Journal of Powder Materials

Friction Welding of Casted SCM440 and Sintered F-05-140 Dissimilar Steels and Their Joint Properties under Various Welding Conditions: Jisung Lee, Hansung Lee, Eunhyo Song, Byungmin Ahn; J Powder Mater. 2024;31(5):414-421. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00311

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Abstract PDF: Friction welding, which uses heat and plastic flow to join metals, is expanding across industries due to its ability to weld heterogeneous alloys and simple process. However, process research is essential for materials with complex geometries, and limited research has been conducted on friction welding between cast and sintered metals. This study analyzed the mechanical properties and microstructural evolution of the joint by controlling the rotational speed and friction pressure, which affect the removal of the heat-affected zone in friction welding of casted SCM440 and sintered F-05-140. Hardness mapping and microstructure observations with material transition were performed to investigate the correlation between phase behavior and welding conditions. These results are anticipated to reduce costs and improve the mechanical properties of key mobility components.

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.

Comparative Review of the Microstructural and Mechanical Properties of Ti-6Al-4V Fabricated via Wrought and Powder Metallurgy Processes: Raj Narayan Hajra, Gargi Roy, An Seong Min, Hyunseok Lee, Jeoung Han Kim; J Powder Mater. 2024;31(5):365-373. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00213

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Abstract PDF: This review examines the microstructural and mechanical properties of a Ti-6Al-4V alloy produced by wrought processing and powder metallurgy (PM), specifically laser powder bed fusion (LPBF) and hot isostatic pressing. Wrought methods, such as forging and rolling, create equiaxed alpha (α) and beta (β) grain structures with balanced properties, which are ideal for fatigue resistance. In contrast, PM methods, particularly LPBF, often yield a martensitic α′ structure with high microhardness, enabling complex geometries but requiring post-processing to improve its properties and reduce stress. The study evaluated the effects of processing parameters on grain size, phase distribution, and material characteristics, guiding the choice of fabrication techniques for optimizing Ti-6Al-4V performance in aerospace, biomedical, and automotive applications. The analysis emphasizes tailored processing to meet advanced engineering demands.

Recovery of Barium, Nickel, and Titanium Powders from Waste MLCC: Haein Shin, Kun-Jae Lee; J Powder Mater. 2024;31(5):374-381. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00192

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Abstract PDF: The development of the electronics industry has led to an increased demand for the manufacture of MLCC (Multilayer Ceramic Capacitors), which in turn is expected to result in a rise in MLCC waste. The MLCC contains various metals, notably barium, titanium, and nickel, whose disposal is anticipated to increase correspondingly. Recently, recycling technologies for electronic waste have garnered attention as they address waste management and raw material supply challenges. This paper investigates the recovery of barium, nickel, and titanium from the MLCC by a hydrometallurgical process. Using citric acid, which is an organic acid, the metal inside the MLCC was leached. Additionally, metal materials were recovered through precipitation and complexing processes. As a result, barium and titanium were recovered from the leachate of the waste MLCC, and 93% of the nickel-based powder was recovered. Furthermore, the optimal recovery process conditions for recycling these metal elements were investigated.

The Use of TiH₂ to Refine Y₂Ti₂O7 in a Nano Mo-ODS Alloy: Yuncheol Ha, Chun Woong Park, Won Hee Lee, Jongmin Byun, Young Do Kim; J Powder Mater. 2024;31(5):399-405. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00178

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Abstract PDF: Mo-ODS alloys have excellent mechanical properties, including an improved recrystallization temperature, greater strength due to dispersed oxides, and the ability to suppress grain growth at high temperatures. In ODS alloys, the dispersed Y2O3 and added Ti form Y-Ti-O complex oxides, producing finer particles than those in the initial Y2O3. The complex oxides increase high-temperature stability and improve the mechanical properties of the alloy. In particular, the use of TiH2 powder, which is more brittle than conventional Ti, can enable the distribution of finer oxides than is possible with conventional Ti powder during milling. Moreover, dehydrogenation leads to a more refined powder size in the reduction process. This study investigated the refinement of Y2Ti2O7 in a nano Mo-ODS alloy using TiH2. The alloy compositions were determined to be Mo-0.5Ti-0.5Y2O3 and Mo-1.0Ti-0.5Y2O3. The nano Mo-ODS alloys were fabricated using Ti and TiH2 to explore the effects of adding different forms of Ti. The sintered specimens were analyzed through X-ray diffraction for phase analysis, and the microstructure of the alloys was analyzed using scanning electron microscopy and transmission electron microscopy. Vickers hardness tests were conducted to determine the effect of the form of Ti added on the mechanical properties, and it was found that using TiH2 effectively improved the mechanical properties.

High-Hardness Cemented Carbide With Nickel-Tungsten Alloy Binder: Hanjung Kwon; J Powder Mater. 2024;31(4):318-323. Published online August 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00227

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Abstract PDF: Cemented carbide for cutting tools, which is composed of carbide as a hard phase and metallic component as a metallic phase, mainly uses cobalt as the metallic phase due to the excellent mechanical properties of cobalt. However, as the demand for machining difficult-to-machine materials such as titanium and carbon fiber-reinforced plastics has recently increased, the development of high-hardness cemented carbide is necessary and the replacement of cobalt metal with a high-hardness alloy is required. In this study, we would like to introduce high-hardness cemented carbide fabricated using nickel-tungsten alloy as the metallic phase. First, nickel-tungsten alloy powder of the composition for formation of intermetallic compound confirmed through thermodynamic calculations was synthesized, and cemented carbide was prepared through the sintering process of tungsten carbide and the synthesized alloy powder. Through evaluating the mechanical properties of high-hardness cemented carbide with the nickel-tungsten alloy binder, the possibility of producing high-hardness cemented carbide by using the alloys with high-hardness was confirmed.

Fabrication of 3D Aligned h-BN based Polymer Composites with Enhanced Mechanical Properties for Battery Housing: Kiho Song, Hyunseung Song, Sang In Lee, Changui Ahn; J Powder Mater. 2024;31(4):329-335. Published online August 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00220

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Abstract PDF Supplementary Material: As the demand for electric vehicles increases, the stability of batteries has become one of the most significant issues. The battery housing, which protects the battery from external stimuli such as vibration, shock, and heat, is the crucial element in resolving safety problems. Conventional metal battery housings are being converted into polymer composites due to their lightweight and improved corrosion resistance to moisture. The transition to polymer composites requires high mechanical strength, electrical insulation, and thermal stability. In this paper, we proposes a high-strength nanocomposite made by infiltrating epoxy into a 3D aligned h-BN structure. The developed 3D aligned h-BN/epoxy composite not only exhibits a high compressive strength (108 MPa) but also demonstrates excellent electrical insulation and thermal stability, with a stable electrical resistivity at 200 °C and a low thermal expansion coefficient (11.46ⅹppm/℃), respectively.

Microstructural Effects on the Mechanical Properties of Ti-6Al-4V Fabricated by Direct Energy Deposition: Juho Kim, Seoyeon Jeon, Hwajin Park, Taeyoel Kim, Hyunjoo Choi; J Powder Mater. 2024;31(4):302-307. Published online August 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00157

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Abstract PDF: This study explored the process-structure-property (PSP) relationships in Ti-6Al-4V alloys fabricated through direct energy deposition (DED) additive manufacturing. A systematic investigation was conducted to clarify how process variables—specifically, manipulating the cooling rate and energy input by adjusting the laser power and scan speed during the DED process—influenced the phase fractions, pore structures, and the resultant mechanical properties of the samples under various processing conditions. Significant links were found between the controlled process parameters and the structural and mechanical characteristics of the produced alloys. The findings of this research provide foundational knowledge that will drive the development of more effective and precise control strategies in additive manufacturing, thereby improving the performance and reliability of produced materials. This, in turn, promises to make significant contributions to both the advancement of additive manufacturing technologies and their applications in critical sectors.

Effect of Anisotropy on the Wear Behavior of Age-Treated Maraging Steel Manufactured by LPBF: Seung On Lim, Se-Eun Shin; J Powder Mater. 2024;31(4):308-317. Published online August 5, 2024; DOI: https://doi.org/10.4150/jpm.2024.00171

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Abstract PDF

Maraging steel has excellent mechanical properties resulting from the formation of precipitates within the matrix through aging treatment. Maraging steel fabricated by the laser powder bed fusion (LPBF) process is suitable for applications including precise components and optimized design. The anisotropic characteristic, which depends on the stacking direction, affects the mechanical properties. This study aimed to analyze the influence of anisotropy on the wear behavior of maraging steel after aging treatment. The features of additive manufacturing tended to disappear after heat treatment. However, some residual cellular and dendrite structures were observed. In the wear tests, a high wear rate was observed on the building direction plane for all counter materials. This is believed to be because the oxides formed on the wear track positively affected the wear characteristics; meanwhile, the bead shape in the stacking direction surface was vulnerable to wear, leading to significant wear.

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A Parametric Study on the L-PBF Process of an AlSi10Mg Alloy for High-Speed Productivity of Automotive Prototype Parts
Yeonha Chang, Hyomoon Joo, Wanghyun Yong, Yeongcheol Jo, Seongjin Kim, Hanjae Kim, Yeon Woo Kim, Kyung Tae Kim, Jeong Min Park
Journal of Powder Materials.2024; 31(5): 390. CrossRef

Study on the Elemental Diffusion Distance of a Pure Nickel Layer Additively Manufactured on 316H Stainless Steel: UiJun Ko, Won Chan Lee, Gi Seung Shin, Ji-Hyun Yoon, Jeoung Han Kim; J Powder Mater. 2024;31(3):220-225. Published online June 27, 2024; DOI: https://doi.org/10.4150/jpm.2024.00164

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Abstract PDF: Molten salt reactors represent a promising advancement in nuclear technology due to their potential for enhanced safety, higher efficiency, and reduced nuclear waste. However, the development of structural materials that can survive under severe corrosion environments is crucial. In the present work, pure Ni was deposited on the surface of 316H stainless steel using a directed energy deposition (DED) process. This study aimed to fabricate pure Ni alloy layers on an STS316H alloy substrate. It was observed that low laser power during the deposition of pure Ni on the STS316H substrate could induce stacking defects such as surface irregularities and internal voids, which were confirmed through photographic and SEM analyses. Additionally, the diffusion of Fe and Cr elements from the STS316H substrate into the Ni layers was observed to decrease with increasing Ni deposition height. Analysis of the composition of Cr and Fe components within the Ni deposition structures allows for the prediction of properties such as the corrosion resistance of Ni.

TiO₂ Thin Film Coating on an Nb-Si–Based Superalloy via Atomic Layer Deposition: Ji Young Park, Su Min Eun, Jongmin Byun, Byung Joon Choi; J Powder Mater. 2024;31(3):255-262. Published online June 27, 2024; DOI: https://doi.org/10.4150/jpm.2024.00052

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Abstract PDF: Nano-oxide dispersion–strengthened (ODS) superalloys have attracted attention because of their outstanding mechanical reinforcement mechanism. Dispersed oxides increase the material’s strength by preventing grain growth and recrystallization, as well as increasing creep resistance. In this research, atomic layer deposition (ALD) was applied to synthesize an ODS alloy. It is useful to coat conformal thin films even on complex matrix shapes, such as nanorods or powders. We coated an Nb-Si–based superalloy with TiO2 thin film by using rotary-reactor type thermal ALD. TiO2 was grown by controlling the deposition recipe, reactor temperature, N2 flow rate, and rotor speed. We could confirm the formation of uniform TiO2 film on the surface of the superalloy. This process was successfully applied to the synthesis of an ODS alloy, which could be a new field of ALD applications.

Recent Developments in Quantum Dot Patterning Technology for Quantum Dot Display: Yeong Jun Jin, Kyung Jun Jung, Jaehan Jung; J Powder Mater. 2024;31(2):169-179. Published online April 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00073

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Abstract PDF: Colloidal quantum dot (QDs) have emerged as a crucial building block for LEDs due to their size-tunable emission wavelength, narrow spectral line width, and high quantum efficiency. Tremendous efforts have been dedicated to improving the performance of quantum dot light-emitting diodes (QLEDs) in the past decade, primarily focusing on optimization of device architectures and synthetic procedures for high quality QDs. However, despite these efforts, the commercialization of QLEDs has yet to be realized due to the absence of suitable large-scale patterning technologies for high-resolution devices., This review will focus on the development trends associated with transfer printing, photolithography, and inkjet printing, and aims to provide a brief overview of the fabricated QLED devices. The advancement of various quantum dot patterning methods will lead to the development of not only QLED devices but also solar cells, quantum communication, and quantum computers.

Data-driven Approach to Explore the Contribution of Process Parameters for Laser Powder Bed Fusion of a Ti-6Al-4V Alloy: Jeong Min Park, Jaimyun Jung, Seungyeon Lee, Haeum Park, Yeon Woo Kim, Ji-Hun Yu; J Powder Mater. 2024;31(2):137-145. Published online April 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00038

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Abstract PDF: In order to predict the process window of laser powder bed fusion (LPBF) for printing metallic components, the calculation of volumetric energy density (VED) has been widely calculated for controlling process parameters. However, because it is assumed that the process parameters contribute equally to heat input, the VED still has limitation for predicting the process window of LPBF-processed materials. In this study, an explainable machine learning (xML) approach was adopted to predict and understand the contribution of each process parameter to defect evolution in Ti alloys in the LPBF process. Various ML models were trained, and the Shapley additive explanation method was adopted to quantify the importance of each process parameter. This study can offer effective guidelines for fine-tuning process parameters to fabricate high-quality products using LPBF.

Inorganic Compound and Cycloserine Composite Particles for Improved Stability: Dongwon Kim, Heeseo Kim, Hongjun Yoon, Hyuk Jun Cho, Sung Giu Jin; J Powder Mater. 2024;31(2):126-131. Published online April 30, 2024; DOI: https://doi.org/10.4150/jpm.2024.00002

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Abstract PDF: The aim of this study was to improve the chemical stability of cycloserine containing organic and inorganic compounds. Composite particles were manufactured with a 1:1 weight ratio of organic/inorganic compounds and cycloserine. The influence of organic/inorganic compounds on the stability of cycloserine was investigated under accelerated stress conditions at 60°C/75% RH for 24 hours. In addition, the properties of the composite particles were evaluated using differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and the dissolution of the drug was assessed by preparing it as a hard capsule. Among the organic and inorganic compounds investigated, calcium hydroxide most improved the stability of cycloserine under accelerated stress conditions (53.3 ± 2.2% vs 1.7 ± 0.2%). DSC results confirmed the compatibility between calcium hydroxide and the cycloserine, and SEM results confirmed that it was evenly distributed around the cycloserine. Calcium hydroxide also showed more than 90% cycloserine dissolution within 15 minutes. Therefore, the calcium hydroxide and cycloserine composite particles may be candidates for cycloserine oral pharmaceuticals with enhanced drug stability.

Fabrication of Ti-Mo Core-shell Powder and Sintering Properties for Application as a Sputtering Target: Won Hee Lee, Chun Woong Park, Heeyeon Kim, Yuncheol Ha, Jongmin Byun, Young Do Kim; J Powder Mater. 2024;31(1):43-49. Published online February 28, 2024; DOI: https://doi.org/10.4150/KPMI.2024.31.1.43

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