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10 August 2025, Volume 35 Issue 04
    

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    Experts Forum
  • FU Zhiqiang, QIN Xiaohui, SU Zhaojiang, CHEN Taoqian, ZHU Chengyuan
    Powder Metallurgy Industry. 2025, 35(04): 1-14. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250129
    Abstract ( ) Download PDF ( )   Knowledge map   Save
    Binder jet 3D printing (BJ3DP) is a non-melting, high-efficiency, and cost-effective metal additive manufacturing technology. In recent years, it has shown great potential in producing complex structures, large-sized parts, and high-precision components. Compared with laser melting techniques, BJ3DP offers several advantages, such as broad material compatibility, low processing temperature, and the absence of residual stress. These features make it particularly suitable for heat-sensitive or easily oxidized metals. This paper reviews the key factors affecting the quality of metal parts produced by BJ3DP, including powder characteristics, printing parameters, and debinding/sintering processes. It focuses on the phase evolution, microstructure, and mechanical properties of various alloy systems, such as iron-based, nickel-based, magnesium-based, aluminum-based, and high-entropy alloys, etc. Finally, current challenges and future development trends were briefly outlined.
  • Research and Development
  • WANG Di, LI Yang, LIU Linqing, WANG Tianyu, TAN Hua, CHEN Laizhu, CHEN Wenlong, YANG Yongqiang
    Powder Metallurgy Industry. 2025, 35(04): 15-29. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250052
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    The stress and deformation of overhanging structures in laser powder bed fusion (LPBF) are critical issues for achieving high-quality and high-precision manufacturing of complex metal components. Real-time strain data measurement during the LPBF process of overhanging structures was achieved by embedding strain gauges in the substrate. Based on the in-situ strain measurement system, the strain behavior of T-shaped overhanging structures and low-angle overhangs (5° and 10°) during the LPBF process was investigated. The effects of different cantilever lengths and various process parameters on the in-situ strain behavior of T-shaped overhangs were analyzed in detail. Furthermore, the influence of different overhang angles and support types on the in-situ strain behavior of low-angle overhanging structures was analyzed. The results indicate that the longer the overhanging length of the T-shaped structure, the greater the deformation. The use of a laser energy gradient and island scanning strategy effectively reduces the deformation of T-shaped overhanging structures. Additionally, the design of the support structure significantly affects the strain behavior and forming quality of low-angle overhanging structures. The optimal forming quality is achieved using the H1 support design strategy (block support spacing of 0.8 mm and conical support spacing of 0.6 mm). These findings provide valuable insights for understanding and controlling the deformation behavior of overhanging structures in the LPBF process.
  • WANG Haibin, YANG Erqi, ZHANG Yanyao, ZHAO Zhi, LIU Xuemei, SONG Xiaoyan
    Powder Metallurgy Industry. 2025, 35(04): 30-39. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250093
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    In this work, spherical WC-Co powder and nylon powder as the binder were used as raw materials for 3D printing of complex-structured cemented carbide components via the selective laser sintering technology, where nylon was melted at a low temperature. Post-processing steps including debinding and sintering were subsequently applied to enhance the density and mechanical properties of the printed parts. The effects of sintering processes on the microstructure and mechanical performance of the printed cemented carbides were studied in detail. The results demonstrate that all samples subjected to different post-treatments exhibite pure phase compositions, highlighting a distinct technical advantage over other thermal printing methods that often lead to carbon-deficient phases. Based on the proposed post-processing process combining atmospheric-pressure pre-sintering and secondary gas-pressure sintering, the printed cemented carbides achieve a nearly fully dense microstructure and exceptional comprehensive mechanical properties. With an average grain size of 2.8 μm, the printed cemented carbide has an average Vickers hardness of 1 247HV30, fracture toughness of 20.1 MPa·m1/2, compressive strength of 3 542 MPa, and transverse rupture strength of 1 861 MPa, respectively. Through comparative analysis of microstructures obtained under different sintering conditions, the densification mechanism of SLS-printed cemented carbides via the two-step sintering method is systematically elucidated.
  • ZHU Xiongjin, ZHAO Ruixin, HOU Yuyang, LI xia, CHEN Chaoyue, REN Zhongming
    Powder Metallurgy Industry. 2025, 35(04): 40-51. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250082
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    The relationship between process parameters and microstructure evolution during the deposition process of typical Ni3Al-based alloy IC-221M prepared by laser directed energy deposition was analyzed, and the mechanical properties at room temperature were obtained. The results of scanning electron microscopy show that the microstructure of the alloy is mainly composed of γ-Ni5Zr eutectic and γ + γ ' low melting point eutectic phase, as well as the spherical γ ' phase at the dendrite. As the scanning speed increases, the (200) diffraction peak shifts to a low angle, the interplanar spacing and lattice constant gradually increase, and the grain size in the solidified structure gradually decreases. In terms of mechanical properties at room temperature, when the laser scanning speed is 700 mm/min and 800 mm/min, the mechanical properties of IC-221M alloy samples are higher than those of as-cast alloys, the yield strength is higher than 550 MPa, the tensile strength is higher than 750 MPa, and the fracture elongation is more than 13%.
  • SHEN Juntao, YUAN Jiaming, MAO Yiwei, TAO Jianquan, XIANG Lin, WEI Qingsong
    Powder Metallurgy Industry. 2025, 35(04): 52-61. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250041
    Abstract ( ) Download PDF ( )   Knowledge map   Save
    To address the challenge of low-pressure powder laying while ensuring high packing density, the influence of the two-stage powder spreading spreader on the quality of the powder bed of binder jetting additive manufacturing (BJAM) is investigated. The effects of roller, scraper, and two-stage powder spreaders on the quality of the powder bed and substrate pressure were compared. Additionally, the impact of the pre-spread layer thickness of the two-stage powder spreader on powder spreading was analyzed. The powder dynamics during the spreading process were examined using the discrete element method to validate the experimental results.The findings indicate that, under the same layer thickness and spreading speed, the quality of the powder bed achieved with the two-stage powder spreading is comparable to that of roller powder spreading and superior to scraper powder spreading. However, the average pressure on the bed with two-stage powder spreading is significantly lower, at 427 Pa, compared to 2178 Pa with roller powder spreading. The pre-spreading layer thickness significantly affects the compaction effect of the powder bed. When the pre-spreading layer thickness increases from 150 μm to 250 μm, the packing density of the powder bed shows a notable improvement. However, beyond 250 μm, the density growth tends to saturate, while the substrate pressure continues to rise steadily with further increases in the pre-spreading layer thickness. These findings provide theoretical insights for optimizing powder spreading mechanisms and process parameters in BJAM, offering a viable strategy to enhance manufacturing efficiency and part reliability.
  • ZHANG Li, LI Yunfei, QU Xinglin, CAO Li, LI Xiaofeng
    Powder Metallurgy Industry. 2025, 35(04): 62-71. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250081
    Abstract ( ) Download PDF ( )   Knowledge map   Save
    Laser powder bed fusion (LPBF) offers a novel pathway for enhancing the performance of lightweight steels through its superior forming capability and microstructure refinement potential. However, current research lacks systematic investigation on LPBF processing of Fe-Mn-Al-Ni-C lightweight steels with high Ni content, while the evolution mechanism of B2 phase and its influence on mechanical properties remain unclear. This study investigates Fe-30Mn-11Al-12Ni-1C lightweight steel through comparative analysis of as-built and heat-treated specimens, focusing on matrix microstructure evolution, B2 phase morphology, dimensional characteristics, and spatial distribution. A defect-free sample with 99.2% relative density was successfully fabricated under optimized parameters (laser power at 95 W, scanning speed at 800 mm/s), followed by microstructure regulation through 1 100 ℃ and 1 200 ℃ heat treatments. The results reveal that the as-printed steel predominantly consists of FCC-γ austenite phase, with angular polygonal B2 particles (average size at 68 nm) discontinuously distributed along grain boundaries, occupying 12.43% area fraction. After 1 100 °C treatment, B2 phase transforms into short rod-like morphology (average length at 0.93 μm) with homogeneous intra- and intergranular distribution, significantly increasing its area fraction to 52.14%. The 1 200 °C treatment induces banded B2 phase formation (average length at 1.89 μm), reducing area fraction to 41.03%. Mechanical characterization demonstrates that 1 100 °C-treated specimens exhibit enhanced microhardness (468.5HV0.2), yield strength (930.2 MPa), and ultimate tensile strength (1 012.6 MPa), but suffer from severe ductility reduction (elongation at 0.88%). The study elucidates that increased B2 phase content and coarsening strengthen materials via secondary phase strengthening mechanism, while their inherent brittleness critically deteriorates matrix plasticity.
  • QI Jieqi, FU Ao, WANG Jian, TANG Hanchun, CAO Yuankui, YANG Yong, LIU Bin
    Powder Metallurgy Industry. 2025, 35(04): 72-80. https://doi.org/10.13228/j.boyuan.issn1006-6543.2025127
    Abstract ( ) Download PDF ( )   Knowledge map   Save
    The high-temperature alloy GH3536, celebrated for its exceptional thermal stability and oxidation resistance, is of paramount importance in sectors such as aeronautics and astronautics. However, conventional manufacturing techniques are limited to produce complex structural components. Thus, laser powder bed fushion (LPBF), an advanced near-net-shape manufacturing process, is increasingly recognized as a vital technology for the rapid fabrication of high-temperature alloy parts with intricate geometries. In this study, LPBF was employed to fabricate GH3536 high-temperature alloy components, and the effects of process parameters on microstructural characteristics and mechanical performance were systematically analyzed. The main phase structure of GH3536 high-temperature alloy formed by LPBF is FCC structure, accompanied by a small amount of M23C6 phase and martensitic (α) phase, with a multi-level structure of molten pool-large columnar crystals-super cellular crystals. It is also observed that upon increasing energy density, the density initially increased but subsequently decreases. The optimal processing window for GH3536 high-temperature alloy formation is identified as between 104.00 and 120.00 J/mm³, achieving a density in excess of 99.5%. Notably, at an energy density of 104.17 J/mm³, the alloy exhibited fine cellular crystal structures and high density. Under these optimal conditions, the GH3536 high-temperature alloy exhibits an exceptional combination of strength and ductility, achieving a yield strength of 649.45 MPa, a tensile strength of 854.74 MPa, and an elongation of 32.30%.
  • CHEN Wen, LI Kun, YIN Bangzhao, LIAO Ruobing, LI Benxiang, HUANG Huanjie, WU Yingjie, WEN Peng, JIANG Bin, PAN Fusheng
    Powder Metallurgy Industry. 2025, 35(04): 81-91. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250104
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    WE43 magnesium alloys exhibit significant potential for applications in aerospace, biomedical, and transportation fields. Laser powder bed fusion (LPBF) technology offers a novel approach to optimize their properties. However, the mechanical performance of magnesium alloys produced via this method is often limited by the anisotropy of their microstructure.In this study, the effects of different deposition orientations on the microstructural evolution and mechanical properties of LPBF-fabricated WE43 magnesium alloys were systematically investigated. The results indicate that the anisotropy in mechanical behavior is closely related to the deposition direction. Specifically, the vertically deposited specimens exhibit an average grain size of 1.86 μm, contributing to a fine-grain strengthening effect. In addition, the high density of low-angle grain boundaries hinders dislocation motion, further enhancing mechanical strength. Moreover, under tensile loading along the build direction, the orientation of existing cracks becomes parallel to the applied stress, thereby reducing crack propagation and improving tensile performance.As a result, vertically deposited specimens demonstrate superior tensile properties compared to the horizontally deposited counterparts, with a yield strength of 282 MPa, an ultimate tensile strength of 325 MPa, and an elongation of 12%. This study provides a theoretical basis for optimizing LPBF deposition strategies and lays a technical foundation for the directional design of microstructure and properties in WE43 magnesium alloys.
  • LI Zongshu, LIU Wentao, PAN Qinxi, HAN Meng, JIA Shaoqi, XU Shenghang
    Powder Metallurgy Industry. 2025, 35(04): 92-100. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250083
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    Additive manufacturing enables the fabrication of metallic porous materials that combine the inherent advantages of metals, such as exceptional heat resistance and corrosion resistance, with multifunctional characteristics including high specific surface area and controllable permeability. This study employed laser powder bed fusion (LPBF) to achieve controllable preparation of porous CM247LC nickel-based superalloy through precise modulation of laser power and scanning velocity. The results demonstrate that the LPBF-processed CM247LC alloy primarily consists of γ/γ′ phases, exhibiting an average grain size of 20 μm. Mechanical properties show significant degradation with decreasing relative density. The relative density of 98% superalloy manifests a tensile yield strength of 989.1 MPa and ultimate tensile strength of 1 395.4 MPa, whereas the porous specimen with 60% relative density displays drastically reduced strengths of 132.8 MPa and 223.2 MPa, respectively. Deformation analysis reveals that the dense material undergoes plastic deformation via dislocation slip, evidenced by characteristic river patterns on fracture surfaces. In contrast, the porous structure fails through brittle fracture at sintering necks, highlighting the critical role of porosity in governing failure mechanisms.
  • WU Yuhang, LIU peng
    Powder Metallurgy Industry. 2025, 35(04): 101-111. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250027
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    In laser powder bed fusion (LPBF), the quality of powder spreading directly affects the performance and forming quality of the components. Current research primarily focuses on blade-based powder spreading, while the exploration of roller-based spreading and its microscopic mechanisms remains relatively limited. Moreover, most studies are based on mono-sized powders, which differs significantly from the continuous size distribution in practical processes. To address this, this study employs the discrete element method (DEM) to simulate the roller-based spreading process of 316L stainless steel powder and combines it with computational fluid dynamics (CFD) to analyze the laser melting behavior under different gap heights. The influence of process parameters on the macroscopic and microscopic properties of the powder bed is systematically investigated, and the results are compared with those of blade-based spreading. The results show that when the roller velocity is 0.04 m/s and the rotational velocity is -15 rad/s, the powder bed exhibits high packing density and excellent uniformity. The quality of the powder bed achieved by roller-based spreading is superior to that of blade-based spreading. Kinetic analysis indicates that as V increases, the motion velocity of powder particles accelerates, and the force chains between the powder and the substrate strengthen, leading to reduced flowability, clogging phenomena, and a subsequent decline in powder bed quality.
  • REN Liqiang, DING Liping
    Powder Metallurgy Industry. 2025, 35(04): 112-120. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240208
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    Laser powder bed fusion (LPBF) additive manufacturing has made significant progress in fabricating multi-material metallic structures, where the quality of the heterogeneous powder bed is a critical factor affecting the final part quality. Among these factors, interparticle cohesion plays a pivotal role in the powder spreading process. Taking 316L stainless steel and CuSn10 alloy as examples, the discrete element method is used to numerically simulate the spreading process of multi-material powder beds, so as to evaluate the influence of interparticle cohesion on the quality of powder layers. Additionally, the impact of cohesion on the formation of sharp interfacial boundaries along the powder spreading direction was examined. Key findings include: (1) Increased interparticle cohesion worsens powder spreadability and exacerbates particle size segregation. (2) Cohesion induces powder agglomeration, leading to cross-contamination. (3) Higher cohesion reduces powder flowability, increases the angle of repose, and results in poor boundary quality with steep gradients.
  • YANG Chao, LI Ruidi, DAI Yanfeng, PENG Weikang, YANG Xianwen
    Powder Metallurgy Industry. 2025, 35(04): 121-128. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250029
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    To further investigate the effect of pretreatment on the chromic acid anodizing and salt spray corrosion resistance of 3D-printed AlSi10Mg alloy, 3D printed AlSi10Mg alloy samples pre-treated by sandblasting and machining were selected, and were conducted chromic acid anodizing and salt spray corrosion tests. The effects of pre-treatment on anodic oxidation and salt spray corrosion resistance of the alloy were analyzed by means of macroscopic morphology, metallographic microscopy, scanning electron macroscopy (SEM) and other macro and micro structure characterization, combined with energy dispersive spectroscopy (EDS) and other elemental analysis methods. No matter the alloy is sandblasted or processed before machining, the surface of the alloy is coated with uniform, dense and good quality anodized film after chromic acid anodizing. After 240 h of salt spray test, the anodized film discolors in a few areas on the surface of the sample, and the microstructure shows that the dense barrier layer still retains good morphology and anti-salt spray corrosion performance. The results show that the pretreatment will not affect the corrosion performance of 3D printing AlSi10Mg alloy chromic acid anodized film and salt spray.
  • LIU Yu, SU Meixia, LI Jia, WANG Changjun, LIU Zhenbao, LIANG Jianxiong
    Powder Metallurgy Industry. 2025, 35(04): 129-136. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240151
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    The evolution mechanism of molten pools and microstructure distribution in the process of preparing 18Ni250 maraging steel by selective laser melting (SLM) technology were explored through simulations and experiments. The research focuses on the molten pools, microstructure evolution and mechanical property testing of SLM-formed parts. Simulation results show that the Marangoni effect occurs when metal powder melts under laser loading, which makes the surface relatively smooth after the molten pool solidifies. Experimental results indicate that the prepared metal bulk has a flat and dense surface. The molten pool sizes obtained from simulation and experiment are quite consistent, suggesting that the prediction of printing quality through simulation is reliable. After heat treatment, the SLM-18Ni250 parts have a tensile strength of 1 970 MPa and a yield strength of 1 900 MPa, which are comparable to those of traditionally forged 18Ni250 maraging steel, but with slightly lower toughness. Observation of the metallographic structure of SLM-18Ni250 reveals that the as-printed molten tracks are regularly distributed, and the microstructure consists of a small amount of austenite and martensite. The solution water quenching treatment transforms austenite into martensite, and after aging and air cooling treatment, the martensite increases significantly with uniform composition, thereby improving the mechanical properties of the material. However, the interlayer bonding and defect distribution of the printed parts result in slightly lower toughness. The research method and idea combining simulation and experiment can provide useful guidance for the preparation of high-strength and high-toughness maraging steel by SLM technology.
  • ZHAO Yue, WANG Haishan, FAN Yonggang
    Powder Metallurgy Industry. 2025, 35(04): 137-146. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250108
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    The diamond/Ni-Cu composite specimens which can be used in the carcass of polycrystalline diamond compact (PDC) drills were successfully prepared by using electron beam selective melting (EBSM) technology, and the effects of diamond volume fraction on the density, flexural strength, wear resistance and erosion resistance of diamond/Ni-Cu composites were systematically investigated. The results indicate that with the increase of diamond volume fraction, the density and flexural strength of diamond/Ni-Cu composite samples generally show a trend of first decreasing, then entering a relatively stable stage, and then rapidly decreasing. However, the wear ratio of diamond/Ni-Cu composites specimens shows a trend of increasing first and then rapidly decreasing when the volume fraction of diamond increases from 10% to 35%, and the wear ratio reaches the maximum value of 1.08 when the volume fraction of diamond is 25%. However, the erosion mass loss of the diamond/Ni-Cu composite specimens shows a trend of first decreasing and then increasing as the volume fraction of diamond gradually increases from 10% to 35%. When the weight loss reaches the minimum value of 7.50 mg, the volume fraction of diamond is 25%. Therefore, when the diamond volume fraction is 25%, the wear resistance and erosion resistance of the diamond/Ni-Cu composites prepared by EBSM are optimized simultaneously.
  • WENG boshen, TANG Hao, ZHANG Jiantao, XIAO Zhiyu
    Powder Metallurgy Industry. 2025, 35(04): 147-156. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250043
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    In this study, selective laser melting (SLM) forming process was successfully employed to fabricate a CuCrZr/316L bimetallic structure, and heat treatment strengthening was also carried out. By means of optical microscope, X-ray diffractometer, scanning electron microscope etc., the interface phase composition and microstructure of the prepared CuCrZr/316L bimetallic structure were characterized and analyzed. Its mechanical properties and the main factors influencing the interfacial bonding performance were further investigated. The results show that the interface of the CuCrZr/316L bimetallic structure can be divided into three parts: the copper-rich layer, the mixed layer, and the iron-rich layer. In the as-formed state, fine grain strengthening and second phase strengthening at the interface make the interface bonding strength higher than that of the CuCrZr matrix. However, the Cu element in the iron-rich layer will cause the embrittlement of the iron matrix, and cracks will be generated during SLM process because of thermal stress. After heat treatment, the hardness of the CuCrZr matrix increases, which leads to a change in the fracture position of the heat-treated CuCrZr/316L bimetallic structure from the CuCrZr matrix to the iron-rich layer in the tensile test, and the fracture mode is transformed from ductile fracture to brittle fracture. The tensile strength increases from 216.7 MPa to 443.9 MPa, while the elongation decreases from 37.5% to 3.0%.
  • WANG Hu, ZHAO Lin, XIANG Yong, PENG Yun, TIAN Zhiling
    Powder Metallurgy Industry. 2025, 35(04): 157-163. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250077
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    The TiAl alloys were prepared by laser coaxial powder feeding additive manufacturing technology, and the evolution of metallurgical defects in the alloy under different laser powers was thoroughly investigated, and the phase composition, microstructure, and mechanical properties of the alloy were analyzed. The results indicate that as the laser power increases, the melt width and depth of the single melt track in the TiAl alloy gradually grow, and the spheroidization phenomenon diminishes. The alloys demonstrate a high density, with porosity below 0.05%, and the porosity slightly decreases as the laser power increases. When the laser power is 1 200 W, cracks appear near the interface between the formed part and the base material. When the laser power is increased to 1 400 W and 1 600 W, the cracks disappear. The TiAl alloys are mainly composed of the γ phase and a small amount of the α2 phase. Their microscopic structure feature is that a small number of blocky γ grains are distributed at the boundaries of the γ/α2 lamellar colonies. With the increase of the laser power, the size of the lamellar colonies of the TiAl alloys shows a gradually increasing trend. When the laser power is 1 400 W, the tensile strength of the TiAl alloy is 476 MPa, and the tensile fracture morphology exhibits the characteristics of brittle fracture.
  • CHEN Ming, ZHOU Shengfeng, WANG Dengzhi, SUN Pengfei, TANG Congwen
    Powder Metallurgy Industry. 2025, 35(04): 164-169. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240179
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    This study investigates the effects of different solidification and aging heat treatment processes on the microstructure, hardness, and tensile properties of the IN718-6W alloy coating deposited by laser cladding. It is found that the amount of Laves phase in the deposited layer decreases gradually with the increase of solution temperature, and basically disappears at 1 160 ℃, which is conducive to reducing the brittleness of the alloy. The hardness, yield strength and tensile strength of IN718-6W alloy can be improved by three kinds of solid solution aging treatments, among them, under STA (solution 1 160 ℃×1 h, air cooling, aging 720 ℃×8 h+620 ℃×8 h, air cooling) process conditions, the vickers hardness, yield strength and tensile strength of IN718-6W alloy are the highest, which are (456.4±12.0) HV, (1 020.91±0.12) MPa and (1 272.08±42.79) MPa, respectively, which are increased by about 50%, 58% and 19% compared with the state without heat treatment, but the elongation decreases from 28.9%±1.27% to 14.30%±4.10%. Tensile fracture morphology analysis shows that the fracture behavior of the samples under different heat treatment processes shows ductile fracture characteristics. Through the above research, the experimental basis and theoretical guidance can be provided for the optimization of heat treatment process and the improvement of comprehensive properties of IN718-6W alloy.
  • ZOU Yu, DENG Cheng, ZENG Delong, HU Lianxi, SHI Changliang, ZHOU Shengfeng
    Powder Metallurgy Industry. 2025, 35(04): 170-177. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240223
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    In this study, 50% 18Ni300 steel powder was added to pure copper powder to prepare Cu-18Ni300 immiscible alloy by laser powder bed fusion (LPBF). The microstructure, relative density, and mechanical properties of Cu-18Ni300 immiscible alloy were characterized and analyzed using optical microscope, electron density meter, scanning electron microscope, X-ray diffractometer, Energy dispersive X-ray spectrometer, digital microhardness tester, and Instron universal testing machine. When the processing parameters of LPBF are laser power of 210 W and scanning speed of 1 100 mm/s, the relative density can reach up to 98.9%. Cu-18Ni300 immiscible alloy is mainly composed of ε-Cu phase, γ-Fe phase and α-Fe phase. The ultimate tensile strength of the printed Cu-18Ni300 immiscible alloy is 516.6 MPa, and the elongation is 8.21%. After heat treatment (500 ℃ insulation for 2 h), air-cooled, the ultimate tensile strength of Cu-18Ni300 alloy is increased to 669.7 MPa with an elongation of 7.37%, resulting in an increase of 153.1 MPa compared to Cu-18Ni300 immiscible alloy without heat treatment.
  • MA Chengyong, DONG Zenghui, JIANG Fengchun, ZHAO Lin
    Powder Metallurgy Industry. 2025, 35(04): 178-184. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250078
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    Laser cladding was carried out on a C18150 chromium-zirconium-copper alloy using Ni3Al-35% Cr7C3 alloy powder to investigate the effect of scanning speed on microstructure, hardness, and wear resistance. The results indicate that the cladding layer consists mainly of γ′-Ni3Al, NiAl, and in-situ Cr7C3 phases. As the scanning speed increases, the Cr7C3 phase is significantly refined, with a decrease in average particle size from 2.030 μm to 0.601 μm due to the rapid cooling rate. The hardness of the cladding layer initially decreases and then increases, with the lowest value recorded at a scanning speed of 4 mm/s. The wear loss decreases from 0.77 mg to 0.42 mg as the scanning speed increases, indicating improved wear resistance. The predominant wear mechanisms are adhesive wear, abrasive wear, and oxidative wear. An increase in scanning speed results in a reduction of wear grooves and spalling.
  • CHEN Xing, DU Kaiping, PI Ziqiang, ZHENG Zhaoran, WANG Chen
    Powder Metallurgy Industry. 2025, 35(04): 185-191. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250084
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    42CrMo was used as the substrate, and AlCoCrFeNi and AlCoCrFeNiY high-entropy alloy (HEA) coatings were prepared by laser cladding technology to investigate the effect of Yttrium (Y) reactive element on the high-temperature oxidation resistance of the coatings at 900 ℃. The results show that the Y-free coating forms a double-layered thermally grown oxide (TGO) structure composed of Cr2O3, Al2O3, and spinel phases after oxidation. Under internal stress, the TGO is prone to cracking and spalling, exposing the substrate and deteriorating the oxidation resistance. By contrast, the Y-added coating primarily generates dense Al2O3 in oxidation products, with minor Al5Y3O12 and Cr2O3. The TGO exhibits a continuous lamellar morphology without spalling. Oxidation weight gain curves reveal that Y addition reduces the steady-state oxidation rate of the coating by 25%. The study indicates that Y addition improves TGO integrity, hinders inward diffusion of O into the coating, and forms Al5Y3O12 at the TGO interface. This enhances the bonding strength between TGO and the substrate, promotes the formation of dense TGO, and effectively improves the oxidation resistance of HEA coatings.
  • LIU Han, LIANG Xiaokang, LIU Zhuangzhuang, HE Xiao, LI Donglai, WANG Haibin
    Powder Metallurgy Industry. 2025, 35(04): 192-199. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250085
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    The microstructure difference of GH4099 alloy formed by laser powder bed fusion and conventional casting was studied. The microstructure evolution of GH4099 alloy formed by the two processes after heat treatment was further analyzed and its effect on mechanical properties was discussed. The results show that the microstructure of GH4099 alloy formed by laser powder bed fusion (LPBF) and cast is epitaxial growth near columnar crystal structure and bimodal equiaxed crystal structure, respectively. The dendritic structure in the grains of the alloys formed by the two processes disappeares, and the carbides and γ' phase precipitate in the subsequent heat treatment, resulting in an increment in ultimate tensile strength and a decrement in plasticity. Compared with cast GH4099 alloy, LPBF GH4099 alloy has static recrystallization and grain refinement after heat treatment, which increases the utimate tensile strength, yield strength and elongation of GH4099 alloy by 66MPa, 187MPa and 14.5% respectively.
  • FENG Yingkai, CHEN Bing, ZHAO Shiyao, WANG Honglei, CAO Shuhong
    Powder Metallurgy Industry. 2025, 35(04): 200-210. https://doi.org/10.13228/j.boyuan.issn1006-6543.20250080
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    To investigate the influencing factors of crack formation and the wear mechanism of Fe3Al/Cr3C2 composites, orthogonal experiments were conducted by laser cladding Fe3Al/Cr3C2 composite coatings on carbon structural steel substrates. The coatings were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and wear tests. The results show that among the factors affecting crack formation in the cladding layer, the Cr3C2 content is the most critical. Coatings with 15% and 25% Cr3C2 exhibit the fewest cracks. In terms of wear resistance, these same coatings also display the lowest wear rates, which can be attributed to their reduced tendency for adhesive wear and the refined microstructure of the reinforcing phases that facilitate surface separation during abrasion. The morphology and distribution of the reinforcing phases in the cladding layer play a crucial role in wear resistance. During friction, the softer Fe3Al matrix wears away first, while the harder carbides support the worn surface and reduce friction. As wear progresses, the carbides gradually disappear from the surface and transform into hard phase particles.
  • LIU Shicheng, YAN Zi'ao, SUN Zhanpeng, SU Nan, LI Kangshuo, YANG Guang
    Powder Metallurgy Industry. 2025, 35(04): 211-220. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240222
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    Laser powder bed fusion (LPBF) processes exhibit highly dynamic, transient, and spatially small-scale characteristics such as keyholes, melt pools, and particle spattering. Conducting in-situ high-speed imaging of powder melting processes aids in deepening our understanding of melt pool dynamics and defect formation mechanisms. This study developed an in-situ imaging system for LPBF using a high-resolution open micro-focus X-ray tube. Observational research focused on phenomena including keyholes, bubble, spattering, and balling during the melting of 316L powder. The results demonstrate the system's capability to detect dynamic changes at the gas/melt pool interface and capture morphological changes of keyholes under certain laser process parameters, including the formation process of keyhole-induced large-scale porosity (~100 μm). Furthermore, it is found that higher X-ray tube voltages (e.g., 220 kV) enhance the system's ability to discern melt pools, although excessive X-ray penetration at this level prevents imaging of small-sized spatters. Conversely, lower X-ray tube voltages (e.g., 90 kV) effectively capture spattering behavior (~30 μm and above), preliminarily revealing mechanisms such as spatter-induced surface protrusions, significant dimensional deviations, and surface rippling defects in melt tracks. Additionally, dynamic processes of balling are replicated. The development of this technology holds significant implications for advancing in-situ studies of materials and processes in additive manufacturing.
  • Review and Communication
  • HU Juan, SONG Hui, GAO Yintao, MAO Yuyi, BAO Jun
    Powder Metallurgy Industry. 2025, 35(04): 221-228. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240218
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    Metal laser powder bed fusion is one of the most widely used, representative and promising additive manufacturing technologies at present. With the improvement of the maturity of this technology, more and more attention is paid to the surface texture of the part. Starting from the necessity of surface texture measurement and characterization, the connotation of surface texture for the part is firstly elucidated, then based on the current literature research, suggestions and expectations for surface texture measurement and characterization of additive manufactured metal part is put forward in view of the difficulties such as the selection of the measurement technology, characterization parameter, filter and evaluation length/area, et al. The current study provides some technical support for the formation of unique surface metrology, measurement and characterization techniques for surface texture of additive manufactured metal parts.
  • ZHOU Liangdong, QI Yanwu
    Powder Metallurgy Industry. 2025, 35(04): 229-240. https://doi.org/10.13228/j.boyuan.issn1006-6543.20240161
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    Additive manufacturing is an emerging material forming technology, whose shaping process is a typical non-equilibrium solidification process, involving complex physical phenomena such as temperature, thermodynamics, and phase transitions. It is difficult to measure and analyze the changes in physical quantities during the additive manufacturing process using traditional methods. Applying finite element numerical simulation technology to additive manufacturing can effectively calculate and predict the processing and outcomes, enhancing the efficiency of research and development in additive manufacturing and reducing costs. This paper provides a comprehensive review from three aspects: the finite element numerical simulation method, the introduction of finite element numerical simulation software, and their current applications in the field of additive manufacturing. It analyzes the advantages and limitations of finite element numerical simulation technology in the additive manufacturing field and offers a perspective on future development trends.