavior and microstructures were investigated in hotcompression of powder metallurgy (P/M) Ti-6Al-4V alloy. The alloy was fabricated by a blended elemental (B/E)approach and it exhibited lamellar α+β microstructure. The hot compression tests were performed in the range of tem-perature 800-1000℃ with 50℃ intervals, strain rate 10−4-10 s−1, and strain up to 0.5. At 800-950℃, continuous flowsoftening after a peak stress was observed with strain rates lower than 0.1 s−1. At strain rates higher than 1 s−1, rapiddrop in flow stress with strain hardening or broad oscillations was recorded. The processing map of P/M Ti-6Al-4V wasdesigned based on the compression test and revealed the peak efficiency at 850℃ and 0.001 s−1. As the processing tem-perature increased, the volume fraction of β phase was increased. In addition, below 950℃, the globularization of phaseat the slower strain rate and kinking microstructures were found. Based on these data, the preferred working conditionof the alloy may be in the range of 850-950℃ and strain rate of 0.001-0.01 s−1.

The effect of particle size distribution on green and sintered properties of Fe-Cr-Mo prealloy powder was investigated in this study. For the study, prealloyed Fe-Cr-Mo powders with different particle sizes were mixed as various ratios and cold compacted at various pressure and sintered at for 30 min, atmosphere in the continuous sintering furnace. The results shows that the powders with large particle size distribution have high compressibility and low ejection force. However the green strength are much less than those with small particle size distribution. Tensile prperties of the sintered specimes with large particles size also have high strength and elongation.

An attempt was made to evaluate creep reliability of two commercial Ni-based superalloys by using ultrasonic wave. The materials include fine-grained PM alloy fabricated by mechanical alloying and subsequent hot isostatic pressing, and IN738LC cast alloy with a grain size of a few cm. Microstructural parameters (fraction of creep cavity and size of precipitates) and ultrasonic parameters (velocity, attenuation) were measured to try to find relationships between them. Ultrasonic velocity decreased with creep cavity formation in PM alloy. On the other hand, no distinct changing trend of ultrasonic velocity was observed for IN738LC alloy. Ultrasonic attenuation was found to have a linear correlation with the size of precipitates and was suggested as a potential parameter for monitoring creep reliability of IN738LC alloy.

A novel PM (powder metallurgy) steel for automotive power-train gear components was developed to reduce manufacturing cost, while meeting application requirements. The high-density PM steel was manufactured by mixing using special Cr-Mo atomized iron powders, high-pressure compaction, and sintering. Tensile strength, charpy impact, bending fatigue, and contact fatigue tests for the PM steel were carried out and compared to conventional forged steel. Pinion gears for auto-transmission were also manufactured by helical pressing, sintering, and surface densification process. In order to evaluate the durability of the PM parts, auto-transmission durability tests were performed using dynamometer tests. Results showed that the PM steel fulfilled the requirements for pinion gears indicating suitable tensile, bending fatigue, contact fatigue strengths and improved gear tooth profile. The PM gears also showed good performance during the transmission durability tests. As a result, the PM gears showed significant potential to replace the conventional forged steel gears manufactured by tooth machining (hobbing, shaving, and grinding) processes.

Electro-Discharge Sintering (EDS) employs a high-voltage/high-current-density pulse of electrical energy, discharged from a capacitor bank, to instantaneously consolidate powders. In the present study, a single pulse of 0.57-1.1 kJ/0.45 g-atomized spherical powders in size range of 10~30 and consisting of -(Ti, Zr) and icosahedral phases were applied to examine the structural evolution of icosahedral phase during EDS. Structural investigation reveals that high electrical input energy facilitates complete decomposition of icosahedral phase into C14 laves and -(Ti, Zr) phases. Moreover, critical input energy inducing decomposition of the icosahedral phase during EDS depends on the size of the powder. Porous Ti and W compacts have been fabricated by EDS using rectangular and spherical powders upon various input energy at a constant capacitance of in order to verify influence of powder shape on microstructure of porous compacts. Besides, generated heat () during EDS, which is measured by an oscilloscope, is closely correlated with powder size.

In this study, as high temperature performance capable thermoelectric materials was manufactured by powder metallurgy.The as-casted Fe-Si alloy was annealed for homogenization below for 3 h. Due to its high brittleness, the cast alloy transformed to fine powders by ball-milling, followed by subsequent compaction (hydraulic pressure; 2 GPa) and sintering (, 12 h). In order to precipitate , heat treatment was performed at with varying dwell time (7, 15 and 55 h). As a result of this experiment thermoelectric phase was quickly transformed by powder metallurgical process. There was not much change in powder factor between 7h and 55h specimens.

The long-period stacking order (LPSO) structures and stacking faults (SFs) in rapidly solidified powder metallurgy (RS P/M) Mg97Zn1Y2 alloy were investigated by high resolution transmission electron microscopy (HRTEM) observations. The 18R-type LPSO structure with a stacking sequence of ACBCBCBACACACBABAB and a period of 4.86 nm was observed in the as-extruded RS P/M Mg97Zn1Y2 alloy. After annealing at 773 K for 5 hr, the 18R-type LPSO structure was transformed to the 14H-type LPSO structure with a stacking sequence of ABABABACBCBCBC and a period of 3.64 nm. The 24R-type LPSO structure containing 24 atomic layers of ABABABABCACACACABCBCBCBC with period of 6.18 nm coexists with the 14H-type LPSO structure in the same grains. The LPSO structures contain intrinsic Type II SFs such as BCB/CABA and ABA/CBCB stacking sequences of a closely packed plane.

P/M high speed steel (1.26% C, 4.42% Cr, 6.54% W, 4.92% Mo, 3.21 % V, 8.77% Co, bal. Fe) was applied to hot former die. It showed that the die life became 2.7 times higher than that of cast/wrought SKH 55 tool steel which is commercially used. The increase of die life was corresponding to the improved hardness and transverse rupture strength of PM high speed steel due to the finer grain and carbide as well as the uniform carbide distribution. The P/M high speed steel with the promoted die life could be an alternative to the conventional SKH55.

Al-42wt%Nb powder was prepared by high-energy mechanical milling(HEMM). The particle size, phase transformation and microstructure of the as-milled powder were investigated by particle size distribution (PSD) analyzer, scanning electron microscopy (SEM), X-ray diffractometery (XRD), transmission electron microscopy (TEM)and differential thermal analysis (DTA). The milled powders were heated to a sintering temperature at 1000C with under vaccum with vaccum tube furnace. Microstructural examination of sintered Ti-42wt%Nb alloy using 4h-milled powder showed Ti-rich phases (α-Ti) which are fine and homogeneously distributed in the matrix (Nb-rich phase: β-Ti). The sintered Ti-42wt%Nb alloy with milled powder showed higher hardness. The microstructure of the as quenched specimens fabricated by sintering using mixed and milled powder almost are same, but the hardness of as quenched specimen fabricated by using mixed powder increased due to solution hardening of Nb in Ti matrix. The aging effect of these specimens on microstructural change and hardening is not prominent.