Journal of Powder Materials

[English]
Fabrication and Pore Characteristics of Metal Powder Filters with a Cross-Sealed Honeycomb Shape Using Material Extrusion Additive Manufacturing: Minji Kim, Min-Jeong Lee, Su-Jin Yun, Poong-Yeon Kim, Hyeon Ju Kim, Juyong Kim, Jung Woo Lee, Jung-Yeul Yun; J Powder Mater. 2025;32(4):299-308. Published online August 29, 2025; DOI: https://doi.org/10.4150/jpm.2025.00234

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Abstract PDF: The development of high-performance metal filters is essential for maintaining ultra-clean environments in semiconductor manufacturing. In this study, cross-sealed honeycomb filters were fabricated using STS316L powder via material extrusion additive manufacturing (MEAM) for semiconductor gas filtration. The effects of filter geometry (4 or 9 channels) and sintering temperature (850°C, 950°C, or 1,050°C) on performance were examined. First, 4-channel and 9-channel filters sintered at the same temperature (950°C) exhibited similar porosities of 50.08% and 50.57%, but the 9-channel filter showed a higher pressure-drop (0.26 bar) and better filtration-efficiency (3.55 LRV) than the 4-channel filter (0.19 bar and 3.25 LRV, respectively). Second, for filters with the same geometry (4-channel) increasing the sintering temperature reduced porosity from 64.52% to 40.33%, while the pressure-drop increased from 0.13 bar to 0.22 bar and filtration-efficiency improved from 2.53 LRV to 3.51 LRV. These findings demonstrate that filter geometry and sintering temperature are key factors governing the trade-off between air permeability, pressure-drop, and filtration efficiency. This work provides insights and data for optimizing MEAM-based high-performance metal powder filter design.

[Korean]
Influence of Powder Particle Size on the Microstructure of UO₂ Fuel Pellets with High Gd₂O₃ Content: Ji-Hwan Lee, Jae Ho Yang, Ji-Hae Yoon, Dong-Joo Kim, Dong-wook Shin, Dong Seok Kim; J Powder Mater. 2025;32(4):344-353. Published online August 29, 2025; DOI: https://doi.org/10.4150/jpm.2025.00178

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Abstract PDF: The recent development of small modular reactors (SMRs) and the adoption of higher-enrichment fuels have intensified the need for advanced burnable absorbers to ensure effective reactivity control and extended fuel cycles. Among various designs, UO2 fuels with high Gd2O3 (gadolinium oxide) content provide notable benefits; in particular, they are compatible with established fabrication methods for burnable absorber fuels. However, achieving a homogeneous dispersion of Gd2O3 at high loading levels remains challenging, and the frequent occurrence of phase segregation and non-uniform microstructures can limit fuel reliability and performance. Overcoming these limitations requires an understanding of the powder characteristics and mixing behaviors during fabrication. In this study, we investigate the effects of the initial particle size and mixing method of UO2 and Gd2O3 powders on the microstructure and mixing homogeneity of high-Gd2O3-content fuels. The findings indicate that both the mixing method and the preparation state of the starting powders significantly affect the resulting microstructure and mixing uniformity.

[Korean]
The Manufacturing Process of Clean Ni-Cr-Co-Based Superalloy Powder Using a Plasma Rotating Electrode: Kyu-Sik Kim, Dae Woong Kim, Yeontae Kim, Jung Hyo Park; J Powder Mater. 2025;32(3):222-231. Published online June 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00171

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Abstract PDF: Ni-based superalloys are widely used for critical components in aerospace, defense, industrial power generation systems, and other applications. Clean superalloy powders and manufacturing processes, such as compaction and hot isostatic pressing, are essential for producing superalloy discs used in turbine engines, which operate under cyclic rotating loads and high-temperature conditions. In this study, the plasma rotating electrode process (PREP), one of the most promising methods for producing clean metallic powders, is employed to fabricate Ni-based superalloy powders. PREP leads to a larger powder size and narrower distribution compared to powders produced by vacuum induction melt gas atomization. An important finding is that highly spheroidized powders almost free of satellites, fractured, and deformed particles can be obtained by PREP, with significantly low oxygen content (approximately 50 ppm). Additionally, large grain size and surface inclusions should be further controlled during the PREP process to produce high-quality powder metallurgy parts.

[English]
The Effect of Aluminum Powder Size on the Structure and Mechanical Properties of Foam: Seunghyeok Choi, Sungjin Kim, Tae-Young Ahn, Yu-Song Choi, Jae-Gil Jung, Seung Bae Son, Seok-Jae Lee; J Powder Mater. 2025;32(3):232-243. Published online June 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00157

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Abstract PDF: In this study, we analyzed the structural and mechanical properties of aluminum foams fabricated using aluminum powders of varying sizes and mixtures. The effects of sintering and pore structure at each size on the integrity and mechanical properties of the foams were investigated. Structural characteristics were examined using scanning electron microscopy and micro–computed tomography, while mechanical properties were evaluated through compression testing. The experimental results demonstrated that smaller powder sizes improved foam integrity, reduced porosity and pore size, and resulted in thinner cell walls. In combination, these effects increased compressive strength as the powder size decreased. The findings of this study contribute to the understanding and improvement of the mechanical properties of aluminum foams and highlight their potential for use in a wide range of applications.

[Korean]
Development of Aluminum Alloys for Additive Manufacturing Using Machine Learning: Sungbin An, Juyeon Han, Seoyeon Jeon, Dowon Kim, Jae Bok Seol, Hyunjoo Choi; J Powder Mater. 2025;32(3):202-211. Published online June 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00150

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Abstract PDF: The present study introduces a machine learning approach for designing new aluminum alloys tailored for directed energy deposition additive manufacturing, achieving an optimal balance between hardness and conductivity. Utilizing a comprehensive database of powder compositions, process parameters, and material properties, predictive models—including an artificial neural network and a gradient boosting regression model, were developed. Additionally, a variational autoencoder was employed to model input data distributions and generate novel process data for aluminum-based powders. The similarity between the generated data and the experimental data was evaluated using K-nearest neighbor classification and t-distributed stochastic neighbor embedding, with accuracy and the F1-score as metrics. The results demonstrated a close alignment, with nearly 90% accuracy, in numerical metrics and data distribution patterns. This work highlights the potential of machine learning to extend beyond multi-property prediction, enabling the generation of innovative process data for material design.

[English]
Thermodynamic and Electronic Descriptor-Driven Machine Learning for Phase Prediction in High-Entropy Alloys: Experimental Validation: Nguyen Lam Khoa, Nguyen Duy Khanh, Hoang Thi Ngoc Quyen, Nguyen Thi Hoang Oanh, , Le Hong Thang, Nguyen Hoa Khiem, Nguyen Hoang Viet; J Powder Mater. 2025;32(3):191-201. Published online June 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00143

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2 Citations

Abstract PDF

High-entropy alloys (HEAs) exhibit complex phase formation behavior, challenging conventional predictive methods. This study presents a machine learning (ML) framework for phase prediction in HEAs, using a curated dataset of 648 experimentally characterized compositions and features derived from thermodynamic and electronic descriptors. Three classifiers—random forest, gradient boosting, and CatBoost—were trained and validated through cross-validation and testing. Gradient boosting achieved the highest accuracy, and valence electron concentration (VEC), atomic size mismatch (δ), and enthalpy of mixing (ΔHmix) were identified as the most influential features. The model predictions were experimentally verified using a non-equiatomic Al₃₀Cu₁₇.₅Fe₁₇.₅Cr₁₇.₅Mn₁₇.₅ alloy and the equiatomic Cantor alloy (CoCrFeMnNi), both of which showed strong agreement with predicted phase structures. The results demonstrate that combining physically informed feature engineering with ML enables accurate and generalizable phase prediction, supporting accelerated HEA design.

Citations

Citations to this article as recorded by

Preparation and Arc Erosion Behavior of Cu-Based Contact Materials Reinforced with High Entropy Particles CuCrNiCoFe
Jiacheng Tong, Jun Wang, Huimin Zhang, Haoran Liu, Youchang Sun, Zhiguo Li, Wenyi Zhang, Zhe Wang, Yanli Chang, Zhao Yuan, Henry Hu
Metallurgical and Materials Transactions B.2025;[Epub] CrossRef
Recent progresses on high entropy alloy development using machine learning: A review
Abhishek Kumar, Nilay Krishna Mukhopadhyay, Thakur Prasad Yadav
Computational Materials Today.2025; : 100038. CrossRef

[Korean]
Friction Stir Spot Welding Characteristics of Dissimilar Materials of Aluminum-Based Damping Composites and Steel Plates: Si-Seon Park, Young-Keun Jeong; J Powder Mater. 2025;32(1):43-49. Published online February 28, 2025; DOI: https://doi.org/10.4150/jpm.2025.00010

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Abstract PDF: Friction Stir Spot Welding (FSSW) is a solid-state welding technology that is rapidly growing in the automotive industry. Achieving superior welding characteristics requires the proper selection of tool geometry and process conditions. In this study, FSSW was performed on dissimilar materials comprising AA5052-HO/hot-melt aluminum alloy sheets and Steel Plate Cold Rolled for Deep Drawing Use(SPCUD) steel sheets. The effects of tool geometry, plate arrangement, and tool plunge depth on the welding process were investigated. At the joint interface between the aluminum alloy and the steel sheet, new intermetallic compounds (IMCs) were observed. As the plunge depth increased, thicker and more continuous IMC layers were formed. However, excessive plunge depth led to discontinuous layers and cracking defects. An analysis of the IMCs revealed a correlation between the IMC thickness and the shear tensile load. Furthermore, compared to the conventional Al-Top arrangement, the St-Top arrangement exhibited reduced deformation and superior shear tensile load values. These findings indicate that plate arrangement significantly influences the mechanical properties of the joint.

[English]
Recent Advances in Thermoelectric Materials and Devices: Improving Power Generation Performance: Momanyi Amos Okirigiti, Cheol Min Kim, Hyejeong Choi, Nagamalleswara Rao Alluri, Kwi-Il Park; J Powder Mater. 2025;32(1):1-15. Published online February 28, 2025; DOI: https://doi.org/10.4150/jpm.2024.00395

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1 Citations

Abstract PDF

Thermoelectric materials have been the focus of extensive research interest in recent years due to their potential in clean power generation from waste heat. Their conversion efficiency is primarily reflected by the dimensionless figure of merit, with higher values indicating better performance. There is a pressing need to discover materials that increase output power and improve performance, from the material level to device fabrication. This review provides a comprehensive analysis of recent advancements, such as Bi2Te3-based nanostructures that reduce thermal conductivity while maintaining electrical conductivity, GeTe-based high entropy alloys that utilize multiple elements for improved thermoelectric properties, porous metal-organic frameworks offering tunable structures, and organic/hybrid films that present low-cost, flexible solutions. Innovations in thermoelectric generator designs, such as asymmetrical geometries, segmented modules, and flexible devices, have further contributed to increased efficiency and output power. Together, these developments are paving the way for more effective thermoelectric technologies in sustainable energy generation.

Citations

Citations to this article as recorded by

Mathematical and simulation modeling of photovoltaic systems utilizing thermoelectric modules for effective thermal management
Muhammad Sohaib Tahir, Xue Dong, Muhammad Mansoor Khan
Results in Engineering.2025; 27: 106344. CrossRef

[Korean]
Fabrication and Optimization of Al₂O₃ Microchannels Using DLP-Based 3D Printing: Jun-Min Cho, Yong-Jun Seo, Yoon-Soo Han; J Powder Mater. 2025;32(1):59-66. Published online February 28, 2025; DOI: https://doi.org/10.4150/jpm.2024.00346

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Abstract PDF: This study focused on optimizing the digital light processing (DLP) 3D printing process for high-precision ceramic components using alumina-based slurries. Key challenges, such as cracking during debinding and precision loss due to slurry sedimentation, were addressed by evaluating the exposure time and the nano-to-micro alumina powder ratios. The optimal conditions—exposure time of 15 seconds and a 1:9 mixing ratio—minimized cracking, improved gas flow during debinding, and increased structural precision. Microchannels with diameters above 1.2 mm were successfully fabricated, but channels below 0.8 mm faced challenges due to slurry accumulation and over-curing. These results establish a reliable process for fabricating complex ceramic components with improved precision and structural stability. The findings have significant potential for applications in high-value industries, including aerospace, energy, and healthcare, by providing a foundation for the efficient and accurate production of advanced ceramic structures.

[Korean]
Fabrication and High-Temperature Performance Evaluation of Light-Weight Insulation Materials and Coatings for Reusable Thermal Protection Systems: Min-Soo Nam, Jong-Il Kim, Jaesung Shin, Hyeonjun Kim, Bum-Seok Oh, Seongwon Kim; J Powder Mater. 2024;31(6):521-529. Published online December 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00318

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Abstract PDF: Light-weight ceramic insulation materials and high-emissivity coatings were fabricated for reusable thermal protection systems (TPS). Alumina-silica fibers and boric acid were used to fabricate the insulation, which was heat treated at 1250 °C. High-emissivity coating of borosilicate glass modified with TaSi2, MoSi2, and SiB6 was applied via dip-and-spray coating methods and heat-treated at 1100°C. Testing in a high-velocity oxygen fuel environment at temperatures over 1100 °C for 120 seconds showed that the rigid structures withstood the flame robustly. The coating effectively infiltrated into the fibers, confirmed by scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction analyses. Although some oxidation of TaSi2 occurred, thereby increasing the Ta2O5 and SiO2 phases, no significant phase changes or performance degradation were observed. These results demonstrate the potential of these materials for reusable TPS applications in extreme thermal environments.

[English]
Epsilon Iron Oxide (ε-Fe₂O₃) as an Electromagnetic Functional Material: Properties, Synthesis, and Applications: Ji Hyeong Jeong, Hwan Hee Kim, Jung-Goo Lee, Youn-Kyoung Baek; J Powder Mater. 2024;31(6):465-479. Published online December 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00290

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Abstract PDF: Iron oxide (ε-Fe₂O₃) is emerging as a promising electromagnetic material due to its unique magnetic and electronic properties. This review focuses on the intrinsic properties of ε-Fe₂O₃, particularly its high coercivity, comparable to that of rare-earth magnets, which is attributed to its significant magnetic anisotropy. These properties render it highly suitable for applications in millimeter wave absorption and high-density magnetic storage media. Furthermore, its semiconducting behavior offers potential applications in photocatalytic hydrogen production. The review also explores various synthesis methods for fabricating ε-Fe₂O₃ as nanoparticles or thin films, emphasizing the optimization of purity and stability. By exploring and harnessing the properties of ε-Fe₂O₃, this study aims to contribute to the advancement of next-generation electromagnetic materials with potential applications in 6G wireless telecommunications, spintronics, high-density data storage, and energy technologies.

[English]
Effect of Calcium Addition on the High-Temperature Recovery of Nd and Dy from Nd-Fe-B Scrap Using Mg-Based Extractants: Hyoseop Kim; J Powder Mater. 2024;31(6):493-499. Published online December 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00283

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Abstract PDF: This study investigated whether calcium (Ca) addition improved the recovery of neodymium (Nd) and dysprosium (Dy) from Nd-Fe-B magnet scrap using magnesium (Mg)-based liquid metal extraction (LME). Traditional LME processes are limited to temperatures up to 850 °C due to oxidation issues, reducing the efficiency of rare earth element (REE) recovery, especially for Dy. By adding 10 wt.% Ca to Mg and increasing the processing temperature to 1,000 °C, we achieved nearly 100% Nd and approximately 38% Dy recovery, compared to 91% and 28%, respectively, with pure Mg at 850 °C. However, excessive Ca addition (20 wt.%) decreased the recovery efficiency due to the formation of stable intermetallic compounds. These results highlight the critical role of Ca in optimizing REE recycling from Nd-Fe-B magnet scrap.

[Korean]
Microstructure and Mechanical Properties of Laser Powder Bed Fusion 3D-Printed Cu-10Sn Alloy: Jonggyu Kim, Junghoon Won, Wookjin Lee; J Powder Mater. 2024;31(5):422-430. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00276

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Abstract PDF: This study investigated the optimal process conditions and mechanical properties of Cu-10Sn alloys produced by the powder bed fusion (PBF) method. The optimal PBF conditions were explored by producing samples with various laser scanning speeds and laser power. It was found that under optimized conditions, samples with a density close to the theoretical density could be fabricated using PBF without any serious defects. The microstructure and mechanical properties of samples produced under optimized conditions were investigated and compared with a commercial alloy produced by the conventional method. The hardness, maximum tensile strength, and elongation of the samples were significantly higher than those of the commercially available cast alloy with the same chemical composition. Based on these results, it is expected to be possible to use the PBF technique to manufacture Cu-10Sn products with complex 3D shapes that could not be made using the conventional manufacturing method.

[Korean]
Effect of TiO₂ Content on High-Temperature Degradation Behavior of Nd₂O₃ and Yb₂O₃ Doped YSZ Composite Materials: Gye-Won Lee, Seonung Choi, Tae-jun Park, Jong-il Kim, In-hwan Lee, Yoon-seok Oh; J Powder Mater. 2024;31(5):431-436. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00269

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Abstract PDF: Hot section components of gas turbines are exposed to a high operating temperature environment. To protect these components, thermal barrier coatings (TBC) are applied to their surfaces. Yttria-stabilized zirconia (YSZ), which is widely used as a TBC material, faces limitations at temperatures above 1200℃. To mitigate these issues, research has focused on adding lanthanide rare earth oxides and tetravalent oxides to prevent the phase-transformation of the monoclinic phase in zirconia. This study investigated the effects of varying TiO2 content in Nd2O3 and Yb2O3 co-doped YSZ composites. Increasing TiO2 content effectively suppressed formation of the monoclinic phase and increased the thermal degradation resistance compared to YSZ in environments over 1200℃. These findings will aid in developing more thermally stable and efficient TBC materials for application in high-temperature environments.

[English]
Machine Learning Modeling of the Mechanical Properties of Al2024-B4C Composites: Maurya A. K., Narayana P. L., Wang X.-S., Reddy N. S.; J Powder Mater. 2024;31(5):382-389. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00234

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Abstract PDF: Aluminum-based composites are in high demand in industrial fields due to their light weight, high electrical conductivity, and corrosion resistance. Due to its unique advantages for composite fabrication, powder metallurgy is a crucial player in meeting this demand. However, the size and weight fraction of the reinforcement significantly influence the components' quality and performance. Understanding the correlation of these variables is crucial for building high-quality components. This study, therefore, investigated the correlations among various parameters—namely, milling time, reinforcement ratio, and size—that affect the composite’s physical and mechanical properties. An artificial neural network model was developed and showed the ability to correlate the processing parameters with the density, hardness, and tensile strength of Al2024-B4C composites. The predicted index of relative importance suggests that the milling time has the most substantial effect on fabricated components. This practical insight can be directly applied in the fabrication of high-quality Al2024-B4C composites.

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