This chapter reviews some of the differences between powder metallurgy and additive manufacturing and explains how they influence the microstructure and properties of various alloys and the formation of defects in manufactured parts.

This appendix defines abbreviations, acronyms, and symbols presented within this book.

This chapter gives a brief review of the development of additive manufacturing (AM) and the appeal of different of different AM methods.

This chapter provides a brief history of powder metallurgy from its earliest known uses to present day applications.

This chapter assesses the state of 3D printing among automakers, medical device manufacturers, and construction companies.

This chapter discusses thermoplastic composite fabrication processes and related equipment and procedures. The discussion covers consolidation and thermoforming operations as well as joining methods.

This chapter provides an overview of sintering techniques and the microstructures and properties that can be achieved in different material systems. It covers conventional furnace sintering, microwave and laser sintering, hot and hot-isostatic pressing, and spark plasma sintering. It describes the advantages and disadvantages of each method, the mechanisms involved, and the effect of sintering parameters on the density, grain size, and mechanical properties of titanium and tungsten heavy alloys, stainless steel, cemented carbides, ceramics, composites, and rare earth magnets.

This chapter discusses material-related problems associated with coal-fired burners. It explains how high temperatures affect heat-absorbing surfaces in furnace combustion areas and in the convection pass of superheaters and reheaters. It describes how low-NOx combustion technology, intended to reduce NOx emissions, accelerates tube wall wastage. It also covers circumferential cracking in furnace waterwalls, thermal fatigue cracking induced by waterlances and water cannons, superheater-reheater corrosion, and erosion in fluidized-bed boilers.

This chapter discusses the effect of powder metallurgy on the design and production of nuclear energy reactors, wind turbines, biomedical devices, and gas turbine engines.

This chapter discusses the advantages and limitations of 3D printing technology for the production of batteries and supercapacitors. It explains how 3D printing methods facilitate the build of microdevices with hierarchical nanoarchitectures and controlled microstructure. It also reviews recent progress in fabricating electrodes and electrolytes using 3D-printed functional materials.

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 describes the processes involved in the fabrication of wrought and cast metal products. It discusses deformation processes including bending and forming, material removal processes such as milling, cutting, and grinding, and joining methods including welding, soldering, and brazing. It also discusses powder consolidation, rolling, drawing and extrusion, and common forging methods.

The increased use of advanced high-strength steels (AHSS) to achieve weight reduction in automobiles has led to the development of tool designs and innovative manufacturing processes. These technologies and processes include: real-time process control, active drawbeads, active binders, flexible binders, flexible rolling, and additive manufacturing. This chapter focuses on these processes and technologies.

This chapter discusses the economic importance of powder metallurgy in various countries, the types of jobs created, and the role of powder metallurgy associations around the world.

This chapter explains how powder metallurgy technologies are being leveraged for the production of automotive components, electric motors, rare-earth permanent magnets, and the infrastructure for high-speed rail transport.

This chapter provides a qualitative overview of powder preparation technologies including milling, mechanical alloying, electrolytic dissolution, metal oxide reduction, solid-state reactive synthesis, and gas, water, and centrifugal atomization. It discusses the general implementation of each process, the materials for which they are used, and the powder characteristics that can be achieved.

Casting is the most economical processing route for producing titanium parts, and unlike most metals, the properties of cast titanium are on par with those of wrought. This chapter covers titanium melting and casting practices -- including vacuum arc remelting, consumable electrode arc melting, electron beam hearth melting, rammed graphite mold casting, sand casting, investment casting, hot isostatic pressing, weld repair, and heat treatment -- along with related equipment, process challenges, and achievable properties and microstructures. It also explains how titanium parts are produced from powders and how the different methods compare with each other and with conventional production techniques. The methods covered include powder injection molding, spray forming, additive manufacturing, blended elemental processing, and rapid solidification.