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Powder Metallurgy Aluminum Alloys: Structure and Porosity

The production of aluminum alloys through powder metallurgy (PM) processes allows for the manufacture of net- or near-net-shape components in a cost-effective and sustainable manner. The high reactivity of aluminum metal, however, complicates PM processing, and special attention must be given to certain steps during production, particularly sintering. PM processing conditions strongly affect the structure and porosity of aluminum PM alloys, which ultimately determine their material properties and performance. In this article, the fundamental aspects of the commercial production of aluminum PM alloys are presented, along with the effects of production conditions on the structure and porosity of aluminum PM alloys. The properties and performance of aluminum PM alloys are then analyzed and interpreted with respect to their structure and porosity.