Pre-alloyed Powder Research Articles

Characterization of Iron – Based Partial Pre - Alloyed Powders as Matrix Materials for Diamond Tools

Fe-Cu-Co is a structural component used in applications requiring both high strength and high hardness. A diamond cutting tool with iron -based (Fe -53%, Cu – 28%, Co -17%, P– 1% & Ni -1%) pre-alloyed powders was prepared in the laboratory using powder metallurgy technique. Commercially available pure powders were combined to create the alloys, which were then roll compacted into bars and right away hot processed into fully dense alloy bars. Solid state sintering technique is used to manufacture composite material as it gives less defectives, more accurate than casting and excellent dimensional control. During sintering process metal powders are blended in ball milling and are compacted on hot press machine by applying heat and pressure simultaneously at different elevated temperatures. The sintered specimens are subjected to hardness, impact, density and porosity tests along with fractography study. From experimental observations it is found that material has high hardness than the steel, which can withstand mechanical vibrations, high impact strength and high toughness. According to experimental results it is most suitable for cutting applications, and there is a possibility to add diamond crystals in this tool, to strengthen hardness helping to cut the rocks.

Achieving exceptional work-hardening capability of additively-manufactured multiphase Fe-Mn alloys via multiple deformation mechanisms

Laser-powder-bed-fusion (LPBF) fabricated Fe-Mn biodegradable alloys provide an attractive prospect for orthopedic applications due to their good tensile strength and high degradation rate. Nevertheless, the ε-martensite and heterogeneous microstructures produced by the LPBF processing often lead to premature failure of alloys. Herein, we report a LPBFed multiphase Fe-18Mn alloy (γ-austenite, ε-martensite, and α-ferrite) fabricated from pre-alloyed powders. After annealing at 650 °C, the alloy with a uniform microstructure displays a high 1 GPa tensile strength, a good fracture elongation of 16 %, and an extremely high work-hardening rate of 8500 MPa. The work-hardening rate is higher than that reported in most Fe-Mn steels and Fe-based high entropy alloys. The grain size of a few hundred nanometers provided the excess Gibbs free energy, resulting in an increase in the stacking fault energy (SFE) to 23.9 mJ/m2. The multiple deformation mechanisms, i.e., SFs, the martensitic transformation (γ → ε → α') and nano-deformation twins (DTs), were sequentially activated. We elucidate such unique work-hardening capability, originating from the interaction between the DTs, SFs and transformed martensite. Besides a high-density of dislocations were accumulated between parallel planar defects, the cooperative deformation of the soft and hard phases provided continuous hardening. Our findings highlight the exceptional work-hardening capability of additively-manufactured Fe-Mn alloys achieved by a multiphase material exhibiting multiple deformation mechanisms. The work also provides a straightforward approach for the development of stable-implanted Fe-based bone substitutes.

Optimization of microstructure and tensile properties for a 13Cr-1W ODS steel prepared by mechanical alloying and spark plasma sintering using pre-alloyed powder

An oxide-dispersion-strengthened (ODS) 13Cr-1W steel has been fabricated through mechanical alloying (MA) and spark plasma sintering (SPS) using pre-alloyed Fe-Cr-W-Y powder and TiO2 powder. Sufficient MA effects, indicated by homogeneous distribution of alloying elements and high level of lattice strain inside the powder, have been obtained within 20 h of high-energy ball-milling. Grain refinement of the bulk materials is successfully achieved by optimizing the sintering temperature and pressure during SPS. A fine-grained ODS steel with average grain size of 626.75 nm is prepared when sintered at 950 °C/80 MPa. Ultrafine oxide dispersoids, identified as Y2O3, Y2TiO5 and Y2Ti2O7, are observed homogeneously distributed in the steel matrix after annealing. They have a number density of 4.5 × 1022 m−3 and an average size of 11.15 nm. Tensile tests from room temperature to 700 °C are conducted to this ODS steel. It exhibits an ultimate tensile strength and a yield strength of 1559.60 MPa and 1352.82 MPa at room temperature, respectively. Due to a good combination of dislocation strengthening, grain boundary strengthening and precipitation strengthening, this alloy wins superior tensile properties over most of the commercial ODS steels and those reported in some previous studies.

High strength and ductility eutectic high entropy alloy with unique core-shell structure

The as-printed AlCoCrFeNi2.1 eutectic high entropy alloys (EHEAs) alloys were manufactured from pre-alloy powders by selective laser melting (SLM) technology. The microstructure, mechanical properties and unique FCC-B2 core-shell structures of as-printed alloys were examined in detail. There are no obvious cracks, pores or defects found in as-printed alloys, and the highest relative density is more than 99.5%, showing an excellent metallurgical combination between contiguous melted layers. The as-printed alloys are consisted of FCC and B2 phases, presenting typical fish scale structures, which contain ultra-fine cellular and columnar structures, and exhibiting preferred orientation. Meanwhile, the ultimate tensile strength and elongation of the as-printed alloy manufactured by the optimum parameters are 1159.4 MPa and 29.0%, respectively. It is believed that the ultra-fine grains and unique FCC-B2 core-shell structures formed during the SLM should be responsible for such outstanding mechanical properties. In addition, the edge dislocations at the interface formed due to thermal stress are observed, while the dislocation motion has been hindered by the unique FCC-B2 core-shell structures, thereby achieving a positive combination between ductility and strength. A certain theoretical analysis value and experimental references have been provided in this work for the further application of EHEAs in additive manufacturing.

Impact of laser scanning strategies on microstructure in laser powder bed fusion (LPBF) of nanoparticle-infused pre-alloyed water-atomized iron powder

This study investigates how two scan strategies impact the microstructural and tensile properties of nanoparticle-infused pre-alloyed water-atomized low-alloy iron powder (Fe-1.50Cu-1.75Ni-0.50Mo) during Laser Powder Bed Fusion (LPBF) under uniform volumetric energy density laser conditions. The two strategies were the rotation method (ROT), in which the laser scan vector was rotated by 67° for each layer (10°, 77°, 144°, 211°, …), and the zig-zag method (ZZ), in which the vector was rotated by 90° for each layer (45°, −45°, …). As a result, the relative density of the ROT specimens was measured to be 95.61 ± 1.01 %, while that of ZZ specimens was 99.76 ± 0.17 %. Furthermore, the surface roughness of ROT specimens was higher than that of ZZ specimens (24.05 μm vs. 10.30 μm). It was found that the scan strategy influences not only the bulk characteristics but also the microstructural changes of the specimens, due to variations in intrinsic heat treatment (IHT). In the ZZ specimens, the regular laser scanning direction resulted in a uniform microstructure across different heights. However, in the ROT specimens, the laser scanning direction varied from layer to layer, with fluctuating heat dissipation influencing the melt pool structure, recrystallized grain distribution, sub-grain cellular structure, and precipitation behavior to obtain lower density and higher surface roughness than those of ZZ samples. Therefore, the samples printed using the ZZ method are found to be advantageous for printing pre-alloyed WA iron powders with uniform microstructure and reliable tensile properties.

Microstructural stability of secondary phases in an ODS ferritic steel after thermal aging at 873 K

An oxide dispersion strengthened (ODS) steel with nominal composition Fe–14Cr–2W–0.4Ti–0.3Y2O3 (wt%) has been manufactured by mechanical alloying of pre-alloyed powders with nanosized Y2O3, compacted by hot isostatic pressing and hot cross rolled. In order to evaluate the long-term thermal resistance of the alloy, it has been subjected to 2000 h of thermal aging at 873 K, which is a relevant temperature for nuclear reactor applications. A thermodynamic equilibrium simulation indicates the precipitation of Laves phase under the aging parameters used. This prediction is confirmed from the detailed multi-technique characterization performed. Before aging, Ti-rich oxides, Cr-W-rich precipitates (M23C6 type) and a homogeneous Y-rich nanoprecipitate dispersion are observed. After aging, some W-rich precipitates are identified as Laves phase, while M23C6 carbides, Ti-rich oxides and Y-rich nanoprecipitates remain stable. Mechanical characterization performed in a previous research showed higher hardness, a loss of total elongation and a slight shift of the ductile-to-brittle transition temperature (DBTT) towards a higher value after aging, with similar strength values before and after the long-term thermal treatment. These changes can be due to the redistribution of precipitates together with the Laves phase formation. The mechanical properties not being dramatically affected seem to be due to the observed stability of Y-rich nanoprecipitates distribution.

Functionally Graded Steels Obtained via Electron Beam Powder Bed Fusion

Electron-Beam Powder Bed Fusion (EB-PBF) is one of the most important metal additive manufacturing (AM) technologies. In EB-PBF, a focused electron beam is used to melt metal powders in a layer by layer approach. In this investigation two pre-alloyed steel-based powders, stainless steel 316L and V4E, a tool steel developed by Uddeholm, were used to manufacture functionally graded materials. In the proposed approach two powders are loaded into the feeding container, V4E powder on top of 316L one, preventing their mixing. Such type of feeding yields components with two distinct materials separated by a zone with gradual transition from 316L to V4E. Microstructure and local mechanical properties were evaluated in the manufactured samples. Optical Microscopy, Scanning Electron Microscopy and EDX on the polished cross-sections show a gradual microstructural and compositional transition from characteristic 316L at the bottom of the specimens to the tool steel towards the top. Nanoindentation experiments confirmed a consequent gradient in hardness and elastic modulus, which gradually increase towards the top surface of the samples. The achieved results provide great possibilities to tailor the composition, microstructure, mechanical properties, and wear resistance by combining different powders in the powder bed AM technology. Potential applications include the tooling industry, where hard and wear-resistant materials are demanded on the surface with tougher and more ductile materials in the core of the tool.

Ti-Zr-Nb based BCC alloy containing Mo prepared by laser directed energy deposition—ω phase and cellular structure

This study focuses on the fabrication of Ti-Zr-Nb β-Ti alloys via laser direct energy deposition (DED) technique using pre-alloyed powder with and without having Mo traces. Microstructural analysis revealed the presence of cellular structures within the grains, resembling dendritic solidification, although no discernible dendritic segregation was observed. Nano-scale solute element clustering, particularly the formation of Nb depletion pockets, led to the development of the ω phase within the β matrix. Strengthening effects resulting from the presence of the ω phase were confirmed through TEM analysis. The DED-fabricated β-Ti alloy exhibited enhanced strength (∼1 GPa), significant elongation (∼15%), and a low elastic modulus (∼65 GPa), positioning it as a promising candidate for load-bearing biomedical implants.

On the transformation temperatures of Ti-6Al-4V: Effect of oxygen pick-up during Laser Powder Bed Fusion

Ti-6Al-4V (Ti64) parts manufactured by Laser Powder Bed Fusion (L-PBF) exhibit a fine martensitic microstructure and significant residual stresses that are detrimental for their mechanical performance. Consequently, post-processing heat treatments are necessary to relieve these internal stresses and achieve a microstructure adequate for the mechanical requirements. Given the variations in powder compositions and processing parameters, there is a large scattering of physical properties of both as-built and heat-treated parts. In this context, this study quantifies the link between interstitial contents (specifically oxygen and nitrogen) and the transition temperatures of as-built parts, using as-atomized pre-alloyed powders for reference. The martensite decomposition temperature and beta transus temperature are assessed using high-temperature X-Ray diffraction and differential scanning calorimetry for both the powder and as-built parts. It was found that the martensite that composes the as-built microstructure can be decomposed into a stable α+β structure at temperatures exceeding 490 °C. Oxygen and nitrogen pick-up occurs during the L-PBF process, leading to an elevated beta transus temperature in as-built parts relative to the original powder. This insight provides a guide for optimizing post-processing heat treatments for Ti64 as-built components.

Improvement in Abrasive Wear Resistance of Metal Matrix Composites Used for Diamond-Impregnated Tools by Heat Treatment.

This work presents the possibilities of producing a substitute for a commercial matrix material for sintered metal-diamond tools which is characterized by increased tribological properties required in machining natural stones and concrete. In this study, the improvement in wear behavior of sintered pre-alloyed matrix caused by a thermal treatment was investigated. Several mixtures made of commercially available powders were homogenized by ball milling and consolidated at 900 °C using the spark plasma sintering (SPS) method. During cooling down, the specimens were subjected to isothermal holding at 350 or 250 °C for 1 h. After consolidation, all specimens were tested for density and hardness, whereas selected specimens were characterized by scanning electron microscopy (SEM) and flexural strength tests. The specimens made of BDCM50 powder (a mixture of the base and pre-alloyed powders in 50:50 proportion) shows excellent properties including σ0.2 = 1045 MPa in the three-point bending test and HV10 ≈ 380. Resistance to abrasive wear evaluated in both three-body and two-body conditions in the MWT abrasion test was estimated at Ai3=18.1±3.9 μm/20 m and Ai2=95.9±11.8 μm/20 m, respectively. A series of diamond-impregnated specimens (segments) was also produced and tested for wear rate on abrasive concrete. The potential graphitization of the diamond grits was investigated using Raman spectroscopy and X-ray diffraction. As a reference, both the base Fe-Mn-Cu-Sn-C and commercially available Co+20%WC alloy were used to compare selected properties of the investigated materials. It has been proved that heat-treated specimens made of the base mixture modified with pre-alloyed powders are characterized by increased hardness and resistance to abrasive wear. The BDCM50 matrix has a negligible effect on diamond graphitization and shows excellent field performance, which makes it a good potential substitute for replacing Co+20%WC in sintered diamond-impregnated tools.

Wear and corrosion resistant HVOF-sprayed WC-xCr3C2-8Co-6Ni coatings produced from pre-alloyed powder

In this work, a new WC-Cr3C2-CoNi coating was fabricated on steel substrate by thermal spraying the feedstock powder after an alumina-assisted pre-alloying treatment. The Cr3C2 content in the cermet coating was optimized based on the comparison of wear and corrosion properties with the conventional WC-based coating. The results showed that a (Co, Ni)6(W,Cr)6C solid-solution binder phase was formed because of the pre-alloying treatment above the eutectic temperature of feedstock powder. Moreover, sufficient diffusion of various atoms enabled the achievement of complete metallurgical bonding between carbides and the binder phase in the feedstock particles. These featured microstructures were partially retained in the resultant coatings, which thus possessed exceptional wear and corrosion resistance. The performance enhancement mechanisms of the developed coatings were proposed in terms of the unique design in composition and microstructure of the pre-alloyed feedstock powder.

Densification kinetics and microstructural evolution of binder jet printed and sintered porous Ni-Mn-Ga magnetic shape-memory alloys

Binder Jet Printing (BJP) of polycrystalline magnetic shape-memory alloys (MSMAs) allows to create complex geometries from pre-alloyed powders, while avoiding elemental evaporation and internal stresses. However, to increase functionality, polycrystalline MSMAs require high porosity and large grains to decrease internal constraints to twin boundary motion. This study focuses on the microstructural evolution of BJPed porous Ni-Mn-Ga during isothermal sintering to understand the densification mechanisms taking place at different temperatures (1070, 1080 and 1090 ℃) over time (0–8 h) in order to tailor the microstructure to regimes of large, interconnected porosity and large grains. Stereology was used to determine the sintering mechanisms as defined by Coble's model for intermediate stage sintering. Densification and grain size increased over time for all temperatures at different rates, while pore size decreased to a minimum near 1 h sintering. Sintering at 1070 ℃ resulted in an interplay of densifying and coarsening mechanisms, while at 1080 ℃ the dominating mechanism was volume diffusion and at 1090 ℃ grain boundary diffusion. No changes in electron concentration occurred during sintering, and thus, transformation temperatures and magnetization remained nearly constant. Transformation enthalpy and Gibbs free energy showed an inverse behavior to pore size, indicating larger pores reduce transformation energy.

A comparative study of in-situ alloying in laser powder bed fusion for the stainless steel X2CrNiMoN20-10-3

This paper compares, for the first time, laser powder bed fusion (PBF-LB/M) processing of a powder mixture (PM), also known as in-situ alloying, with that of a pre-alloyed (PA) powder from gas atomization with the same chemical composition, using the example of X2CrNiMoN20-10-3 ferritic-austenitic stainless steel. The focus is on the differences in the microstructure formation mechanisms during PBF-LB/M between PM and PA using different energy inputs, in order to gain new insights into the process transferability of in-situ alloying to the processing of pre-alloyed powders. The microstructure investigations are carried out using electron backscattered diffraction (EBSD), energy dispersive (EDS) as well as wavelength dispersive X-ray spectrometry (WDS), X-ray diffraction (XRD) and magneto-inductive method (Feritscope®). The microstructures of samples produced from PM and PA differ significantly in terms of the resulting ferritic and austenitic phase fractions, so that a ferritic-austenitic microstructure forms for PM, while the PA is predominantly austenitic. The differences are mainly based on the increased chemical inhomogeneities for the PM in comparison to the PA state, which are discussed based on EDS map analysis through spatial statistics. With increasing energy input, the chemical homogeneity of the PM approaches that of the PA, but it cannot reach it even with maximum energy input. The formation of a ferritic-austenitic microstructure in the case of the PM leads to the formation of a finer microstructure compared to single-phase PA steel resulting in higher hardness of PBF-LB/M-built PM.

Selective laser melting of AlCoCrFeMnNi high entropy alloy: Effect of heat treatment

The dilemma concerning the trade-off between the strength and ductility of alloys has persistently been a significant problem in engineering applications. Conventional techniques such as grain refinement, severe plastic deformation, and precipitation strengthening usually increase strength at the expense of ductility. High entropy alloys with dual-phase structures, on the other hand, generally display excellent strength-ductility synergy. In this study, we attempted to mix pre-alloyed powders of two distinct phases (body-centered cubic - bcc and face-centered cubic - fcc) to fabricate AlCoCrFeMnNi HEAs with a dual-phase structure by selective laser melting. Furthermore, we investigate the impact of varying heat treatment temperatures (900 °C, 1000 °C, and 1100 °C) on its phase composition, microstructure, and mechanical properties. The results show that with an increase in the heat treatment temperature, the volume of the fcc phase increases gradually and the volume of the bcc phase decreases. The columnar structure in the fcc phase transforms into a cellular structure, and a spinodal decomposition is observed with the bcc phase. As the heat treatment temperature increases, the yield strength decreases while the elongation substantially increases, with the samples heat-treated at 1100 °C showing the best comprehensive properties (yield strength ∼700 MPa, tensile strength ∼950 MPa, and ∼15% ductility).

Effect of Mo Oxides on the Phase Composition and Characteristics of Mo-10Re Pre-Alloyed Powders Co-Reduced with NH4ReO4.

Mo-Re pre-alloyed powders are crucial raw materials in fabricating Mo-Re alloys, and their properties can significantly impact the properties of the resulting alloys. The powders are usually produced by the co-reduction of a mixture of Mo and Re oxides. However, it remains unclear if the overall characteristics of the produced Mo-Re powders rely on the different combinations of the Mo and Re oxide precursors. Therefore, in this work, a comparative study is conducted on the co-reduction processes of different Mo oxides together with NH4ReO4, along with its influence on the size distribution and phase composition of the resulting Mo-10Re pre-alloyed powders. The results show that MoO3 is more promising than MoO2 as a precursor material. The powders fabricated using MoO3, when compared to MoO2, have a much more uniform size distribution, with a primary particle size ranging from 0.5-4 μm. In addition, it is also beneficial to achieve atomic-scale homogeneous mixing with Mo and Re elements and the formation of a solely Mo(Re) solid solution if MoO3 is used as a precursor oxide. In contrast, such desirable features were not identified when using the MoO2 route. The reason for this discrepancy may relate to whether Mo-O-Re metallurgical bonding has formed during the co-reduction process.

Fabrication of High-Entropy Alloys Using a Combination of Detonation Spraying and Spark Plasma Sintering: A Case Study Using the Al-Fe-Co-Ni-Cu System

The use of pre-alloyed powders as high-entropy alloy (HEA) coating precursors ensures a predetermined (unaltered) elemental composition of the coating with regard to the feedstock powder. At the same time, it is interesting to tackle a more challenging task: to form alloy coatings from powder blends (not previously alloyed). The powder-blend-based route of coating formation eliminates the need to use atomization or ball milling equipment for powder preparation and allows for the introduction of additives into the material in a flexible manner. In this work, for the first time, a HEA was obtained using detonation spraying (DS) followed by spark plasma sintering (SPS). A powder mixture with a nominal composition of 10Al-22.5Fe-22.5Co-22.5Ni-22.5Cu (at.%) was detonation-sprayed to form a multicomponent metallic coating on a steel substrate. The elemental composition of the deposited layer was (9 ± 1)Al-(10 ± 1)Fe-(20 ± 1)Co-(34 ± 1)Ni-(27 ± 1)Cu (at.%), which is different from that of the feedstock powder because of the differences in the deposition efficiencies of the metals during DS. Despite the compositional deviations, the deposited layer was still suitable as a precursor for a HEA with a configurational entropy of ~1.5R, where R is the universal gas constant. The subsequent SPS treatment of the substrate/coating assembly was carried out at 800–1000 °C at a uniaxial pressure of 40 MPa. The SPS treatment of the deposited layer at 1000 °C for 20 min was sufficient to produce an alloy with a single-phase face-centered cubic structure and a porosity of <1%. Interestingly, the hardness values of the as-sprayed and SPS-treated coatings were close to each other (~320 HV0.3). The hardness of the coatings measured in two perpendicular directions did not differ significantly. The features of the DS–SPS route of the formation of HEA coatings and its potential applications are discussed.

Study on the Microstructure and High-Temperature Oxidation Performance of β-NiAl/γ′-Ni3Al Intermetallic Compounds Fabricated by Laser Metal Deposition

Four Ni-Al intermetallic compounds with the Al concentrations in range of 28 to 35 (in atomic percentage) have been fabricated by laser metal deposition (LMD) through mixing appropriate contents of pure Ni powder with pre-alloyed high-Al nickel aluminide powder. Ni-35Al and Ni-32Al are both composed of more than 45 vol.% β-NiAl matrix phase dispersing γ′-Ni3Al, while Ni-30Al and Ni-28Al consisted of worm-like, needle-like γ′-Ni3Al mainly and less than 37 vol.% β-NiAl. After 20 h oxidation in air at 1000 °C, the results of thermobalance, X-ray diffraction and scanning electron microcopy, indicated that Ni-35Al and Ni-32Al are more oxidation-resistant than the Ni-30Al and Ni-28Al. Because the first two can thermally grow an external Al2O3 scale but the second two form a duplex oxide scale consisting of outer NiAl2O4 layer and inner Al2O3 layer.

A high-temperature Ti-6.8Al-6.8Zr-2.3V-2.1Mo-0.7Nb alloy suitable for laser-additive manufacturing

A high-temperature Ti-6.8Al-6.8Zr-2.3V-2.1Mo-0.7Nb alloy suitable for laser additive manufacturing is designed on the basis of the cluster formula of Ti–6Al–4V, composed of twelve α-[Al–Ti12](AlTi2) units and five β-[Al–Ti12Zr2](AlV1.2Mo0.6Nb0.2) ones, featuring enhanced β stability via Zr, Mo, Nb, and V co-alloying. Using pre-alloyed powders, this alloy shows a fine surface roughness about 83 μm, which is comparable to that of reported Ti–6Al–4V. The as-deposited alloy exhibits a typical bimodal basket-weave microstructure and superior mechanical properties at room temperature (ultimate tensile strength (UTS) of 1348 MPa, yield strength (YS) of 1253 MPa, and elongation of 4.4%) as well as at 600 °C (UTS of 657 MPa, YS of 578 MPa, and elongation of 44.6%), which are comparable to wrought-state high-temperature Ti alloys. At 650 °C, its UTS of 424 MPa and YS of 337 MPa still maintains a high level.

Diffusion behavior of Ta and Re in tungsten alloy with different addition methods

The addition of Ta or Re alone can improve the performance of tungsten alloys, but the combined addition of Ta and Re results in complex diffusion behavior and the formation of new phases. In this work, W-Ta-Re-Ni-Fe alloys with different Re contents were prepared by two methods (direct mixed powder sintering and pre-alloyed powder sintering), the compositions and structures of the precipitated phase through two preparation methods were analyzed, and the diffusion paths of Ta and Re were summarized. The addition of Re contributed to refining the grain size of tungsten alloys, but excessive Re addition led to the formation of hexagonal and tetragonal solid solution mesophases. Mechanical alloying not only strengthened the W particles substantially but also inhibited the growth of mesophases. In-situ Ni3Ta coherent nano-reinforced phase was generated by the diffusion reaction of Ta and Ni, which substantially increased the strength of the matrix phase. These findings suggest that the composite addition of Ta and Re is expected to further improve the toughness of tungsten alloys by adjusting the addition amounts of Ta and Re and improving the powder pretreatment.

Influence of technological synthesis conditions on corrosion behaviour and mechanical properties for NiTi alloys

PurposeThis study aims to investigate NiTi alloys’ characterization and corrosion behaviour produced by two different powder metallurgy (PM) methods.Design/methodology/approachIt was pre-formed under a protective atmosphere at 900 °C under a force of 45 MPa and sintered for 1 h under 10–6 Mbar in an atmosphere-controlled heat treatment furnace at 1,100 °C. The relationship between microstructural properties, SEM, XRD, density, microhardness and corrosion behaviour of pre-alloyed NiTi alloys produced by two different methods with the production method was investigated.FindingsAs a result of the studies, TiO, NiTi, NiTi2 and Ni3Ti intermetallics were determined in XRD examinations. The best surface roughness was observed in the mechanically milled (MM’ed) pre-alloyed NiTi alloy compared to the pre-alloyed NiTi alloy mixed with turbula. The corrosion tests performed in 3.5% NaCl solution determined that the MM’ed pre-alloyed NiTi alloy had better corrosion resistance than the pre-alloyed NiTi alloy mixed with turbula. Pitting corrosion was visualized in the SEM images taken from the corrosion surfaces.Originality/valueTwo different PM methods produced pre-alloyed NiTi powders, and the effects of these methods on the mechanical and corrosion resistance of NiTi alloys were systematically investigated for the first time.