Impact of Metallic Powder Particle Size on Densification Behavior and Mechanical Properties in Conventional Powder Metallurgy Processes

The particle size of metallic powders plays a central role in determining the densification behavior and mechanical properties of components produced through conventional powder metallurgy. Fine particles, due to their high surface energy and short diffusion paths, tend to enhance green density and accelerate sintering, resulting in improved particle bonding and reduced porosity. However, excessively fine powders may lead to agglomeration and surface oxidation, which can compromise mechanical integrity. Coarse powders, while offering better flowability and reduced surface reactivity, often exhibit lower packing efficiency and increased residual porosity after sintering. Optimized particle size distributions—particularly bimodal blends—strike a balance by enabling fine particles to fill voids between larger ones, thereby increasing green density and mechanical performance. Additionally, the production route of the powder, such as gas atomization, mechanical alloying, or chemical synthesis, significantly affects the consistency, morphology, and PSD characteristics, which in turn influence compaction behavior and sintered strength. Although literature agrees on the overarching trends, variations in material systems, measurement methods, and processing parameters introduce discrepancies that underscore the need for standardized characterization and further in-situ investigations, especially regarding fatigue behavior and microstructural evolution in multimodal systems. DOI: https://doi.org/10.52783/jchr.v16.i1.11502