This article focuses on mechanical testing characterization of blended elemental powder metallurgy (PM) titanium alloys and prealloyed PM titanium alloys. It examines the tensile properties, fracture toughness, stress-corrosion threshold resistance, fatigue strength, crack propagation properties, and processing-microstructure-property relationships of these alloys. The article also reviews five considerations for powder process selection.

This article focuses on the mechanical properties, production of titanium powder metallurgy (P/M) compacts, namely, blended elemental (BE) compacts and prealloyed (PA) compacts. It explains the postcompaction treatments of titanium P/M compacts, including heat treatment, and thermochemical processing. The article talks about the applications of titanium P/M products, namely, BE and PA products. It concludes with a short note on the future trends in titanium P/M technology.

Consolidation of titanium powders at room temperature may be performed by low-cost conventional powder metallurgy processes. This article provides information on various consolidation methods, namely, die pressing, direct powder rolling, and cold isostatic pressing. It also describes the sintering of blended elemental powders, high-strength titanium alloys, and porous material as well as the sintering of titanium powders by microwave heating.

Bronze and brass alloys are two key classes of materials in copper-base powder metallurgy applications. They are often compacted using mechanical or hydraulic pressing machines. This article provides an overview of the powder pressing process, providing information on the powder properties of bronze and brass and the roles of lubricant and compaction dies in the pressing process. It discusses the structural defects that originate during the compaction process. The article also describes the major factors that influence the sintering response in bronze, prealloyed bronze, brass, and nickel-silver.

Direct powder rolling (DPR) is a process by which a suitable powder or mixture of powders is compacted under the opposing forces of a pair of rolling mill rolls to form a continuous green strip that is further densified and strengthened by sintering and rerolling. This article discusses the basic principle, process considerations, and advantages of DRP, and describes the application of this process in the manufacture of powder titanium and titanium alloy components. It further illustrates the complexity of the process and describes the benefits of using DRP in terms of economics and product quality.

Quality control of cemented carbides includes the evaluation of physical and chemical properties of constituent raw material powders, powder blends/formulations, green compacts, and fully dense finished product. This article provides a summary of the underlying principles and size ranges for the American Society for Testing and Materials (ASTM) standard methods of particle sizing and distribution. It presents the methods used to analyze the chemical composition of cemented carbide materials in a tabular form. The article also presents information on microstructural evaluation and physical and mechanical property evaluation of cemented carbides.

This article describes the unique aspects of cold isostatic pressing (CIP) in comparison with die compaction, for powder metallurgy parts. It details the components of CIP equipment, including pressure vessels, pressure generators, and tooling material. The article reviews the part shapes and their influence in determining tap density of the filled mold. It provides a discussion on process parameters, such as dwell time, depressurization rate, evaluation of green strength and density, and thermal processing, and illustrates a process flowchart for the production of CIP parts.

Iron powders are the most widely used powder metallurgy (P/M) material for structural parts. This article reviews low to medium density iron and low-alloy steel parts produced by the pressing and sintering technology. It explains different powder production methods, including Hoeganaes process, Pyron process, atomization of liquid metal, thermal decomposition and the electrodeposition process for carbonyl and electrolytic iron powders. It describes the types of compaction and sintering, explaining their effects of processing with designations. Further, the article deals with the mechanical and physical properties of ferrous P/M materials, which may depend on certain factors, namely microstructure, porosity, density, infiltration, re-pressing, chemical composition, and heat treatment.

This article discusses the pressing and sintering of various refractory metal powders for the production of intermediate products as well as special cases of finished products. The metal powders considered include tungsten, molybdenum, tantalum, niobium and their alloys, as well as rhenium.

This article discusses the characteristics, properties, and production methods of copper powders and copper alloy powders. Bulk of the discussion is devoted to production and applications of powder metallurgy (P/M) parts, including pure copper P/M parts, bronze P/M parts, brass and nickel silver P/M parts, copper-nickel P/M parts, copper-lead P/M parts, copper-base P/M friction materials, copper-base P/M electrical contact materials, copper-base P/M brush materials, infiltrated parts, and oxide-dispersion-strengthened copper P/M materials.

The powder metallurgy (PM) process is a relatively efficient and economic process that can be used to produce high quantities of aluminum components with a reasonable degree of precision and finds application in camshaft bearing cap (cam cap) production. The article discusses the production steps involved in cam cap manufacturing: powder production, compaction, sintering, repressing, and heat treatment. In addition, it reviews the R&D work involved in improving the structural properties of emerging aluminum alloy systems.

Various powder production processes allow precise control of the chemical composition and physical characteristics of powders and allow tailoring of specific attributes for targeted applications. Metal powders are produced by either mechanical methods or chemical methods. The commonly used mechanical methods include water and gas atomization, milling, mechanical alloying, and electrolysis. Some chemical methods include reduction of oxides. This article provides information on the reliable techniques for powder characterization and testing to evaluate the chemical and physical properties of metal powders, both as individual particles and in bulk forms.

This article describes several factors, which help in determining the compressibility of metal powders: particle shape, density, composition, hardness, particle size, lubrication, and compacting. It discusses the uses of annealing metal powders and describes compressibility testing of the powders. The article details green strength and its mechanism and the variables affecting the strength. It also discusses two test methods for determining the green strength: the Rattler test and the transverse bend test.

High-temperature sintering of ferrous components continues to be important in the powder metallurgy (PM) industry. Improvements in both production rates and properties are possible as sintering temperatures increase above 1120 deg C. This article provides an overview of the different various stages of the sintering process and the physical, chemical, and metallurgical phenomena occur within the mass of metal powder particles. It discusses the four advantages of high-temperature sintering of various ferrous PM materials: improved mechanical properties, improved physical properties, development of liquid phase, and ability to sinter active elements in alloy steels. The article also provides information on three sources of process control requirements, namely, the powder blend, green density, and sintering conditions.

This article provides information on the process details that differ from general water atomization of metals as they relate to basic and engineering properties that are specific to stainless steel powders. The discussion focuses on the compacting-grade stainless steel powders. The process details include raw materials, melting method, and control of physical and chemical powder characteristics. The article describes the gas atomization of stainless steel powders and processes that are done after water atomization: drying, screening, annealing, and lubricating. It also discusses the two types of quality assurance testing measures for powder metallurgy stainless steels: tests for powder contamination and tests of chemical and physical properties.

Powder metallurgy (PM) processes include press and sinter hardening, metal injection molding, powder forging, hot isostatic pressing, powder rolling, and spray forming. This article provides an overview of PM processing methods and general considerations of heat treatment of PM parts that are case-hardened to obtain higher hardness, wear, fatigue, and impact properties. It describes the effects of porosity on heat treatment, alloy content on PM hardenability, and starting material on homogenization of PM steels. The article describes the properties, following heat treatment, of low-alloy steels tempered at 175 ºC for one hour, and lists recommended quench and temper parameters to achieve good wear resistance and core strength based on different ranges of porosity.

This article briefly reviews the production methods and characteristics of plain carbon and low-alloy water-atomized iron and steel powders, high-porosity iron powder, carbonyl iron powder, and electrolytic iron powder. It emphasizes on atomized powders, because they are the most widely used materials for ferrous powder metallurgy. The article provides information on the properties and applications of these powders. It also includes an overview of diffusion alloying, basics of admixing, and bonded premixes.