Metallic material concepts associated with the sustainable and efficient use of resources are currently the subject of intensive research. Al addition to steel offers advantages in view of lightweight, durability, and efficient use of high-Fe scrap from the Al industry. In the present work, Al was added to Fe-12Cr-(9,12)Ni-3Mn-0.3C-xAl (x = 0.1–6) (wt.%) stainless steels to assess its influence on microstructure and mechanical properties. According to density measurements based on Archimedes’ principle, densities were between 7.70 and 7.08 g/cm³. High-energy X-ray diffraction estimations of the lattice parameter indicated that nearly 31% of density reduction was caused by the lattice expansion associated with Al addition. Depending on Al concentration, austenitic and duplex matrix microstructures were obtained at room temperature. In the presence of up to 3 wt.% Al, the microstructure remained austenitic. At the same time, strength and hardness were slightly enhanced. Al addition in higher quantities resulted in the formation of duplex matrix microstructures with enhanced yield strength but reduced ductility compared to the austenitic alloys. Due to the ready formation of B2-(Ni,Fe)Al intermetallics in the ferrite phase of the present alloy system, the increase in strength due to the presence of ferrite was more pronounced compared to standard duplex stainless steels. The occurrence of B2 intermetallics was implied by dilatometry measurements and confirmed by electron microscopy examinations and high-energy X-ray diffraction measurements.

In this study, the alloying of stainless steels with various sulfur contents is investigated to obtain steel powders with significantly reduced mean diameters without changing the operational parameters of the atomizing unit. The steels are produced in a VIM12 furnace and atomized on a VIGA‐1B setup with high‐pressure argon. The desired reduction in the mean diameter is attributed to the decrease in surface tension with increasing sulfur content, which is in good agreement with previous findings. A transition from a positive to a negative thermal gradient of the surface tension is observed, along with a shift to higher temperatures with increasing sulphur concentration. In addition, the chemical assessment of the powders reveals a lower evaporation of manganese and a reduced increase in nitrogen content with increasing sulfur content. The sphericity and flowability are not affected by the addition of sulfur. Viscosity and density measurements are also conducted to characterize the steels thoroughly. Scanning electron microscopy reveals the presence of manganese sulfide, which was submicron in size and well distributed. Iron sulfides, mostly attributed to hot shortness, were not observed, which was also confirmed by thermodynamic modeling using Thermo‐Calc software.