This chapter discusses the growing role of powder metallurgy in the production of intermetallic, Heusler, and high-entropy alloys. It reviews the challenges of producing these materials by conventional methods and the advantages of sinter-based PM techniques. It explains why PM processes are better suited for complex materials than casting and compares the properties of intermetallic, Heusler, and high-entropy alloys prepared by casting and powder-metal techniques.

This chapter discusses the methods by which stainless steel powders are shaped and compacted prior to sintering, including rigid die compaction, metal injection molding, extrusion, and hot isostatic pressing. It explains where each process is used and how processing parameters, such as temperature and pressure, and powder characteristics, such as particle size and shape, influence the quality of manufactured parts. It describes the various stages of metal powder compaction, the role of lubricants, and how to account for dimensional changes in the design of tooling and process sequences.