Powder casting was developed to produce metal components with near-theoretical density from low-cost, loose powder using hydrogen sintering and phase transformation. This has significant implications for non-beam metal additive manufacturing processes (e.g., metal extrusion AM, binder jetting, and ordered powder lithography), which produce green parts with relatively low densities. Additionally, powder casting can enable the production of geometries typically not suitable for powder processing, such as plate and bar stock. In the current study, Ti-6Al-4V, Zr, and Hf were densified to 99.2%, 95.7%, and 94.0% of their respective theoretical densities, when sintered from loose powder at 1200°C for 4 h. The relative density and pore size distributions of Ti-6Al-4V produced by powder casting were very similar to those produced by press-and-sinter HSPT. The powder-cast Ti-6Al-4V samples also displayed ductility consistent with press-and-sinter HSPT. However, they exhibited lower strength due to unintentional overheating during the dehydrogenation step.

中文翻译：

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粉末铸造：无需压制即可从粉末中生产大块金属部件

粉末铸造被开发用于使用氢烧结和相变从低成本的松散粉末生产具有接近理论密度的金属部件。这对生产密度相对较低的生坯零件的非梁金属增材制造工艺（例如金属挤压增材制造、粘合剂喷射和有序粉末光刻）具有重要意义。此外，粉末铸造可以生产通常不适合粉末加工的几何形状，例如板材和棒材。在目前的研究中，Ti-6Al-4V、Zr 和 Hf 将松散粉末在 1200°C 下烧结 4 小时，致密化到各自理论密度的 99.2%、95.7% 和 94.0%。粉末铸造生产的 Ti-6Al-4V 的相对密度和孔径分布与压制烧结 HSPT 生产的非常相似。粉末铸造的 Ti-6Al-4V 样品还显示出与压制烧结 HSPT 一致的延展性。然而，由于在脱氢步骤中无意过热，它们表现出较低的强度。