Search Results (118)

In this work, the development of Al-based metal matrix composites (MMCs) is achieved using hybrid SiC and ZrO₂ reinforcement particles for automotive applications. Powder metallurgy (PM) is employed with various combinations of important process parameters for the fabrication of MMCs. MMCs were characterized using scanning electron microscopy (SEM), X-ray diffractometry (XRD), and a microhardness study. All XRD graphs adequately exhibit Al, SiC, and ZrO₂ peaks, indicating that the hybrid MMC products were satisfactorily fabricated with appropriate mixing and sintering at all the considered fabrication conditions. Also, no impurity peaks were observed, confirming high composite purity. MMC products in all the XRD patterns, suitable for the desired applications. According to the SEM investigation, SiC and ZrO₂ reinforcement components are uniformly scattered throughout Al matrix in all produced MMC products. The occurrence of Al, Si, C, Zr, and O in EDS spectra demonstrates the effectiveness of composite ball milling and sintering under all manufacturing conditions. Moreover, an increase in interfacial bonding of fabricated composites at a higher sintering temperature indicated improved physical properties of the developed MMCs. The highest microhardness value is 86.6 HVN amid all the fabricated composites at 7% silica, 14% zirconium dioxide, 500° sintering temperature, 90 min sintering time, and 60 min milling time. An integrated Particle Swarm Optimization–Support Vector Machine (PSO-SVM) model was developed to predict microhardness based on the input parameters. The model demonstrated strong predictive performance, as evidenced by low values of various statistical metrics for both training and testing datasets, highlighting the PSO-SVM model’s robustness and generalization capability. Specifically, the model achieved a coefficient of determination of 0.995 and a root mean square error of 0.920 on the training set, while on the testing set, it attained a coefficient of determination of 0.982 and a root mean square error of 1.557. These results underscore the potential of the PSO-SVM framework, which can be effectively leveraged to optimize process parameters for achieving targeted microhardness levels for the developed Al-SiC-ZrO₂ Composites. Full article

Aluminum and its alloy magnetron sputtering targets, owing to their superior electrical/thermal conductivity and robust substrate adhesion, serve as critical materials in advanced electronics and information technologies. It is known that the microstructure of the target, including grain uniformity and crystallographic texture, directly affects the sputtering performance and the quality of the deposited thin film. Despite extensive research efforts, the review paper focused on the microstructure of aluminum target materials is still absent. In that context, the recent progress on the Al alloy target is reviewed, focusing on grain refinement and texture control strategies. The roles of alloying elements, such as Si, Cu, and rare-earth Sc and Nd, are described first. The two conventional manufacturing techniques of fabricating Al targets, including melting and powder metallurgy, are introduced. Then, studies on grain refinement by thermomechanical processing routes (hot/cold rolling, annealing and forging) are summarized. Lastly, texture engineering through deformation and heat treatment protocols (unidirectional/multidirectional rolling, deformation thickness, and composite deformation modes) is reviewed. By establishing the relationship between thermomechanical processing and microstructure, this review provides insights for designing high-performance aluminum targets tailored to next-generation advanced thin-film applications. Full article

This study presents a novel flake powder metallurgy approach for fabricating Al/CNT composites, combining the dual-matrix (DM) method with shift-speed ball milling (SSBM) to optimize mechanical performance. Samples prepared via DM-SSBM were systematically compared to those produced by conventional high-speed ball milling (HSBM), single-stage SSBM, and dual-matrix (DM) routes. Tensile testing revealed that the DM₁MR₅₀-SSBM composite achieved a superior balance of strength and ductility, with an ultimate tensile strength of ~267 MPa, elongation of ~9.9%, and the highest energy absorption capacity (~23.4 MJ/m³) among all tested samples. In contrast, the HSBM sample, while achieving the highest tensile strength (~328 MPa), exhibited limited elongation (~4.7%), resulting in lower overall toughness. The enhanced mechanical response of the DM-SSBM composites is attributed to improved CNT dispersion, refined cold-welding interfaces, and pure Al matrix softness, which together facilitate superior load transfer and hinder crack propagation under tensile stress. In the final consolidated state, aluminum forms a continuous matrix embedding the CNTs, justifying the use of the term “aluminum matrix” to describe the composite structure. These findings highlight the DM-SSBM approach as a promising method for developing lightweight, high-toughness aluminum composites suitable for energy-absorbing structural applications. Full article

Beryllium-based intermetallic compounds, such as Be₁₂Nb, are attracting growing interest for their high thermal stability and potential to replace pure beryllium as neutron reflectors and multipliers in both fission and future fusion reactors, with additional applications in metallurgy, aerospace, and hydrogen technology. The paper presents the results of an investigation of the thermal treatment and phase formation of the intermetallic compound Be₁₂Nb from a mixture of niobium and beryllium powders in the temperature range of 800–1300 °C. The phase evolution was assessed as a function of sintering temperature and time. A nearly single-phase Be₁₂Nb composition was achieved at 1100 °C, while decomposition into lower-order beryllides such as Be₁₇Nb₂ occurred at temperatures ≥1200 °C, indicating thermal instability of Be₁₂Nb under vacuum. Careful handling of sintering in low vacuum minimized oxidation, though signs of possible BeO formation were noted. The findings complement and extend earlier reports on Be₁₂Nb synthesis via plasma sintering, mechanical alloying, and other powder metallurgy routes, providing broader insight into phase formation and synthesis. These results provide a foundation for optimizing the manufacturing parameters required to produce homogeneous Be₁₂Nb-based components and billets at an industrial scale. Additionally, they help define the operational temperature limits necessary to preserve the material’s phase integrity during application. Full article

Bone diseases lead to an increasing demand for implants to treat long bone defects and for load-bearing applications. Osteoporosis care and accidental injuries are major contributors to this rising need. Our research aims to demonstrate innovative material systems and methods for preparing implants that can be used in regenerative medicine. We hypothesize that by combining titanium alloys (Ti6Al4V) with hydroxyapatite (Hap), we can enhance biocompatibility and tribo-mechanical performance, which are critical for the longevity of Ti-based surgical implants. Additionally, we investigate the application of laser surface treatments to expose the underlying porosity, thereby enhancing cell transport and promoting cell growth. In this study, we investigate the effects of two fabrication techniques—Spark Plasma Sintering (SPS) and powder metallurgy (PM)—on the properties of laser-textured Ti64/Hap biocomposites. Our findings demonstrate that the selected processing route significantly influences the microstructure, tribological performance, and surface properties of these materials. An X-ray diffraction (XRD) analysis corroborates our results from incubation studies in simulated body fluids, highlighting the impact of phase transformations during sintering on the chemical properties of Ti-Hap composites. Additionally, while laser surface texturing was found to slightly increase the friction coefficient, it markedly enhanced the wear resistance, particularly for the PM and SPS Ti + 5%Hap composites. Full article

In recent years, W-Cu composite systems have become very interesting subjects due to good electrical and thermal conductivity, high-temperature strength, certain plasticity, and excellent radiation resistance. W-Cu composites are a very important class of materials in applications like PFM (plasma facing materials), functional graded materials (FGM), electronic packaging materials, high-voltage electrical contacts, sweating materials, shaped charge liners, electromagnetic gun-rail materials, kinetic energy penetrators, and radiation shielding/protection. There is no possibility of forming a crystalline structure between these two materials. However, due to the unique properties these materials possess, they can be used by preparing them as a composite. Generally, W-Cu composites are prepared via the conventional powder metallurgy routes, i.e., sintering, hot pressing, hot isostatic pressing, isostatic cold pressing, sintering and infiltration, and microwave sintering. However, these processes have certain limitations, like the inability to produce bulk material, they are expensive, and their adoptability is limited. Here, in this review, we will discuss in detail the fabrication routes of additive manufacturing, and its current progress, challenges, trends, and associated properties obtained. We will also explain the challenges for the additive manufacturing of the composite. We will also compare W-Cu composites to other materials that can challenge them in terms of specific applications or service conditions. The solidification mechanism will be explained for W-Cu composites in additive manufacturing. Finally, we will conclude the progress of additive manufacturing of W-Cu composites to date and suggest future recommendations based on the current challenges in additive manufacturing. Full article

Shape memory alloys (SMAs) are functional materials with a wide range of applications, from the aerospace sector to the biomedical field. Nowadays, there is a worldwide interest in developing SMAs through powder metallurgy like additive manufacturing (AM), which allows innovative building processes. However, producing SMAs using AM techniques is particularly challenging because of the microstructure required to obtain optimal functional properties. This aspect is critical in the case of Cu–Al–based SMAs, due to their high elastic anisotropy, making them brittle in polycrystalline form. In this work, we approached the processing of a Cu–Al–Ni SMA following a specific powder metallurgy route: gas atomization of a pre-alloyed melt; compaction of the atomized powders through hot isostatic pressing; and a final hot rolling plus thermal treatments. Then, the microstructure of the material was characterized by electron microscopy showing a specific [001] texture in the rolling direction that improved the functional behavior. The successive processing steps produce an increase of about 40 °C in the martensitic transformation temperatures, which can be well controlled and reproduced through the developed methodology. The thermomechanical functional properties of superelasticity and shape memory were evaluated on the final SMA. Outstanding, fully recoverable superelastic behavior of 4.5% in tension, as well as a ±5% full shape memory recovery in bending, were reported for many cycles. These experiments demonstrate the enhanced mechanical and functional properties obtained in polycrystalline Cu–Al–Ni SMAs by powder metallurgy. The present results pave the road for producing this kind of SMA with the new AM technologies, which always produce polycrystalline components and can improve their processes taking the powder metallurgy SMA, here produced, as reference material. Full article

Multiple phase transformations were carried out during dehydrogenation process of TiH2-based powder metallurgy. The influence of phase transformation on the microstructure is highly worthy of attention. In situ synchrotron radiation was employed to investigate the phase transformation sequence of TiH2 powder compact during the vacuum sintering process. It was found that a transformation route TiH1.971 → TiH2 + TiH + TiH0.71 + α(H) → TiH + TiH0.71 + α(H) → TiH + TiH0.71 + α(H) + β(H) → α(H) → α took place, resulting in an equiaxed microstructure. Increasing heating rate and avoiding the intense dehydrogenation to retain hydrogen-rich β (β(H)) and TiHx aciculae at the interfaces is found to be a feasible method to fabricate hierarchical α-Ti structures. A fully dense fine martensitic microstructure was produced after fast heating the TiH2 powder compact to 1100 °C and an immediate hot extrusion. Subsequently, by vacuum annealing treatment at 700 °C, composite α/βt lamellar structures were generated and a simultaneously enhanced tensile strength of 746 MPa and excellent elongation to fracture of 33.8% were achieved. It is suggested that adjusting the dehydrogenation reactions of TiH2-based powder metallurgy is conductive to generating hierarchical lamellar structures with a highly promising combination of strength and ductility for pure Ti. Full article

The present investigation addresses the mechanical properties, wear behaviour, and high-temperature oxidation of cermets and hardmetals based on either Ti(C,N) or WC and a metal binder based on Fe15Ni or Fe15Ni10Cr. This study also includes a commercial-grade WC-Co for comparative purposes. The production of these materials involved a powder metallurgy and sinter-HIP processing route under identical conditions. It is found that WC-based materials have superior mechanical properties, including hardness, fracture toughness, transversal rupture strength (TRS), and wear response, compared to Ti(C,N)-based materials. However, the latter show better oxidation behaviour than the former. Notably, WC-FeNi exhibits a higher hardness and TRS than the commercial-grade material (an increase of 7% and 9%, respectively). The difference in wear behaviour is due to the difference in wear mechanisms. In this regard, cermets wear through a tribolayer of Ti and Fe oxides, while hardmetals primarily wear through abrasion from ploughing. Thus, hardmetals exhibit a lower coefficient of friction (COF) and wear rate than cermets. Furthermore, Ti(C,N)-based materials form a protective layer of TiO₂, which enhances their integrity and reduces mass gain. The addition of Cr to the FeNi binder only appears to have a clear effect on the TRS of the materials. Full article

This paper presents corrosion resistance results of a 12Cr ferritic ODS steel (Fe-12Cr-2W-0.5Zr-0.3Y₂O₃) fabricated via a powder metallurgy route as a prospective applicant for fuel cladding materials. In a spent nuclear fuel reprocessing facility, nitric acid serves as the primary solvent in the PUREX method. Therefore, fundamental immersion and electrochemical tests were conducted in various nitric acid solutions to evaluate corrosion degradation behavior. Additionally, polarization tests were also performed in 0.61 M of sodium chloride solutions (seawater-like atmosphere) as a more general, all-purpose procedure that produces valid comparisons for most metal alloys. For comparison, martensitic X46Cr13 steel was also examined under the same conditions. In general, the corrosion resistance of the 12Cr ODS steel was better than its martensitic counterpart despite a lower nominal chromium content. Potentiodynamic polarization plots exhibited a lower corrosion current and higher breakdown potentials in chloride solution in the case of the ODS steel. It was found that the corrosion rate during immersion tests was exceptionally high in diluted (0.1–3 M) boiling nitric acid media, followed by its sharp decrease in more concentrated solutions (>4 M). The results of the polarization plots also exhibited a shift toward more noble corrosion potential as the concentrations increased from 1 M to 4 M of HNO₃. The results on corrosion resistance were supported by LSCM and SEM observations of surface topology and corrosion products. Full article

Porous copper (Cu), with varying porosities, has been made using carbamide as a space holder through the powder metallurgy route. Two shapes of carbamide particles were used, (i) needlelike and (ii) spherical, in order to investigate the effect of the space holder shape on the pore structure and mechanical properties of porous Cu. The compressive deformation behavior of porous Cu was studied under a compression test. The pores’ structural characteristics and mechanical properties of the porous Cu varied significantly with the shape of the space holder. Although the effect of the space holder shape on the porosity was not regular, the effect on the mechanical properties was regular. The stress increased monotonically with the increase in the strain, and strain hardening occurred at the plastic yield stage. The elastic modulus and yield strength followed the power law, with the relative density irrespective of the space holder shape. The empirical constants associated with different empirically developed power law relations were different, according to the shape of space holder. A quantitative relationship between the elastic modulus and yield strength and the spacer content was obtained to control the mechanical properties of the present porous Cu or other porous metals and metal foams using the well-known space holder method. Full article

Galena is a natural mineral enriched with lead sulfide (PbS). It typically forms in hydrothermal veins associated with igneous rocks and can also occur as a gangue mineral in other ore deposits. PbS is of special importance for scientific research applications due to the possibility of tuning its semiconductor energy gap using nanotechnology in conjunction with powder metallurgy as an easy, controllable production route. In this paper, almost pure PbS was successfully produced starting from a high ratio of PbS phase galena ore. As-received galena lumps were roughly pulverized and milled to produce four particle size ranges of 38, 63, 125, and 250 µm prior to compaction and sintering in a vacuum (pre-flushed with argon gas). SEM coupled with the EDAX analysis unit was employed to investigate the microstructure and chemical composition of the as-received galena and the subsequent products after sintering. The chemical analysis confirmed the high ratio of PbS compound in the as-received galena and sintered products with approximately 85% Pb and 13% S mass ratio. The sintering process of the galena powder was carried out at different values of temperature, time, and compaction pressure. Additionally, the effect of length to diameter ratio of compacted and sintered samples was investigated. XRD analysis confirmed the existence of the PbS phase in the as-received and sintered samples at 700 °C with approximately 98 wt.%, as well as a new phase that is formed at 800 °C with a lower percentage. The micro-hardness of the as-received and sintered samples was measured and compared with the as-received galena ore. The results showed a significant reduction in the hardness of sintered galena powder compared with the bulk as-received galena by 52%. Furthermore, a relative sintered density of 99.3% for the as-received galena density signifies a novel result using powder metallurgy techniques. Full article

The two-step PM (powder metallurgy)-route procedure was proposed to fabricate a super-engineering plastic gear directly from powder feedstock. Its lightweight, fully dense integrity and high-stiffness has been found to be suitable for reducers in robotics and electric vehicles, as they work even in severe environmental conditions. In this study, the green compaction and sinter-forging processes were used to consolidate the polyimide powder feedstock and to sinter forge the solid preform into the final products. To demonstrate the high density of preforms and sinter-forged gears, a hardness measurement and X-ray computer tomography were employed. The gear-grade balancing was also evaluated to describe the effect of fine sinter-forging conditions on the dimensional quality of polyimide gears. High gear grade with JIS-2 class proved that the polyimide was useful as a matrix of lightweight and high-strength gears. Full article

Aluminum metal matrix composites (AMMCs) havewidespread application due to their exceptional properties. This study reinforced aluminum alloy 7075 with nano-titanium carbide across varying weight percentages using powder metallurgy. Optimization by TAGUCHI and ANOVA techniques which was carried out consideringthe following key parameters: sintering temperature (250–400 °C), sintering time (30–120 min), compacting pressure (300–450 MPa), and TiCnp content. Microhardness, evaluated with a Vickers tester and an L16 orthogonal array, led to optimal conditions: 15 wt.% TiCnp, 120 min sintering, 450 MPa pressure, and 400 °C temperature. Confirmation tests validated the resulting enhanced microhardness. Full article

The powder metallurgy (PM) route for the production of closed-cell metallic foams has recently received a significant amount of attention. One of the major issues is the non-uniform and non-spherical nature of the cells produced, which can negatively affect the mechanical behavior. The current paper uses the PM route to process metallic foams for the first time using novel Al-TiH₂ foamable precursor “particles” (FPPs). The effect of FPP content (0–10 wt.%) on the developed foam structure of aluminum and its mechanical properties is investigated. An increase in FPP content results in a decline in product density by forming uniform and near-spherical cells. The main advantage of the FPPs is the localization of the blowing agent TiH₂ particle content within Al-TiH₂ composite particles (i.e., giving rise to a higher local TiH₂ content), which has led to the production of pores with relatively high circularities even at very low overall TiH₂ contents. The foams produced displayed energy absorption capacities of 10–25 MJ/m³ at 50% strain, and maximum energy absorption efficiencies ranging from 0.6–0.7 (for 40–60% closed cell content) Full article