Journal of Powder Materials

[English]
SnF₂-Induced LiF Interphase for Stable Lithium Metal Anodes with Suppressed Dendrite Growth: Yeong Hoon Jeon, Seul Ki Choi, Yun Seung Nah, Wonil Shin, Yong-Ho Choa, Minho Yang; J Powder Mater. 2025;32(3):212-221. Published online June 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00164

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Abstract PDF: Lithium (Li) metal is a promising anode for next-generation batteries due to its high capacity, low redox potential, and low density. However, dendrite growth and interfacial instability limit its use. In this study, an artificial solid electrolyte interphase layer of LiF and Li-Sn (LiF@Li-Sn) was fabricated by spray-coating SnF2 onto Li. The LiF@Li-Sn anode exhibited improved air stability and electrochemical performance. Electrochemical impedance spectroscopy indicated a charge transfer resistance of 25.2 Ω after the first cycle. In symmetric cells, it maintained a low overpotential of 27 mV after 250 cycles at 2 mA/cm2, outperforming bare Li. In situ microscopy confirmed dendrite suppression during plating. Full cells with NMC622 cathodes and LiF@Li-Sn anodes delivered 130.8 mAh/g with 79.4% retention after 300 cycles at 1 C and 98.8% coulombic efficiency. This coating effectively stabilized the interface and suppressed dendrites, with promising implications for practical lithium metal batteries.

[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]
Fabrication and Alloying Behavior of Ultra-Lightweight AlTiCrVMg High-Entropy Alloy via Al-Mg Mutual Solubility and Sintering Control: Eunhyo Song, Hansung Lee, Byungmin Ahn; J Powder Mater. 2025;32(3):254-261. Published online June 12, 2025; DOI: https://doi.org/10.4150/jpm.2025.00059

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Abstract PDF: High-entropy alloys (HEAs) incorporating low-melting-point elements (Mg and Al) and high-melting-point elements (Ti, Cr, and V) were fabricated via mechanical alloying and spark plasma sintering. Sintering temperatures were varied to investigate phase behavior and microstructural evolution. X-ray diffraction was used to identify phase structures, scanning electron microscopy to analyze microstructures, X-ray fluorescence to determine elemental composition, and a gas pycnometer to measure density. Micro-Vickers hardness testing was conducted to evaluate mechanical properties. Mechanical-alloyed HEAs exhibited a body-centered cubic (BCC) phase and lamellar structures with element-enriched regions. Sintering introduced additional BCC and Laves phases, while higher temperatures promoted Mg liquid-phase sintering, increasing density and hardness. This study highlights the effects of sintering on HEAs containing elements with differing melting points to optimize their properties.

[English]
Stretch-Flangeability of Laser Powder Bed Fusion-Processed 316L Stainless Steel: Rae Eon Kim, Yeon Taek Choi, Sang Guk Jeong, Do Won Lee, Hyoung Seop Kim; J Powder Mater. 2025;32(2):87-94. Published online April 30, 2025; DOI: https://doi.org/10.4150/jpm.2025.00017

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Abstract PDF Supplementary Material: Metal additive manufacturing (AM) facilitates the production of complex geometries with enhanced functionality. Among various AM techniques, laser powder bed fusion (LPBF) is distinguished by its precision and exceptional mechanical properties achieved via laser fusion deposition. Recent advancements in AM have focused on combining LPBF with post-processing methods such as cold rolling, high-pressure torsion, and forming processes. Therefore, understanding the forming behavior of LPBF-processed materials is essential for industrial adoption. This study investigates the stretch-flangeability of LPBF-fabricated 316L stainless steel, emphasizing its anisotropic microstructure and mechanical properties. Hole expansion tests were employed to assess stretch-flangeability in comparison to wrought 316L stainless steel. The results demonstrate that LPBF-processed samples exhibit significant anisotropic behavior, demonstrating the influence of microstructural evolution on formability. These findings contribute valuable insights into optimizing LPBF materials for industrial forming applications.

[English]
A Review of Recent Developments in CoCrFeMnNi High-Entropy Alloys Processed by Powder Metallurgy: Cheenepalli Nagarjuna, Sheetal Kumar Dewangan, Hansung Lee, Eunhyo Song, K. Raja Rao, Byungmin Ahn; J Powder Mater. 2025;32(2):145-164. Published online April 30, 2025; DOI: https://doi.org/10.4150/jpm.2024.00430

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Abstract PDF: In recent years, high-entropy alloys (HEAs) have attracted considerable attention in materials engineering due to their unique phase stability and mechanical properties compared to conventional alloys. Since the inception of HEAs, CoCrFeMnNi alloys have been widely investigated due to their outstanding strength and fracture toughness at cryogenic temperatures. However, their lower yield strength at room temperature limits their structural applications. The mechanical properties of HEAs are greatly influenced by their processing methods and microstructural features. Unlike traditional melting techniques, powder metallurgy (PM) provides a unique opportunity to produce HEAs with nanocrystalline structures and uniform compositions. The current review explores recent advances in optimizing the microstructural characteristics in CoCrFeMnNi HEAs by using PM techniques to improve mechanical performance. The most promising strategies include grain refinement, dispersion strengthening, and the development of heterogeneous microstructures (e.g., harmonic, bimodal, and multi-metal lamellar structures). Thermomechanical treatments along with additive manufacturing techniques are also summarized. Additionally, the review addresses current challenges and suggests future research directions for designing advanced HEAs through PM techniques.

[English]
High-Temperature Steam Oxidation Behavior of Silicide- or Aluminide- Coated Mo and Nb Refractory Metals: Woojin Lim, Je-Kyun Baek, JaeJoon Kim, Hyun Gil Kim, Ho Jin Ryu; J Powder Mater. 2024;31(6):546-555. Published online December 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00381

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Abstract PDF: Refractory materials, such as molybdenum and niobium, are potential candidates for cladding material due to their high melting temperatures and desirable mechanical properties at higher temperatures than those of zirconium alloys. However, refractory materials have low resistance to oxidation at elevated temperatures. Therefore, this study examined silicide or aluminide surface coatings as protection against rapid oxidation of refractory materials at elevated temperatures for a potential accident-tolerant fuel cladding. Silicide or aluminide layers were formed on refractory metal substrates by using the pack cementation method. The steam oxidation behavior of both coated and uncoated samples was compared by thermogravimetric analysis at 1200°C. The weight changes of the coated samples were greatly reduced than those of uncoated samples. Microstructural analyses demonstrated that the silicide and aluminide layers were oxidized to form a protective surface oxide that prevented rapid oxidation of the refractory substrate at elevated temperatures.

[English]
Advances in Powder Metallurgy for High-Entropy Alloys: Sheetal Kumar Dewangan, Cheenepalli Nagarjuna, Hansung Lee, K. Raja Rao, Man Mohan, Reliance Jain, Byungmin Ahn; J Powder Mater. 2024;31(6):480-492. Published online December 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00297

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Abstract PDF: High-entropy alloys (HEAs) represent a revolutionary class of materials characterized by their multi-principal element compositions and exceptional mechanical properties. Powder metallurgy, a versatile and cost-effective manufacturing process, offers significant advantages for the development of HEAs, including precise control over their composition, microstructure, and mechanical properties. This review explores innovative approaches integrating powder metallurgy techniques in the synthesis and optimization of HEAs. Key advances in powder production, sintering methods, and additive manufacturing are examined, highlighting their roles in improving the performance, advancement, and applicability of HEAs. The review also discusses the mechanical properties, potential industrial applications, and future trends in the field, providing a comprehensive overview of the current state and future prospects of HEA development using powder metallurgy.

[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]
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.

[English]
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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2 Citations

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.

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Removal of Organic and Inorganic Contaminants from Titanium Turning Scrap via Alkali and Acid Two-Step Cleaning
Seong Min An, Raj Narayan Hajra, Chan Hee Park, Jin-Ho Yoon, Jinsung Rho, Chang-Min Yoon, Jeoung Han Kim
MATERIALS TRANSACTIONS.2025; 66(7): 855. CrossRef
Effect of oxygen content in feedstock powders on microstructure and mechanical properties of ELI Ti-6Al-4V fabricated via laser powder bed fusion
Woo Hyeok Kim, Sang Woo Kim, Raj Narayan Hajra, Gargi Roy, Jeoung Han Kim
Powder Metallurgy.2025;[Epub] CrossRef

[Korean]
Effect of Sintering Conditions on the Microstructure of an FeCrMnNiCo High-Entropy Alloy: Seonghyun Park, Sang-Hwa Lee, Junho Lee, Seok-Jae Lee, Jae-Gil Jung; J Powder Mater. 2024;31(5):406-413. Published online October 31, 2024; DOI: https://doi.org/10.4150/jpm.2024.00185

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Abstract PDF

We investigated the microstructure of an FeCrMnNiCo alloy fabricated by spark plasma sintering under different sintering temperatures (1000–1100°C) and times (1–600 s). All sintered alloys consisted of a single face-centered cubic phase. As the sintering time or temperature increased, the grains of the sintered alloys became partially coarse. The formation of Cr7C3 carbide occurred on the surface of the sintered alloys due to carbon diffusion from the graphite crucible. The depth of the layer containing Cr7C3 carbides increased to ~110 μm under severe sintering conditions (1100°C, 60 s). A molten zone was observed on the surface of the alloys sintered at higher temperatures (>1060°C) due to severe carbon diffusion that reduced the melting point of the alloy. The porosity of the sintered alloys decreased with increasing time at 1000°C, but increased at higher temperatures above 1060°C due to melting-induced porosity formation.

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Fabrication and Alloying Behavior of Ultra-Lightweight AlTiCrVMg High-Entropy Alloy via Al-Mg Mutual Solubility and Sintering Control
Eunhyo Song, Hansung Lee, Byungmin Ahn
Journal of Powder Materials.2025; 32(3): 254. CrossRef

[Korean]
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.

[English]
Trends in Materials Modeling and Computation for Metal Additive Manufacturing: Seoyeon Jeon, Hyunjoo Choi; J Powder Mater. 2024;31(3):213-219. Published online June 27, 2024; DOI: https://doi.org/10.4150/jpm.2024.00150

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Abstract PDF

Additive Manufacturing (AM) is a process that fabricates products by manufacturing materials according to a three-dimensional model. It has recently gained attention due to its environmental advantages, including reduced energy consumption and high material utilization rates. However, controlling defects such as melting issues and residual stress, which can occur during metal additive manufacturing, poses a challenge. The trial-and-error verification of these defects is both time-consuming and costly. Consequently, efforts have been made to develop phenomenological models that understand the influence of process variables on defects, and mechanical/electrical/thermal properties of geometrically complex products. This paper introduces modeling techniques that can simulate the powder additive manufacturing process. The focus is on representative metal additive manufacturing processes such as Powder Bed Fusion (PBF), Direct Energy Deposition (DED), and Binder Jetting (BJ) method. To calculate thermal-stress history and the resulting deformations, modeling techniques based on Finite Element Method (FEM) are generally utilized. For simulating the movements and packing behavior of powders during powder classification, modeling techniques based on Discrete Element Method (DEM) are employed. Additionally, to simulate sintering and microstructural changes, techniques such as Monte Carlo (MC), Molecular Dynamics (MD), and Phase Field Modeling (PFM) are predominantly used.

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Review of “Integrated Computer-Aided Process Engineering Session in the 17th International Symposium on Novel and Nano Materials (ISNNM, 14–18 November 2022)”
Yeon-Joo Lee, Pil-Ryung Cha, Hyoung-Seop Kim, Hyun-Joo Choi
MATERIALS TRANSACTIONS.2025; 66(1): 144. CrossRef

[English]
Characterization of the Manufacturing Process and Mechanical Properties of CoCrFeMnNi High-Entropy Alloys via Metal Injection Molding and Hot Isostatic Pressing: Eun Seong Kim, Jae Man Park, Do Won Lee, Hyojeong Ha, Jungho Choe, Jaemin Wang, Seong Jin Park, Byeong-Joo Lee, Hyoung Seop Kim; J Powder Mater. 2024;31(3):243-254. Published online June 27, 2024; DOI: https://doi.org/10.4150/jpm.2024.00059

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Abstract PDF: High-entropy alloys (HEAs) have been reported to have better properties than conventional materials; however, they are more expensive due to the high cost of their main components. Therefore, research is needed to reduce manufacturing costs. In this study, CoCrFeMnNi HEAs were prepared using metal injection molding (MIM), which is a powder metallurgy process that involves less material waste than machining process. Although the MIM-processed samples were in the face-centered cubic (FCC) phase, porosity remained after sintering at 1200°C, 1250°C, and 1275°C. In this study, the hot isostatic pressing (HIP) process, which considers both temperature (1150°C) and pressure (150 MPa), was adopted to improve the quality of the MIM samples. Although the hardness of the HIP-treated samples decreased slightly and the Mn composition was significantly reduced, the process effectively eliminated many pores that remained after the 1275°C MIM process. The HIP process can improve the quality of the alloy.

[English]
Investigation of the Thermal-to-Electrical Properties of Transition Metal-Sb Alloys Synthesized for Thermoelectric Applications: Jong Min Park, Seungki Jo, Sooho Jung, Jinhee Bae, Linh Ba Vu, Kwi-Il Park, Kyung Tae Kim; J Powder Mater. 2024;31(3):236-242. Published online June 27, 2024; DOI: https://doi.org/10.4150/jpm.2024.00031

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2 Citations

Abstract PDF

The development of thermoelectric (TE) materials to replace Bi2Te3 alloys is emerging as a hot issue with the potential for wider practical applications. In particular, layered Zintl-phase materials, which can appropriately control carrier and phonon transport behaviors, are being considered as promising candidates. However, limited data have been reported on the thermoelectric properties of metal-Sb materials that can be transformed into layered materials through the insertion of cations. In this study, we synthesized FeSb and MnSb, which are used as base materials for advanced thermoelectric materials. They were confirmed as single-phase materials by analyzing X-ray diffraction patterns. Based on electrical conductivity, the Seebeck coefficient, and thermal conductivity of both materials characterized as a function of temperature, the zT values of MnSb and FeSb were calculated to be 0.00119 and 0.00026, respectively. These properties provide a fundamental data for developing layered Zintl-phase materials with alkali/alkaline earth metal insertions.

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Improving thermoelectric properties of CuMnSb alloys via strategic alloying with magnetic MnSb and Cu
Jong Min Park, Seungki Jo, Soo-ho Jung, Jinhee Bae, Linh Ba Vu, Jihun Yu, Kyung Tae Kim
Materials Letters.2025; 381: 137796. CrossRef
Highly deformable and hierarchical 3D composite sponge for versatile thermoelectric energy conversion
Jong Min Park, Changyeon Baek, Min-Ku Lee, Nagamalleswara Rao Alluri, Gyoung-Ja Lee, Kyung Tae Kim, Kwi-Il Park
Applied Surface Science.2025; 692: 162730. CrossRef

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