The present study shows a comparison between two sintering processes, microwave and conventional sintering, for the manufacture of NiTi porous specimens starting from powder mixtures of nickel and titanium hydrogenation–dehydrogenation (HDH) milled by mechanical alloying for a short time (25 min). The samples were sintered at 850 °C for 15 min and 120 min, respectively. Both samples exhibited porosity, and the pore size results are within the range of the human bone. The NiTi intermetallic compound (B2, R-phase, and B19′) was detected in both sintered samples through X-ray diffraction (XRD) and electron backscattering diffraction (EBSD) on scanning electron microscopic (SEM). Two-step phase transformation occurred in both sintering processes with cooling and heating, the latter occurring with an overlap of the peaks, according to the differential scanning calorimetry (DSC) results. From scanning electron microscopy/electron backscatter diffraction, the R-phase and B2/B19′ were detected in microwave and conventional sintering, respectively. The instrumented ultramicrohardness results show the highest elastic work values for the conventionally sintered sample. It was observed throughout this investigation that using mechanical alloying (MA) powders enabled, in both sintering processes, good results, such as intermetallic formation and densification in the range for biomedical applications.

Reducing pollutant emissions and improving safety standards are primary targets for modern mobility improvement. To meet these needs, the development of low-density steels containing aluminum is a new frontier of research for automotive applications. Low-density Fe-Mn-Al-C alloys are promising. In this regard, an alloy with high aluminum content and niobium addition belonging to the Fe-Mn-Al-C system was evaluated to understand the possible phase transformations and thus obtain a transformation diagram by continuous cooling to help future processing. Dilatometry tests were performed in a Gleeble thermomechanical simulator with different cooling rates (1, 3, 5, 10, 15, 20, 30, and 50 °C/s). Chemical analyses carried out simultaneously with dilatometry tests showed the presence of proeutectoid ferrite (α_p), δ-ferrite, retained austenite, and niobium carbide (NbC). In the case of low cooling rates (1 and 3 °C/s), lamellar colonies of the eutectoid microconstituents were observed with a combination of α-ferrite and k-carbide. For higher cooling rates (5 to 50 °C/s), martensite was observed with body-centered cubic (BCC) and body-centered tetragonal (BCT) structures.

The structural and thermophysical characteristics of an Ni-rich NiTi alloy rod produced on a laboratory scale was studied. The soak temperature of the solution heat-treatment steps above 850 °C taking advantage of the precipitate dissolution to provide a matrix homogenization, but it takes many hours (24 to 48) when used without thermomechanical steps. Therefore, the suitable reheating to apply between the forging process steps is very important, because the product’s structural characteristics are dependent on the thermomechanical processing history, and the time required to expose the material to high temperatures during the processing is reduced. The structural characteristics were investigated after solution heat treatment at 900 °C and 950 °C for 120 min, and these heat treatments were compared with as-forged sample structural characteristics (one hot deformation step after 800 °C for a 30 min reheat stage). The phase-transformation temperatures were analyzed through differential scanning calorimetry (DSC), and the structural characterization was performed through synchrotron radiation-based X-ray diffraction (SR-XRD) at room temperature. It was observed that the solution heat treatment at 950 °C/120 min presents a lower martensitic reversion finish temperature (A_f); the matrix was fully austenitic; and it had a hardness of about 226 HV. Thus, this condition is the most suitable for the reheating stages between the hot forging-process steps to be applied to this alloy to produce materials that can display a superelasticity effect, for applications such as crack sensors or orthodontic archwires.

Over the last decades, alloy 718 usage has expanded and requirements imposed by its industrial applications became more critical. The knowledge about grain boundary character distribution (GBCD) in alloy 718 and its effect on properties improvement is mostly built based on iterative processing through cold rolling steps interspersed with solution annealing. Alloy 718 is found in the industry in many different forms and geometries, and fabricated by multiple thermomechanical processes such as wire drawing, rolling, forging or extrusion. The present study focused on understanding how wires respond to deformation mode related to drawing in regard to GBCD evolution, crystallographic orientation, precipitation of δ-phase and grain size. Lastly, assessing the resulting mechanical properties. The findings show that microstructural evolution is a consequence of competing mechanisms such as strain induced boundary migration, recrystallization, grain growth and phase precipitation. The deformation gradient along wire cross section plays an important role in affecting microstructural features, such as δ precipitation, GBCD and microtexture.

Reducing structural mass and volume is critical to improving efficiency and payload capacity in next-generation small satellites and CubeSats. Additive manufacturing, particularly material extrusion, offers design flexibility and enables the production of lightweight, functional metallic components. This study investigates the integration of nickel–titanium shape memory alloy wires into aluminum-based matrices using a sinter-based material extrusion process, aiming to develop compact actuator systems for aerospace applications. A customized AlSi7Mg aluminum alloy feedstock was extruded into filament form, printed, and embedded with shape memory alloy wires, allowing consolidation during sintering. X-ray micro-computed tomography was used to analyze internal defects and matrix–wire interfacial contact, before and after sintering. Tensile testing of the embedded actuator structures revealed effective mechanical bonding and actuation behavior. The results demonstrate that controlled shrinkage and interfacial bonding enable reliable embedding of shape memory elements without compromising structural integrity. This work provides a promising framework for developing multifunctional aerospace components, where active actuation and structural efficiency can be combined through advanced material extrusion-based manufacturing.