Conventional Powder Research Articles

Optimizing the Microstructure and Properties of Fe–Ni–Cu–Mo–C Sintered Steel by TiB2

The Fe–Ni–Cu–Mo–C powder metallurgy sintered steels with TiB2 reinforced were prepared by the conventional powder metallurgy techniques. This study explored the influence of incremental TiB2 additions, ranging from 0.1 to 0.6 wt.%, on the microstructure and properties of these steels. The results reveal that the microstructures primarily consist of martensite, Ni-rich austenite, Cu-rich pearlite, TiB2, and Ti–O rich nanoparticles. The latter form via a reaction between TiB2 and free oxygen. Notably, both the density and impact strength of the steels showed enhancement with increasing TiB2 content. The optimal values, 7.25 g/cm3 for density and 17.23 J/cm2 for impact strength, were observed at a TiB2 concentration of 0.5%. The hardness and ultimate tensile strength also increased steadily, reaching maxima of 38.7 and 1083.7 MPa at 0.6% TiB2, respectively. However, excessive TiB2 led to the formation of a net-like B-containing eutectic network, adversely affecting the steel properties. Steels with 0.5% TiB2 exhibited excellent wear resistance. At 200 rpm, the dominant failure mode was abrasive wear, which shifted to adhesive wear with oxidation at 400 rpm, followed by abrasive wear.

Chip morphology’s effect on properties of PLA-based bamboo–plastic composites produced using hot-pressing

This study explored the effect of raw material morphology on the properties of bamboo–plastic composites produced using hot-pressing. To provide a reference for reducing the production cost and improve the product properties of the composites, polylactic acid (PLA)-based bamboo–plastic composites were prepared using bamboo chips with a shaved morphology (BS) and fiber morphology (BF) and PLA as the matrix material, via hot-pressing. The properties of the bamboo–plastic composites formed with BS and BF chips were studied and compared with those of composites with conventional granular morphology (BM) and powder morphology (BP). The results showed that when the content of the bamboo chips was at 50% (the same below), the mechanical properties of the BF/PLA composites were remarkably better than those of the other PLA-based composites. However, the BF/PLA composites showed a high degree of hydrophilicity, with a water contact angle of 70.0° and a water absorption of 10.8% at 288 h. More holes could be seen in the BF/PLA composites using a scanning electron microscope. Among the four types of PLA-based composites, better melt fluidity was found only in the BF/PLA composites, and the melting index was 65.3 g/min.

Sintering behaviour of liquid phase sintered 90Mo-10(Ni–Cu) alloys

Molybdenum (Mo), a refractory material, boasts an elevated melting point of 2610 °C and is predominantly synthesised through powder metallurgy at high temperatures reaching 2000 °C, necessitating the use of liquid phase sintering (LPS) technique. This study investigates the LPS of Mo with varying proportions of Ni–Cu binders, aiming to understand the mechanism of intermetallic formation and to manufacture low-cost, dense, intermetallic-free and near-net-shape Mo-base alloys. Employing the manufacturing design paradigm for 90W-10(Ni–Cu) tungsten heavy alloys (WHAs) and utilising conventional powder metallurgy techniques, Mo-based 90Mo10(Ni–Cu) alloys were synthesised. Initial findings indicate that the densification of Mo-compacts increases with increasing the Ni–Cu ratio in the binder phase. However, an excess of Ni results in the loss of structural rigidity and geometric distortion during sintering. In Ni-rich alloys, two distinct liquid phases, Ni-rich and Cu-rich, emerge at sintering temperatures. These phases exhibit different solubilities for Mo and solidify into a dual-phase matrix. Intriguingly, in contrast to WHAs, 90Mo-10(Ni–Cu) alloys with a Ni-rich composition manifested irregular Mo particles, a dual-phase matrix, and δ-MoNi intermetallic compound formation. The formation of the intermetallic compound can be avoided by reducing the solubility of Mo in the Ni-rich liquid during sintering. Microstructural evolution and distortion are analysed using stereological quantification of various microstructural parameters. It reveals that alloys with low Mo solubility, high connectivity and high dihedral angle maintain their structural rigidity and resist distortion. Both micro-hardness and bulk hardness increased with increasing Ni–Cu ratios in the binder phase. Based on the present results, a mechanism for liquid phase sintering in the 90Mo-10(Ni–Cu) system in the presence of two liquid phases is postulated.

Heat treatment effects on tribocorrosion resistance of Inconel 718® alloy produced by conventional and laser powder bed fusion methods

The article presents a study of the tribocorrosion phenomenon and its effects on Inconel 718 alloy produced conventionally by extrusion and additively manufactured using the laser powder bed fusion method. In addition, the samples were subjected to a heat treatment process to change their properties. The research was carried out using the pin-on-disk method in 3.5% NaCl. Based on the study, it was found that the material made with additive technology is more resistant to tribocorrosion phenomenon, and the difference from conventionally made material is about 50%. The synergistic effect between friction and corrosion (ΔZ) occurred. However, heat treatment in the AA-2 variant ensures higher hardness and reduces purely mechanical wear (ZM) and the synergy effect (ΔZ).

Exploring Olive Pit Powder as a Filler for Enhanced Thermal Insulation in Epoxy Mortars to Increase Sustainability in Building Construction

This article explores the use of olive pit powder (OPP) as a promising resource for enhancing the thermal insulation properties of epoxy mortars. A comprehensive analysis of the chemical and physical characteristics of OPP was conducted, employing analytical techniques including scanning electron microscopy (SEM), thermogravimetric analysis and emitted gas analysis (TG-MS-EGA), and proximal analysis. Experimental samples of epoxy grout were prepared by using different proportions of a conventional inorganic filler, quartz powder, and OPP within an epoxy mortar matrix. As the percentage of OPP in the formulation increased, the microstructure of the samples gradually became more porous and less compact. Consequently, there was a decrease in density with the increase in OPP content. The 28-day compressive strength decreased from 46 MPa to 12.8 MPa, respectively, in the samples containing only quartz (Sample E) and only OPP (Sample A) as a filler. Similarly, flexural strength decreased from 35.2 to 5.3 MPa. The thermal conductivity decreased from 0.3 W/mK in Sample E to 0.11 in Sample A. Therefore, increasing the %wt of OPP improved insulating properties while reducing the mechanical resistance values. This study highlights the potential of OPP as an environmentally friendly and thermally efficient filler for epoxy mortars, thereby promoting sustainable construction practices.

Improvement of thermal stability by co-introducing Dy and Co with dual-alloy method in NdFeB magnets

A dual-main-phase magnet with excellent thermal stability was prepared by co-mixing two types of magnetic powders, which was the conventional N55-grade powder without Dy elements, while the Co and Dy contents reached 50 wt% and 6 wt% respectively in another Co-rich powder. Studies showed that the magnetic properties along with the thermal stabilities of the magnets exhibited significant differences with the changes in the mixing ratio of the two powders. Especially, when mixing the two powders in equal proportions, a great remanence temperature coefficient of −0.0725 %/°C at 20–100 °C was obtained with a rather high Curie temperature of 581 °C, possessing its magnetic properties with Br = 12.58 kGs, Hcj = 15.9 kOe, and (BH)max = 36.88 MGOe. Note that as the proportion of Co-rich powder increased to 2/3, although the Curie temperature of the prepared magnets further increased to 622 °C, both the remanence temperature coefficient and the magnetic properties deteriorated significantly. The phase composition and microstructure analyses revealed that when the proportion of added Co-rich component exceeded 1/2, the RE(Fe,Co)2B phase transformed into the RE(Fe,Co)4B phase, and a significant amount of RE(Fe,Co)1.8B0.2 phase precipitated at the grain boundaries, leading to a deterioration in magnetic performance. In addition, dynamic domain evolution analyses under variable temperature conditions demonstrated the positive effect of the appropriate introduction of Co/Dy on the anti-demagnetization in high temperatures. This work provides insights and an experimental foundation for the development of high-performance magnets with high thermal stability, used in high-temperature environments.

A comparative study of electric current-assisted and conventional sintering of Inconel 718 superalloy

In this study, In718 powder mixtures prepared from elemental powders following stoichiometric composition and supplied as a commercial product were produced by conventional powder metallurgy (1300 °C/4 h) and electric current-assisted sintering (ECAS)(1700-2300A/10 min) methods and followed by a double-aging heat treatment. The characterization studies determined that the best results were the sample produced by the ECAS method using the elemental powder mixture. The targeted precipitate γ′, γ″, and δ phases were obtained after the heat treatment, and a hardness value of 344 ± 41 HV0.5 and a relative density of 98.96% were achieved. The sample preserved its surface integrity by exhibiting high corrosion resistance from hot corrosion studies in the temperature range of 650–850 °C and NaSO4 + 60%V2O5 environment. The corrosion rate of the sample, which was subjected to electrochemical corrosion tests in 3.5% NaCl and 10% NaNO3 solutions, was determined as 45.59 mpy and 10.56 mpy, respectively.

Microstructure and mechanical properties of Ti-Nb alloys: comparing conventional powder metallurgy, mechanical alloying, and high power impulse magnetron sputtering processes for supporting materials screening

At the interface of thin film development and powder metallurgy technologies, this study aims to characterise the mechanical properties, lattice constants and phase formation of Ti-Nb alloys (8–30 at.%) produced by different manufacturing methods, including conventional powder metallurgy (PM), mechanical alloying (MA) and high power impulse magnetron sputtering (HiPIMS). A central aspect of this research was to investigate the different energy states achievable by each synthesis method. The findings revealed that as the Nb content increased, both the hardness and Young’s modulus of the PM samples decreased (from 4 to 1.5 and 125 to 85 GPa, respectively). For the MA alloys, the hardness and Young’s modulus varied between 3.2 and 3.9 and 100 to 116 GPa, respectively, with the lowest values recorded for 20% Nb (3.2 and 96 GPa). The Young’s modulus of the HiPIMS thin film samples did not follow a specific trend and varied between 110 and 138 GPa. However, an increase in hardness (from 3.6 to 4.8 GPa) coincided with an increase in the β2 phase contribution for films with the same chemical composition (23 at.% of Nb). This study highlights the potential of using HiPIMS gradient films for high throughput analysis for PM and MA techniques. This discovery is important as it provides a way to reduce the development time for complex alloy systems in biomaterials as well as other areas of materials engineering.Graphical abstract

Two-layered Lu3Al5O12:Ce/ Y3Al5O12:Ce composite phosphor converter for white light-emitting diode devices

Thermal management poses a significant challenge for conventional phosphor-converted white LEDs (pc-WLEDs), thereby affecting their overall efficiency. Single crystal phosphors (SCPs), such as Y3Al5O12:Ce (YAG:Ce), exhibit enhanced efficiency and thermal stability in comparison to conventional powder phosphors. The garnet Lu3Al5O12:Ce (LuAG) has been characterized as a green phosphor with even higher than YAG:Ce temperature stability, making it suitable for use in high-power WLEDs. However, there are some difficulties in obtaining suitable components with longer emission wavelengths in LuAG:Ce phosphors. As a way to solve this issue, the article suggests the growth of LuAG:Ce single crystalline films onto YAG:Ce substrates, thereby producing a composite color converter that possesses adjustable parameters. This paper presents a comprehensive analysis of the fabrication process as well as the characteristics of a two-layered LuAG:Ce film/YAG:Ce substrate composite color converter. The results of investigations of the structural, luminescence and photoconversion characteristics of composite color converters were presented as well. This study includes also consideration of the effect of varying LuAG:Ce film thicknesses and concentrations of Ce3+ in YAG:Ce substrates on photoconversion characteristics of composite converters.

Tailoring metal powders by dry nanoparticle coating for powder bed fusion applications

The influence of high intensity mixing of graphene platelets with stainless steel particles in the scope of additive manufacturing is investigated. Therefore, 0.75 vol% graphene platelets were coated onto conventional stainless steel powder as a model material, resulting in very homogenously distributed graphene layers. The specific energy input during mixing was found to be the main factor for increasing the flowability and decreasing the reflectivity of the powder. Furthermore, the resulting surface roughness of the coated powders could be correlated with a theoretical consideration of van der Waals forces. In this way, the mixing process can be controlled regarding its specific energy input to achieve tailored powders for the application in PBF-LB/M. Cubic parts were produced with different laser parameters and analysed. As a result, the admixing of graphene at lower specific energies resulted in a wider process window and parts with a relative density of 99.99% were achieved.

Hierarchical etching-assembly engineering of Fe-based composite microspheres with balanced magnetic-dielectric synergy towards ultrahigh electromagnetic wave absorption

Hierarchical engineering of magnetic-dielectric composite microspheres has attracted increasing attention owing to its potential to enhance electromagnetic wave absorption (EMA) through magnetic-dielectric synergy. However, optimizing magnetic-dielectric balance in composite microspheres at the nanoscale remains a formidable task due to their limited component optimization and microstructural regulation. Herein, a novel approach is proposed to modify conventional carbonyl iron powder (CIP) microspheres via synergistic etching-assembly strategy. By applying a polydopamine coating, successive tannic acid (TA) etching-assembly, and pyrolysis, hierarchical iron@carbon-1/N-doped carbon (Fe@C-1/NC) composite microspheres are obtained. This overcomes the drawbacks of CIP microspheres, including their high density and poor impedance matching, which hinder EMA performance. Hierarchical carbon layer engineering can introduce abundant dipole centers, heterogeneous interfaces, and conductive networks to induce dielectric loss, while magnetic components contribute to magnetic resonance and eddy current loss, as demonstrated by the results. Accordingly, Fe@C-1/NC composite microspheres demonstrate a minimum reflection loss (RLmin) of −70.7 dB and an effective absorption bandwidth of 3.75 GHz at a matching thickness of 2.3 mm. Generally, this work paves the way towards CIP engineering to provide guidance to the future exploration of hierarchical magnetic-dielectric EMA materials.

Grain structure tailoring strategy for heterogeneous lamella SiCp/2024Al composites with exceptional strength-ductility synergy

In this work, a novel grain structure tailoring strategy using one-stepped planetary ball milling, different from conventional powder metallurgy routes that pre-prepared components with different microstructures and then mixed them up, was implemented to fabricate micro- and nano-sized SiC particles (m- & n-SiCp)/2024Al composites with heterogeneous lamella structure. The controllable transformation from homogeneous to heterogeneous grain structures is achieved via nonuniformly distributed n-SiCps induced local grain refinement. Heterogeneous lamella composites exhibit a superior modulus-strength-ductility synergy of 95.3 GPa in Young's modulus, 750.7 MPa in tensile strength and 4.9 % in uniform elongation, particularly with no less than 145 % and 175 % improvements in ductility and toughness, compared with homogeneous composites. Compressive stress relaxation experiments were conducted to reveal the structural dependence of plastic deformation behaviors. Sustainedly rising hetero-deformation induced (HDI) stress produced by extra geometrically necessary dislocation (GND) accumulation at heterogeneous soft/hard domain interfaces and sequential activation of multiple dislocation mediated mechanisms based on load transfer in heterogeneous lamella composites contribute to the enhanced strain hardening capacity, which offers intrinsic toughening. Also, extrinsic toughening originates from enhanced microcrack multiplication and crack-tip blunting.

Enhancement of the magnetic property of Nd-Fe-B sintered magnets through novel powder rounding modification

Two types of sintered Nd-Fe-B magnets were fabricated by the process of powder metallurgy technology through two different powder preparation processes i.e., conventional powder preparation process and novel powder rounding modification. The microstructure, composition and properties of the two type powders have been studied including the particle size distributions and flowabilities. Furthermore, magnetic properties, microstructure and alignment degree of the magnets prepared by the corresponding powder also have been investigated. The novel powder rounding modification rounds the sharp edges and corners of the particles compared to the conventional powder preparation process, thereby reducing friction between the particles and improving flowability of the powder. As a result, the alignment degree of the sintered magnet is enhanced, which contribute to the improvement of the remanence and the energy product density. The powder that experienced rounding process changed the distribution of RE (rare earth)-rich particles, causing tiny RE-rich particles to adhere around the main phase particles, facilitating the compact of bulk during liquid-phase sintering process and achieving uniform distribution of RE-rich phases around the Nd2Fe14B main phase, resulting in increasing the magnet density and coercivity. As a consequence, we have produced the magnet with Br = 1.43 T, Hcj = 1049 kA/m and (BH)max = 393.2 kJ/m3, which is fully superior to conventional magnet with Br = 1.41 T, Hcj = 969 kA/m and (BH)max = 383.7 kJ/m3 by adopting powder rounding process. This indicates that the novel powder rounding modification is an efficient approach for synchronous improvement of magnetic performance of sintered Nd-Fe-B without any heavy rare earth elements.

Improving Laser Powder Bed Fusion Printability of Tungsten Powders Using Simulation-Driven Process Optimization Algorithms.

This study applies numerical and experimental techniques to investigate the effect of process parameters on the density, structure and mechanical properties of pure tungsten specimens fabricated by laser powder bed fusion. A numerical model based on the simplified analysis of a thermal field generated in the powder bed by a moving laser source was used to calculate the melt pool dimensions, predict the density of printed parts and build a cost-effective plan of experiments. Specimens printed using a laser power of 188 W, a scanning speed of 188 mm/s, a hatching space of 80 µm and a layer thickness of 30 µm showed a maximum printed density of 93.2%, an ultimate compression strength of 867 MPa and a maximum strain to failure of ~7.0%, which are in keeping with the standard requirements for tungsten parts obtained using conventional powder metallurgy techniques. Using the optimized printing parameters, selected geometric artifacts were manufactured to characterize the printability limits. A complementary numerical study suggested that decreasing the layer thickness, increasing the laser power, applying hot isostatic pressing and alloying with rhenium are the most promising directions to further improve the physical and mechanical properties of printed tungsten parts.

Effect of yttrium-doped grain boundary on sintering behavior and properties of transparent ZnAl2O4 ceramics

Pore-closed ZnAl2O4 ceramic can hardly be pressureless sintered from conventional (>100 nm) powder, which restricts the fabrication of the transparent ceramic by capsule-free hot isostatic pressing technique. This work focused on the effect of yttrium-doping on the microstructural evolution in the sintering of a ∼180-nm ZnAl2O4 powder. At a concentration of 300 or 600 ppm, the yttrium ions segregated along the grain boundaries and contributed to ordered nanostructures, which could suppress abnormal grain growth in both air sintering and hot isostatic pressing. The optimized Y-doped ZnAl2O4 transparent ceramic owned good visible light transmittance (>65 %) and a wide transmission range (6.0 μm at the 60 % transmittance) at a thickness of 1.5 mm, as well as high thermal conductivity (24.9 W·m−1·K−1) and reasonable mechanical properties (Vickers hardness of 12.9 GPa and Young’s modulus of 281.3 GPa), meeting the application requirements for infrared windows.

Dry-processed technology for flexible and high-performance FeS2-based all-solid-state lithium batteries at low stack pressure

All-solid-state lithium batteries (ASSLBs) are considered promising energy storage systems due to their high energy density and inherent safety. However, scalable fabrication of ASSLBs based on transition metal sulfide cathodes through the conventional powder cold-pressing method with ultrahigh stacking pressure remains challenging. This article elucidates a dry process methodology for preparing flexible and high-performance FeS2-based ASSLBs under low stack pressure by utilizing polytetrafluoroethylene (PTFE) binder. In this design, fibrous PTFE interweaves Li6PS5Cl particles and FeS2 cathode components, forming flexible electrolyte and composite cathode membranes. Beneficial to the robust adhesion, the composite cathode and Li6PS5Cl membranes are tightly compacted under a low stacking pressure of 100 MPa which is a fifth of the conventional pressure. Moreover, the electrode/electrolyte interface can sustain adequate contact throughout electrochemical cycling. As expected, the FeS2-based ASSLBs exhibit outstanding rate performance and cyclic stability, contributing a reversible discharged capacity of 370.7 mAh g−1 at 0.3C after 200 cycles. More importantly, the meticulous dQ/dV analysis reveals that the three-dimensional PTFE binder effectively binds the discharge products with sluggish kinetics (Li2S and Fe) to the ion–electron conductive network in the composite cathode, thereby preventing the electrochemical inactivation of products and enhancing electrochemical performance. Furthermore, FeS2-based pouch-type cells are fabricated, demonstrating the potential of PTFE-based dry-process technology to scale up ASSLBs from laboratory-scale mold cells to factory-scale pouch cells. This feasible dry-processed technology provides valuable insights to advance the practical applications of ASSLBs.

Manufacturing Oxide Dispersion Strengthened (ODS) steel plate via cold spray and friction stir processing

Oxide dispersion strengthened (ODS) steels, traditionally fabricated by ball milling and conventional powder metallurgy techniques to achieve bulk form, followed by intricate rolling and thermal treatment steps to achieve plate or sheet form. Here, we present a novel processing route that combines cold spray (CS) with friction stir processing (FSP) to manufacture ODS steel plate directly from gas atomization reaction synthesis (GARS)-prepared powder, thus no rolling steps involved. Microstructural and mechanical characterizations were performed to assess the quality and properties of the resulting ODS steel plate. Our findings demonstrate that the slightly porous CS deposited layer was fully consolidated after FSP, yielding a fully dense ODS steel plate that exhibited a favorable tradeoff between strength and ductility upon extraction from the substrate. Furthermore, through microstructural analysis, we revealed the presence of an appreciable density (∼1022/m3) of nano-sized oxide particles, with the majority being smaller than 5 nm via the combined CS + FSP fabrication route. This work serves as a first proof-of-concept demonstration of the manufacturing approach described herein, offering a possible alternative route for producing ODS steel plates.

Additive Manufacturing of TiC/Steel Composites Using Electron Beam Melting and In Situ Infiltration

Cemented carbides containing titanium carbide (TiC), characterized by low specific weight, superior hardness, and excellent high‐temperature resistance, are widely used as wear‐resistant cutting tools and brake discs. Instead of using conventional powder metallurgical approaches, composites comprising TiC and stainless steel are fabricated in this study by means of an innovative method combining electron beam powder bed fusion (PBF‐EB) and in situ liquid metal infiltration. For PBF‐EB, a pure TiC powder as feedstock and a stainless steel plate as substrate are used, respectively. Owing to the high processing temperature in the hatching area, the TiC particles are inhomogeneously sintered. Simultaneously, an in situ infiltration of liquid steel into the pores between TiC particles takes place during PBF‐EB, forming a dense and crack‐free composite material containing ≈68% TiC. The electrical properties of the raw TiC powder are investigated at different temperatures to optimize the process parameters ensuring high process stability during PBF‐EB. The microstructure and mechanical properties (compression strength, hardness, and fracture toughness) of the PBF‐EB‐produced TiC/steel composite are analyzed.

Structural, vibrational, and optical studies of newly synthesized Yavapaiite-type phases BaSb2/3X1/3(PO4)2 (X = Mn, Co, Cu, Zn)

The synthesis and structural characterization of four newly synthesized phosphates, BaSb2/3X1/3(PO4)2 phases where X represents Mn, Co, Cu, and Zn, are presented here for the first time. These BaSb2/3X1/3(PO4)2 phases, denoted as [BaSbMn], [BaSbCo], [BaSbCu], and [BaSbZn], were prepared by a solid-state reaction at 900 °C in air atmosphere. The crystal structures of these [BaSbX] materials were investigated using Rietveld analysis based on conventional X-ray powder diffraction. The structural analysis revealed that all four compounds are isostructural, exhibiting the Yavapaiite-type structure with a monoclinic C2/m space group. Raman and infrared spectroscopy were employed to elucidate the bonding characteristics within the [BaSbX] phases. UV–vis-NIR spectroscopy provided insights into the electronic properties of the compounds, revealing charge transfer and d-d transitions in Mn2+, Co2+, and Cu2+ ions. In contrast, Zn2+ exhibited full d orbitals. The absorption spectra revealed UV bands indicative of charge transfer, with optical bandgap values spanning from 3.8 eV to 4.6 eV. This range signifies a distinctive semiconducting property inherent in the synthesized materials. Analysis of the Urbach tails revealed the presence of localized states, with lower values indicating higher crystallinity, giving valuable insights into the electronic behavior of the compounds.

Diffusion behavior of heavy rare-earths for grain boundary engineering of sintered Nd-Fe-B-based permanent magnets produced by the 2-powder method

The 2-powder method (2PM) for the production of high-performance Nd2Fe14B-based sintered magnets consists of blending a coarser heavy rare-earth (HRE) free main phase powder (here D50 = 5.3 µm) and a finer HRE-containing anisotropy powder (here D50 = 2.6 µm) of Dy content of 10 wt.%. The development of the core-shell structure was observed for different sintering conditions, namely at 1090 °C for 5, 10, 30, 60, and 120 min. The diffusion behavior of the 2PM was investigated and the diffusion coefficient for the heavy rare-earth element dysprosium of D = (1.83 ± 0.54) x 10−11 cm2/s was determined. Magnets containing 0, 1, 2, and 3 wt.% Dy were produced by the 2PM and magnetic properties were analyzed in detail. A constant coercivity gain of around 120 kA/m per added Dy contents was reached. Dy was obtained without a significant decrease in remanence. Finally, the 2PM was compared with the conventional powder metallurgical production process. The enormous potential for decreasing the amount of critical HREs in Nd-Fe-B–based sintered magnets is demonstrated, especially in large volume magnets as 2PM is not restricted to 5 mm thick pieces, but can be applied to large scale.