Milled Powders Research Articles

Mechanical characteristics of dual‐phase medium‐entropy boride/carbide ceramics synthesized through SPS

AbstractMaterial scientists constantly look for new compounds with exceptional properties to meet the ever‐changing technology and industry needs. Hereby, the dual‐phase medium‐entropy ceramics have fabricated by employing high‐energy ball milling (HEBM) and spark plasma sintering (SPS) techniques on commercial boride and carbide powders of IVB group metals. The boride and carbide powders have undergone 3‐hour milling in a planetary ball mill, followed by SPS processing at 1800°C and 2000°C under 30 MPa uniaxial pressure for 10 min. The milled powders and SPS'ed ceramics have been characterized, focusing on composition, density, and microstructure using X‐ray diffractometry (XRD) and scanning electron microscopy (SEM)/energy dispersive spectroscopy (EDS). Microhardness and sliding wear tests have also been performed on the SPS'ed ceramics. The systematic analysis of the characterization results has revealed that the microstructural evolution and mechanical properties of the dual‐phase ceramics have developed to a comparable level with the single‐phase ceramics, regardless of the sintering temperature. In fact, the dual‐phase ceramics sintered at 1800°C come to the forefront due to the superior hardness and fracture toughness values (∼ 16 GPa and ∼ 5.4 MPa.m1/2).

Impact of morphology of hydrophilic and hydrophobic bentonites on improving the pour point in the recycling of waste cooking oils

Waste Cooking Oils (WCOs) are generated worldwide through industrial food processing and household use, posing environmental concerns upon disposal. Bentonites often showed to be effective in removing minor contaminants in vegetable oil refining. The present research focused on the processing of raw WCOs using four bentonites, two commercials and two obtained by ball milling of the latest. The different bentonites (hydrophobic and hydrophilic) were characterized before and after ball milling (BM) procedure, including an exhaustive analyses of crystal structure, morphology and surface area via x-ray diffraction (XRD), transmission electron microscopy (TEM), scanning electron microscopy (SEM), and N2-physisorption technique. Optimization of BM processing in terms of milling time was achieved within 60 min. The milled powders were then tested as adsorbents for recycling WCOs with different degrees of decomposition (expressed in terms of free fatty acids, FFAs, content). Employing a design of experiments approach, the impact of five parameters (FFAs content, temperature, specific surface area, stirring, BM time) on the resulting pour point (PP), taken as a quality benchmark for recycled oil, was assessed. Quantitative multivariate statistical analysis revealed temperature's negligible role and identified the significant impact of two characteristics of the bentonite (specific superficial area and ball milling time), as well as the relevant role of the stirring during the treatment. At the end, hydrophilic bentonite resulted able to improve the PP of waste oils with a low content of free fatty acids of about 10 °C.

Fabrication of TiN-doped Ti nanocomposites with high strength and ductility by plasma-assisted ball milling and laser powder bed fusion

An efficient method to fabricate titanium nitride (TiN)-doped titanium (Ti) nanocomposites through a combination of plasma milling, plasma spheroidization, and laser powder bed fusion (LPBF) was developed to obtain Ti-based materials with high strength and ductility from commercially pure titanium (CP-Ti). Nitrogen plasma milling and plasma spheroidization were used to fabricate Ti-TiN nanocomposites, which were mixed with CP-Ti powder at a 1:9 ratio and printed by LPBF forming. The resulting materials possessed a dual-scale morphology with both coarse lath-like and fine acicular-like grains. The Ti-TiN nanocomposites possessed higher hardness and tensile strength and lower ductility than those of the control sample without TiN. The mechanical properties of the LPBF-printed Ti-TiN nanocomposites were improved compared with those of LPBF-printed CP-Ti because of the TiN particles and resulting dual-scale structure. Nitrogen plasma milling provides a simple route to fabricate TiN nanophase-reinforced Ti-based nanocomposites suitable for LPBF printing.Graphical

Production and Characterization of Fine-Grained Multielement AlCoxCrFeNi (x = 1, 0.75, 0.5) Alloys for High-Temperature Applications.

In the present work, three different AlCoxCrFeNi (x = 1, 0.75, 0.5) alloys were produced through the mechanical milling of powders and spark plasma sintering. These alloys were characterized in terms of their microstructural, mechanical, and oxidation behaviors. Mechanical milling and spark plasma sintering were chosen to achieve a fine and homogeneous microstructure. Pore-free samples were produced by properly setting the sintering parameters. The unavoidable uptake of oxygen from the powders when exposed to air after milling was advantageously used as a source of oxides, which acted as reinforcing particles in the alloy. Oxidation behavior, studied through TGA tests, showed that decreasing the Co content promotes better oxidation protection due to the formation of a dense, compact Al2O3 layer. The alloy containing the lowest amount of Co is considered a good candidate for high-temperature structural applications.

Hardness and Corrosion Behavior of CrMnFeCoNi Alloy Fabricated by Ball Milling and Spark Plasma Sintering.

The mechanical properties and electrochemical stability of high-entropy alloys are substantially affected by their composition distribution and crystal structure. However, the details concerning the conditions of milling and sintering for sintered alloys have rarely been reported. In this work, a series of CrMnFeCoNi alloys were fabricated by ball milling and spark plasm sintering for different periods. Their crystal structure, density, hardness, and corrosion resistance were investigated. As a result, a partial alloying of Cr, Mn, Fe, Co, and Ni was achieved by ball milling. However, Cr-rich particles, including Mn, were formed in the milled powders. The sintered alloys inherited the Cr-rich particles to form Cr-rich zones. The formation and change of chromium carbide were also confirmed in sintered alloys. Extended milling or sintering to 12 h achieved high hardness and corrosion resistance for the sintered alloys. The Cr-rich zones showed high hardness and Kelvin potential, which affect both the hardness and the corrosion resistance.

Dissociative Oxygen Adsorption and Incorporation in Co3O4-Dispersed BaZr0.9Sc0.1O2.95 for PCFC Cathode.

The development of air electrodes with superior surface oxygen exchange properties at intermediate temperatures is crucial for improving the efficiency of protonic ceramic fuel cells. This study evaluated the surface exchange properties of Co3O4 dispersed protonic conductors, BaZr0.9Sc0.1O2.95. Although Co3O4 is widely acknowledged as superior dissociative adsorption catalysts, there is still ambiguity regarding the enhancement mechanisms of their surface exchange properties by Co3O4, as well as their optimal composition to achieve high catalytic activity. To overcome these difficulties, this study elucidated the effect of the chemical states and composition of composites on their surface exchange properties by evaluating their chemical states and surface exchange reaction rates with several compositions prepared at different temperature conditions using a vibrating-sample magnetometer and the pulse isotope exchange technique. For samples annealed at a high temperature, it became evident that the surface exchange activity became the most active by adding only 1 vol % Co3O4 and indicated an abrupt decline above this composition despite an increase in the volume of the catalysts. This was attributed to the combined effect of the high dissociative adsorption activity of the Co-containing solid solutions formed at a high temperature and a decrease in oxygen vacancies due to hole compensation. For samples annealed at intermediate temperature, their chemical states remained unchanged from those of the original milled powders, and their surface exchange properties monotonically improved with an increase in the volume of Co3O4. Based on the results, different chemical states of composites derived from different preparation conditions lead to completely different activation behavior of the surface exchange reaction.

Deformation-induced grain boundary segregation in a powder-metallurgy ultrafine-grained MoNbTaTiV refractory high-entropy alloy

A powder-metallurgy MoNbTaTiV refractory high-entropy alloy synthesized by mechanical alloying (MA) and spark plasma sintering was subjected to hot deformations at different temperatures and strain rates. The microstructural morphologies were characterized, and component element segregation was elucidated. With grain refinement and lattice strain increase, the large inhomogeneous milled powder became refined and homogeneous after the MA. Component element segregation was observed at relatively low deformation temperatures and high strain rates. As the deformation temperature increased and the strain rate decreased, the segregation gradually disappeared, which was attributed to dislocation movement.

A step to microplastic formation: Microcracking and associated surface transformations of recycled LDPE, LLDPE, HDPE, and PP plastics exposed to UV radiation

Plastics when exposed to UV radiation start to degrade via photooxidative aging including free radical formation, oxidation, chain scission and/or crosslinking reactions. These chemical changes can cause loss in mechanical strength, surface embrittlement, and eventually surface erosion. The eroded particles are microplastics (MPs), which have been identified as a potentially serious threat to the environment and its inhabitants. In general, photodegradation of virgin plastics has been studied extensively, but there is not much literature on the degradation of recycled plastics. The goal of the study was to investigate the changes caused by photodegradation in recycled plastics and assess the potential risks of MPs formation. And eventually, knowing the chemical and physical transformations occurring on the surface understand the mechanism behind surface microcracking, which is the first step of MPs formation. Pellets of five industrially recycled plastics (low-density polyethylene (rLDPE), linear low-density polyethylene (rLLDPE), high-density polyethylene (rHDPE), and two polypropylenes (rPP)) from different waste sources were analysed. UV irradiation was performed in an accelerated weathering chamber for milled (< 400 µm) plastic powder to ensure homogeneous changes throughout the sample. The properties were investigated by ATR-FTIR, HT-SEC, XPS and DSC. Formation of microcracks was studied on plastic pellets by SEM. The results showed that the degradation significantly differed between the recycled plastics, and the waste source was more important than the plastic type. rLDPE and one of the rPP samples showed a significant increase in carbonyl index as well as decrease in molar mass during the first 500 h of UV exposure. The other rPP and rHDPE samples showed first considerable signs of degradation only after 1000 h of UV exposure. Minor changes were observed for the rLLDPE sample during the whole test. The SEM revealed microcracking on the surface of all samples, which also had noticeable degradation identified by other methods. These recycled plastics can be considered the ones with the highest potential of MPs formation. From the chemical and physical transformations identified on the surface, the mechanism leading to microcracking, which is the first step in the formation of MPs, is proposed.

Effect of Zr content on the microstructure, mechanical properties, electrochemical behavior, and biocompatibility of Mg–3Zn–xZr alloy using powder metallurgy

Abstract In this study, Mg–3Zn–xZr (x = 0, 0.5, 1, 2 and 3) alloy were produced using powder metallurgy incorporating high-energy ball milling. Scanning electron microscope (SEM), energy dispersive X-ray (EDX) analyzer and X-ray diffraction (XRD) have been used to investigate the microstructure, chemical composition and phase distribution of the samples. XRD results show that the Mg solid solution wholly formed, and the milled powders were single phase, and no secondary phase was observed. While the secondary phases were formed after sintering. Hardness of Mg–Zn–xZr sample increased from 58.8 Hv (for Zr = 0) to 87.81 Hv with addition of 3 wt.% Zr. The result shows that the corrosion potential of Mg–Zn–Zr alloy was more positive than Mg–3Zn. However, the Mg–3Zn–Zr alloy exhibited higher corrosion current than Mg–3Zn due to galvanic effect of Zr rich area. All of Mg–3Zn–Zr alloys showed better antibacterial and biocompatibility properties than Mg–3Zn alloy due to the presence of Zr as additive. According to the mechanical, corrosion, and biological evaluations in this study, it can be concluded that the Mg–3Zn–1Zr alloy can be used as a suitable biomaterial for the use of orthopedic implants.

Synthesis and electrochemical characteristics of metal nanoparticles decorated composite anode made of domestic alloy, used in lithium ion batteries

In this work, appropriate material selection and process design enable the succesful production of high energy density electrode active material in the form of XAZ (where X, A and Z stand for electrochemically active, electrochemically inactive and carbon materials, respectively). Herein, the precipitates rich in iron and chromium are extracted selectively from a local ferrochromium alloy utilizing hydrometallurgy procedures. The precipitates are then exposed to separate calcination to get iron-rich and chromium-rich oxides seperately. In the end, a composite (XAZ) is fabricated under the mild synthesis conditions by combining these oxides with activated carbon and aluminum powder in a planetary ball mill. The composite's morphological, structural, and chemical properties are all optimized. The galvanostatic test results clearly demonstrate that the powder made of XAZ composite with embedded metal nanoparticles delivers 798 mAh g-1 after 100th cycle under a current load of 50 mA g-1 and high capacity (600 mAh g−1) over 300 cycles with an exceptional rate performance. It is anticipated that this research will create novel opportunities for producing high-value electrode active materials from accessible, low-cost raw ingredients.

Evaluation of tribo-mechanical measurements and thermal expansion of Cu-based nanocomposites reinforced by high strength hybrid ceramics

It is known that Copper’s (Cu) electrical conductivity makes it a desirable material for use in industry. Due to poor properties such as hardness, thermal expansion, and corrosion resistance, its applications are limited. This manuscript solves these problems while maintaining no breakdown in electrical conductivity. In this study, high-strength ceramics (SiC nanoparticles and graphene nanosheets) were used as reinforcements in the manufacture of Cu-based hybrid nanocomposites using powder metallurgy technique. X-ray diffraction analysis (XRD) was used to investigate phase composition and crystal size of the milled powders. Transmission electron microscopy (TEM) and field emission scanning electron microscopy (FESEM), respectively examined the microstructure of the prepared powder powders and sintered nanocomposites. Then, various properties of the sintered samples are measured, including physical, electrical and thermal properties and wear resistance. The obtained XRD technique and TEM images showed decreases in the crystal and particle size of milled samples reaching up to 14.08 and 28.30 nm, respectively for the sample contained 8 vol. % SiC + 0.8 vol. % graphene (SG8). A surprising improvement in the mechanical properties of up to 809.15, 341.84 MPa and 336.56 GPa for microhardness, strength and longitudinal modulus for the sample containing the highest reinforcements, achieving an improvement of up to 122, 61.37 and 41 percent compared to the Cu matrix. Moreover, there was a noticeable improvement in the coefficient of thermal expansion (CTE) and wear rate values of the samples by increasing the percentages of hybrid reinforcements in the examined sintered nanocomposite samples. The Sample SG8 recorded the lowest value, decreasing by about 50.2 and 76.5% compared to the SG1 sample. Finally, adding reinforcements to the Cu matrix had a negative effect on the relative density and electrical conductivity, and the lowest values was 92.94% and8.59 × 106 S/m, respectively for the SG sample.

Neutron shielding performance of Cd/316L composite fabricated by arc plasma sintering

Ensuring subcriticality over storage duration, even in accident condition, is one of the important requirements for dry cask designed to store spent fuel from nuclear reactor. To comply this requirement, neutron absorbers are incorporated in the spent fuel basket to decrease the neutron multiplication factor and reactivity. The objectives of this study are to prepare Cd/316L composite for neutron absorber material by powder metallurgy and determine the neutron shielding performance of the obtained composite. Powder mixtures of SS316L with various Cd contents were milled using high energy milling, followed by pressing and sintering at 450 °C and 700 °C. The analyses of the samples were carried out using XRD, SEM-EDS, XRF, and neutron transmittance test. Additionally, the neutron transmittance was also calculated using MCNP5. The results show that transformation of austenite to α-ferrite occurred during powder milling process which remained in the sample after sintering at 450 °C. Transformation of α-ferrite in the milled sample to austenite occurred after sintering at 700 °C. Cd in the samples were predominantly oxidized to form CdO phase during sintering process at both temperature conditions. The loss of Cd content in the Cd/SS316L samples after milling process was approximately 10 %. The Cd content further decreased by approximately 10 and 50 % after sintering at 450 and 700 °C, respectively. Neutron transmittance test shows that the transmittance value for thermal neutron decreased with the increased of Cd in the Cd/316 sample. A good agreement has been obtained between the results from experiment and MCNP calculation.

THE MECHANICALLY ACTIVATED COMPOSITES BASED ON TUNGSTEN DISULFIDE: SYNTHESIS AND PROPERTIES

In this work, the physicochemical properties of mechano-activated composites (hereinafter referred to as the mechanocomposites) obtained by mechanical activation of commercial tungsten disulfide powder in a planetary mill were studied. Mechanical activation was carried out for 2, 4 and 8 h, but this work presents the results for the last two experiments. The acceleration of the grinding media was controlled through frequency adjustment; a frequency value of 15.5 Hz, according to calculations, corresponds to an acceleration of the grinding media of 50 m/s2 or 5G. The material of the balls from which the grinding balls are made is stainless steel. Due to the relatively low acceleration values, the problem of contamination of the sample with stainless steel components does not occur as a result of surface erosion that occurs when the balls collide with each other and with the walls of the grinding bowl. Mechanical activation was carried out in an inert argon environment, since these were preliminary studies and therefore there was a need to minimize the environmental parameters taken into account. However, the oxidation process will occur during the process of discharging the sample from the grinding bowl of the planetary mill. The resulting mechanocomposites are precursors for the synthesis of monocomponent catalysts for the processing of heavy oil residue. For this purpose, it is necessary to obtain mechanocomposites containing tungsten trioxide and tungsten disulfide. The results of an experimental study of the influence, mainly, of the duration of mechanical activation on the production of tungsten mechanocomposites are presented. The resulting compounds were characterized by X-ray phase analysis (XRD), IR spectroscopy, scanning electron microscopy (SEM), thermogravimetry (TGA) and simultaneous thermal analysis (STA). For citation: Akimov Al.S., Zhirov N.A., Sudarev E.A., Akimov A.S. The mechanically activated composites based on tungsten disulfide: synthesis and properties. ChemChemTech [Izv. Vyssh. Uchebn. Zaved. Khim. Khim. Tekhnol.]. 2024. V. 67. N 8. P. 36-43. DOI: 10.6060/ivkkt.20246708.2t.

Magnetic and microstructural properties of thin film Fe-Sb obtained by thermal evaporation of nanostructured milled powder

Magnetic and microstructural properties of thin film Fe-Sb obtained by thermal evaporation of nanostructured milled powder

Sorbents utilizing h-BN micro- and nanoparticles for efficient antibiotic removal in wastewater treatment

Currently, there is a high demand for novel sorbents for wastewater treatment. Nanostructured materials are often considered as more promising sorbents compared to their microsized counterparts, which, however, requires experimental verification. In this work, two types of h-BN materials (micro- and nanosized) are compared as candidates for antibiotic sorption. The initial h-BN was in the form of microsized pellets. Nanostructurued h-BN was obtained by high energy ball milling of the initial powder. The effect of ball milling on the microstructure, morphology, chemical composition and surface chemical state was investigated by SEM, TEM, STEM, EDX, XRD, XPS, FTIR and BET techniques. Adsorption properties were studied on samples in the form of pellets and powders. Activated carbon powder was used as a reference material. The antibiotic adsorption process was studied using tetracycline and linezolid. The influence of the h-BN structure on the adsorption characteristics was elucidated using DFT calculations.

Temperature-dependent structural and magnetic properties of mechanically alloyed Ni80Co17Mo3 powder mixture

Nanostructured materials containing nickel improve the effectiveness of several applications. This study examines the preparation and characterization of nanostructured Ni80Co17Mo3 alloy powders using high-energy mechanical alloying and subsequent annealing. A 72 h milling process used pure elemental powders to synthesise nanocrystalline FCC-NiCo(Mo) solid solution. The milled powders were then subjected to annealing at different temperatures:300°C, 500°C, and 750°C. X-ray diffraction, scanning electron microscopy coupled with energy-dispersive spectroscopy, and vibrating sample magnetometry indicated significant changes in the powdered alloy properties. The particles growth occurred as the annealing temperature increased, while the microstrain decreased significantly; 14.30±0.07 nm up to 56.30±0.28 nm and 0.680±0.003% up to 0.180±0.001%, at 25°C and 750°C respectively. SEM analysis revealed differences in particle size and shape as milling progressed. Surprisingly, the milled powdered alloy displayed improved magnetic properties, manifesting significant magnetic susceptibility and enhanced saturation magnetisation, remanent magnetisation, and coercivity within the temperature range of 300°C to 750°C. These findings indicate the development of a consistent and structured state, accompanied by significant crystal growth due to the annealing temperature. This study highlights the great importance of high-energy mechanical milling and subsequent annealing to tune / tailor the characteristics and subsequently investigate the potential utilization of nanostructured Ni-based alloys.

Preparation of W-Ni-Cu Alloy Powder by Hydrogen Reduction of Metal Oxides

The effect of powder processing on the microstructure and sinterability of the heavy alloy W-Ni-Cu was investigated. The heavy alloy powders were prepared by the ball milling and hydrogen reduction of metal oxide powders. As the milling time increased, the size of the powder mixture decreased and at 5 h of milling was found to be about 2.5 μm. Microstructural analysis revealed that the powder mixture was changed to W and NiCu alloys with an average particle size of about 200 nm after hydrogen reduction at 800°C for 2 h. The reduction kinetics of the oxide powder mixture was evaluated by the amount of peak shift with heating rates using TGA in a N&lt;sub&gt;2&lt;/sub&gt;-10% H&lt;sub&gt;2&lt;/sub&gt; atmosphere. The activation energy of the reduction reaction, calculated from the slope of the Kissinger plot, was measured to be 42.8 kJ/mol for CuO, 57.9 kJ/mol for NiO, and 50.1~112.6 for kJ/mol WO&lt;sub&gt;3&lt;/sub&gt;. The relative densities of the heavy alloy sintered at 1100oC and 1200oC using oxide powder were 81.4% and 96.0%, while the specimen using metal powder as a raw material showed a relatively low value of 67% and an inhomogeneous microstructure. It was explained that the changes in sintered microstructure with different powder synthesis methods are mainly due to the powder characteristics, such as the size of the particles of the initial mixed powder.

Effect of Processing Routes on Physical and Mechanical Properties of Advanced Cermet System

The present research focuses on the effects of different processing routes on the physical and mechanical properties of nano Ti(CN)-based cermets with metallic binders. Tungsten carbide (WC) is added as a secondary carbide and Ni-Co is added as a metallic binder to nano Ti(CN)-based cermet processed via conventional and spark plasma sintering (SPS). A systematic comparison of the composition and sintering conditions for different cermets’ systems was carried out to design novel composition and sintering conditions. Nano TiCN powder was prepared by 30 h of ball milling. The highest density of &gt;98.5% was achieved for the SPS-processed cermets sintered at 1200 °C and 1250 °C for 3 min at 60 MPa of pressure in comparison to the conventionally sintered cermets at 1400 °C for 1 h with a two-stage compaction process—uniaxially at 150 MPa and isostatically at 300 MPa of pressure. Comparative X-ray diffraction (XRD) analysis of the milled powders at different time intervals was performed to understand the characteristics of the as-received and milled powders. Peak broadening was observed after 5 h of ball milling, and it increased to 30 hr. Also, peak broadening and a refined carbide size was observed in the XRD and scanning electron microscope (SEM) micrographs of the SPS-processed cermet. Transmission electron microscope (TEM) analysis of the milled powder showed that its internal structure had a regular periodic arrangement of planes. SEM base scattered electron (BSE) images of all the cermets primarily showed three major microstructural phases of the core–rim–binder with black, grey, and white contrast, respectively. With the present sintering conditions, a high hardness of ~16 GPa and a fracture toughness of ~9 MPa m1/2 were obtained for SPS-processed cermets sintered at higher temperatures.

The production of $B_{4}C$ reinforced metal matrix composite from waste $AZ91$ magnesium alloy using the ball milling method

In this study, the Mg/$B_4$C composite reinforced with boron carbide particles was produced by mechanical milling method using waste AZ91 magnesium alloy chips. The mechanical and tribological properties of the produced composites were investigated through hardness and wear tests. A mixture of AZ91 magnesium alloy chips, aluminum, and $B_4$C powders was milled at a rotation speed of 300 rpm with a ball-to-powder ratio of 20:1 for 3 hours. The milled powders were first cold pressed and then sintered at 550 °C for 3 hours. In density measurement, it was observed that the sample reinforced with B4C exhibited an increase in density. In X-ray diffraction analysis, peaks corresponding to Mg, $Mg_{17}Al_{12}$, and MgO were detected, while the $B_4$C phase could not be identified. On the other hand, $B_4$C particles in the microstructure were revealed in the energy dispersive X-ray spectroscopy analysis. Scanning electron microscope images revealed that the Mg/$B_4$C composite had lower porosity, consistent with density measurements. It was found that the hardness and wear resistance of the Mg/B4C composite were higher than those of the Mg alloy, which can be attributed to the presence of homogenously distributed hard B4C particles within the microstructure.

Characteristics of oxide-dispersion strengthened alloys produced by high-temperature severe deformation

This study is to explore an economically attractive and technically feasible processing method for oxide-nanoparticle strengthened alloys for fusion reactor application. Despite many scientific merits of the advanced oxide-dispersion strengthened (ODS) alloys, such as the nanostructured ferritic alloy (NFA) 14YWT, the only viable production path for a high-quality NFA is the high-power mechanical alloying process. This process is often a multi-day high-speed ball milling of alloy powder with a small quantity of yttria (Y2O3) powder, followed by the milled-powder consolidation using extrusion or other methods and additional thermomechanical processing (TMP) for property control. This complex production path, including the low-temperature mechanical alloying in particular, has limited technical advancement toward the cost-effective and scale-up production of ODS alloy components. To overcome such a practical limitation, we proposed to explore alternative low-cost processing routes using traditional thermomechanical processing (TMP) method only. A series of continuous TMP cycles, which were designed to impose high-temperature severe plastic deformation (HT-SPD) conditions to the consolidated powder mixtures, were applied to achieve the effective distribution of oxide particles in nanograin structure and thus desirable mechanical properties. Since the reduced-activation ferritic-martensitic (RAFM) alloy powders (Fe-10Cr and Fe-14Cr alloys with various Y contents) are available in our inventory, we focused to utilize the new solid-state synthesis approach for controlling oxide (oxygen source) dissolution and nanoscale clustering in nanograin structure in those alloys. A combination of powder consolidation at 900 °C and continuous thermomechanical activation at 600 °C yielded two essential ODS alloy microstructure contents–nanograin structure and nanoparticle distribution–and thus demonstrated a good combination of strength and ductility.