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The effect of adding molybdenum to the heavy tungsten alloy of W-Ni-Fe on its material characteristics was examined in the current study. The elemental powders of tungsten, iron, nickel, and molybdenum, with a composition analogous to W-3Fe-7Ni-xMo (x = 0, 22.5, 45, 67.5 wt.%), were fabricated using the spark plasma sintering (SPS) technique at a sintering temperature of 1400 °C and under pressure of 50 MPa. The sintered samples were subjected to microstructural characterization and tested for mechanical strength. The smallest grain size of 9.99 microns was observed for the 45W-45Mo alloy. This alloy also gave the highest tensile and yield strengths of 1140 MPa and 763 MPa, respectively. The hardness increased with the increased addition of molybdenum. The high level of hardness was observed for 67.5Mo with a 10.8% increase in the base alloy’s hardness. The investigation resulted in the alloy of 45W-7Ni-3Fe-45Mo, observed to provide optimum mechanical properties among all the analyzed samples.

In this research, we intended to examine the effect of heating mode on the densification, microstructure, mechanical properties, and corrosion resistance of sintered aluminum alloys. The compacts were sintered in conventional (radiation-heated) and microwave (2.45 GHz, multimode) sintering furnaces followed by aging. Detailed analysis of the final sintered aluminum alloys was done using optical and scanning electron microscopes. The observations revealed that the microwave sintered sample has a relatively finer microstructure compared to its conventionally sintered counterparts. The experimental results also show that microwave sintered alloy has the best mechanical properties over conventionally sintered compacts. Similarly, the microwave sintered samples showed better corrosion resistance than conventionally sintered ones.

This review paper provides insight into current developments in refractory high-entropy alloys (RHEAs) based on previous and currently available literature. High-temperature strength, high-temperature oxidation resistance, and corrosion resistance properties make RHEAs unique and stand out from other materials. RHEAs mainly contain refractory elements like W, Ta, Mo, Zr, Hf, V, and Nb (each in the 5–35 at% range), and some low melting elements like Al and Cr at less than 5 at%, which were already developed and in use for the past two decades. These alloys show promise in replacing Ni-based superalloys. In this paper, various manufacturing processes like casting, powder metallurgy, metal forming, thin-film, and coating, as well as the effect of different alloying elements on the microstructure, phase formation, mechanical properties and strengthening mechanism, oxidation resistance, and corrosion resistance, of RHEAs are reviewed.

In the present work, nano Cu (0, 5, 10, 15, 20, 25 wt.%) was added to W, and W–Cu composites were fabricated using the spark plasma sintering (S.P.S.) technique. The densification, microstructural evolution, tensile strength, micro-hardness, and electrical conductivity of the W–Cu composite samples were evaluated. It was observed that increasing the copper content resulted in increasing the relative sintered density, with the highest being 82.26% in the W75% + Cu25% composite. The XRD phase analysis indicated that there was no evidence of intermetallic phases. The highest ultimate (tensile) strength, micro-hardness, and electrical conductivity obtained was 415 MPa, 341.44 HV0.1, and 28.2% IACS, respectively, for a sample containing 25 wt.% nano-copper. Fractography of the tensile tested samples revealed a mixed-mode of fracture. As anticipated, increasing the nano-copper content in the samples resulted in increased electrical conductivity.

The traditional solid-state reaction method was employed to synthesize bulk calcium cobaltite (Ca349/Ca3Co4O9) ceramics via ball milling the precursor mixture. The samples were compacted using conventional sintering (CS) and spark plasma sintering (SPS) at 850, 900, and 950 °C. The X-ray diffraction (XRD) pattern indicates the presence of the Ca349 phase for samples sintered at 850 and 900 °C. In addition, SPS fosters higher densification (81.18%) than conventional sintering (50.76%) at elevated sintering temperatures. The thermo-gravimetric analysis (TGA) and differential thermal analysis (DTA) performed on the precursor mixture reported a weight loss of ~25.23% at a temperature range of 600–820 °C. This current work aims to analyze the electrical properties (Seebeck coefficient (s), electrical resistivity (ρ), and power factor) of sintered samples as a function of temperature (35–500 °C). It demonstrates that the change in sintering temperature (conventional sintering) did not evince any significant change in the Seebeck coefficient (113–142 μV/K). However, it reported a low resistivity of 153–132 μΩ-m and a better power factor (82–146.4 μW/mK2) at 900 °C. On the contrary, the SPS sintered samples recorded a higher Seebeck coefficient of 121–181 μV/K at 900 °C. Correspondingly, the samples sintered at 950 °C delineated a low resistivity of 145–158 μΩ-m and a better power factor (97–152 μW/mK2).

Titanium aluminide (TiAl) is one of the most promising materials for aerospace applications. It is a suitable replacement for nickel-based superalloys predominantly used in these applications. Titanium aluminide with superior processability is the main task in carrying out this work. A less brittle TiAl alloy was fabricated using spark plasma sintering by adding the nominal composition (2.5, 5, and 7.5 wt.%) of manganese (Mn) to Ti-48Al-2Cr-2Nb. The samples were sintered at 1150 °C using spark plasma sintering (SPS), which helped produce highly dense models with fine grain sizes at the high heating rate (here, 100 °C per minute). The effects produced by Mn additions on the densification, mechanical properties (yield strength, hardness, and % elongation), and microstructure of the Ti aluminide alloys are studied. Scanning electron microscopy (SEM) has been used to explore the sintered samples’ microstructures. The alloyed materials are entirely dissolved in the gamma matrix due to the manganese approaching its melting point. XRD and SEM analysis confirmed the new intermetallic related to Mn neither with titanium nor aluminum. The enhancement of % elongation at break is evident for the little improvement in the ductility of TiAl by the addition of Mn. The samples’ tensile fracture nature is also evidence for enhancement in the alloy’s % elongation.

In this study, Al-TiB2 compacts fabricated by spark plasma sintering methods at different temperatures were characterized for densification, microstructural development, and mechanical properties. Sintering parameters used were temperatures of 500 °C and 550 °C under the pressure of 30 MPa. A very dense microstructure with uniform phase distribution and porosity was produced in the sample sintered at 550 °C with 2.5 wt% TiB2. The same sample exhibited excellent hardness value, and a high-tensile strength attributed to full metallurgical bonding, presence of sub-micron sized grains, and their uniform distribution. These results show that the TiB2 addition enhanced the composite’s hardness, sintered density, and tensile strength. In all the sintered samples, the fractographs revealed a mixed-mode fracture (ductile and brittle).

The influence of silicon carbide (SiC) addition to W-Ni-Cu-based heavy alloys has been investigated in the present study. The powders of W-Ni-Cu with varying percentages of SiC were blended and sintered using conventional and Spark Plasma Sintering (SPS) techniques. The sintered samples were characterized to determine the density, microstructure, and mechanical properties. The alloy (W-7Ni-3Cu-0.5SiC) exhibits high ultimate tensile strength 430 MPa for conventional sintering and 831 MPa for spark plasma sintering, relative sintered density 71.84% and 88.25% of conventional sintered and spark plasma sintering, respectively. After the tensile test, the fracture surfaces show a mixed-mode fracture consisting of brittle W/W intergranular and ductile mode of fracture in the matrix.