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New Insight of Powder Metallurgy: Microstructure, Durability and Mechanical Properties—2nd Edition

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 June 2025 | Viewed by 2223

Special Issue Editors

Dr. Jaroslav Kováčik

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Guest Editor
Institute of Materials and Machine Mechanics, Slovak Academy of Sciences, 845 13, Bratislava, Slovak Republic
Interests: powder metallurgy; metal matrix composites; copper–graphite; titanium; aluminum foams; concentrated solar power
Special Issues, Collections and Topics in MDPI journals
Dr. Anchalee Manonukul

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Guest Editor
National Metal and Materials Technology Center (MTEC), National Sciences and Technology Development Agency (NSTDA), 114 Thailand Science Park, Klong Luang, Pathumthani 12120, Thailand
Interests: additive manufacturing; powder metallurgy; metal injection moulding; titanium alloys; metal foam; material modelling; solid mechanics
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Pasquale Cavaliere

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Guest Editor
Department of Innovation Engineering, University of Salento, Via per Arnesano 73100 Lecce, Italy
Interests: thermal spray coatings; powder metallurgy; severe plastic deformation; ironmaking and steelmaking
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We would like to invite submissions to the second edition of this Special Issue of Materials focusing on the fundamental and applied aspects of novel materials fabrication using powder metallurgy technologies and their properties.

Powder metallurgy technologies offer flexibility in materials, microstructure and design, as major fractions of the material remain in the solid state and even insoluble material combinations can be employed.

Powder metallurgy methods are used for the manufacturing of materials where other property and shaping technologies cannot be applied. A key example is the additive manufacturing of materials from powders.

The high purity of powders, controlled at their production stage, together with the possibility of changing their size and morphology determine the end properties of powder metallurgy products and are highly attractive at material markets.

Papers dealing with sintering; process parameters; the influence of innovative preparation methods such as electric-current-assisted sintering, microwave radiation or lasers; and fully compacted materials or porous preforms or foams are of interest to this Special Issue.

Finally, contributions that focus on additive manufacturing preparation from powders are also highly welcome.

We hope to receive high-quality articles, communications, and reviews reporting advancements in the fascinating field of powder metallurgy.

Dr. Jaroslav Kováčik
Dr. Anchalee Manonukul
Prof. Dr. Pasquale Cavaliere
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • powder metallurgy
  • additive manufacturing from powders
  • novel production methods
  • microstructure
  • applications
  • durability
  • physical properties
  • mechanical properties
  • recycling
  • carbon dioxide footprint

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Published Papers (3 papers)

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Research

20 pages, 11102 KiB  
Article
Liquid Phase Sintering of Al Powder Using Al-X (X=Cu, Ca, Mg) Eutectic Alloy Powders: Effect of Alloy Elements and Oxide Film Thickness
by Ryotaro Kusunoki, Hideaki Hayashi, Erika Matsumoto, Asuka Suzuki, Naoki Takata, Makoto Kobashi, Akira Yoshida, Takahiro Hamada and Moe Mekata
Materials 2025, 18(8), 1755; https://doi.org/10.3390/ma18081755 - 11 Apr 2025
Viewed by 82
Abstract
Sinter-based additive manufacturing (AM) requires sintering for the densification of green bodies. Al powder is difficult to sinter due to the dense oxide film on the surface, and it is difficult to apply to sinter-based AM. Liquid phase sintering using Al-based eutectic alloy [...] Read more.
Sinter-based additive manufacturing (AM) requires sintering for the densification of green bodies. Al powder is difficult to sinter due to the dense oxide film on the surface, and it is difficult to apply to sinter-based AM. Liquid phase sintering using Al-based eutectic alloy powder is promising for sintering Al powder without external pressure. In this study, Al powders with various oxide film thicknesses were sintered using Al-X eutectic alloy powders (X=Cu, Ca, and Mg) to clarify suitable alloy elements in the sintering aids for the liquid phase sintering. When an as-supplied Al powder with an oxide film thickness of approximately 2 nm (presumably amorphous Al2O3 film) was used, Al-Cu and Al-Ca aids promoted the densification, whereas numerous pores were observed in the sample sintered using Al-Mg aid. The pores would be formed during the cooling after sintering, along with the homogenization of Mg distribution. When Al powder with an oxide film thickness of around 4 nm was used, a high relative density of over 95% was maintained using Al-Cu aid, whereas the relative density of the sample sintered using Al-Ca aid significantly degraded, presumably due to the formation of Ca-based oxide. These results indicate that the Al-Cu eutectic alloy powder is a promising sintering aid for the liquid phase sintering of Al powder. Full article
(This article belongs to the Special Issue New Insight of Powder Metallurgy: Microstructure, Durability and Mechanical Properties—2nd Edition)
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16 pages, 10404 KiB  
Article
Development of 17-4 PH Stainless Steel for Low-Power Selective Laser Sintering
by Yu-Deh Chao, Shu-Cheng Liu, Fu-Lin Chen, Mayur Jiyalal Prajapati, Ajeet Kumar, Jung-Ting Tsai and Jeng-Ywan Jeng
Materials 2025, 18(2), 447; https://doi.org/10.3390/ma18020447 - 19 Jan 2025
Viewed by 755
Abstract
Selective laser sintering (SLS) is one of the prominent methods of polymer additive manufacturing (AM). A low-power laser source is used to directly melt and sinter polymer material into the desired shape. This study focuses on the utilization of the low-power laser SLS [...] Read more.
Selective laser sintering (SLS) is one of the prominent methods of polymer additive manufacturing (AM). A low-power laser source is used to directly melt and sinter polymer material into the desired shape. This study focuses on the utilization of the low-power laser SLS system to successfully manufacture metallic components through the development of a metal–polymer composite material. In this study, 17-4 PH stainless powders are used and mixed with polyoxymethylene (POM) and high-density polyethylene (HDPE) to prepare the composite powder material. The polymeric mixture is removed during the thermal degreasing process and subsequent sintering results in a solid metallic component. Sinterit Lisa with a 5 W, 808 nm laser source is used to fabricate the green part. For the printing parameters of 140 °C, laser power of 35.87 mJ/mm2, and layer thickness of 100 μm, the printed samples achieved a maximum density of 3.61 g/cm3 and a complete shape. After sintering at 1310 °C for 180 min, the tensile strength of the shrunk sample is 605.64 MPa, the hardness is HRC 14.8, the average shrinkage rate is 22%, and the density is 7.57 g/cm3, which can reach 97% of the theoretical density. This process allows the use of a wide range of particle sizes that the usual AM technologies have, making it a low-cost, low-energy-consumption, high-speed AM technology. Full article
(This article belongs to the Special Issue New Insight of Powder Metallurgy: Microstructure, Durability and Mechanical Properties—2nd Edition)
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9 pages, 9026 KiB  
Article
Innovative Powder Pre-Treatment Strategies for Enhancing Maraging Steel Performance
by Drahomír Dvorský, David Nečas, Esther de Prado, Jan Duchoň, Petr Svora, Ondřej Ekrt, Angelina Strakošová, Jiří Kubásek and Dalibor Vojtěch
Materials 2025, 18(2), 437; https://doi.org/10.3390/ma18020437 - 18 Jan 2025
Viewed by 585
Abstract
Maraging steel is a high-performance material valued for its exceptional properties, making it ideal for demanding applications such as aerospace, tooling, and automotive industries, where high strength, toughness, and precision are required. These steels can be prepared by powder metallurgy techniques, which offer [...] Read more.
Maraging steel is a high-performance material valued for its exceptional properties, making it ideal for demanding applications such as aerospace, tooling, and automotive industries, where high strength, toughness, and precision are required. These steels can be prepared by powder metallurgy techniques, which offer new processing possibilities. This paper introduces novel thermal powder pre-treatment and its impact on the final mechanical properties. Solid solution pre-treatment results in a modest improvement in strength (from 972 MPa to 1000 MPa), while the use of pre-aged powder achieves the highest strength (1316 MPa) and lowest ductility (2.6%). A self-composite material is created by mixing pre-treated powders with the same chemical composition but different properties. Such material was characterized by intermediate strength (1174 MPa) and ductility (3.1%). Although challenges such a porosity and oxidation were present, this approach allows for tuning of mechanical properties by mixing pre-treated powders, offering significant potential for advanced engineering applications. Full article
(This article belongs to the Special Issue New Insight of Powder Metallurgy: Microstructure, Durability and Mechanical Properties—2nd Edition)
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