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An amorphous/nanocrystalline 50Ni–50Ti powder was produced from elemental Ti and Ni powders by solid state synthesis utilizing low energy mechanical alloying with times up to 100 h. The morphology, microstructure, and phase composition of the milling products were evaluated by using scanning electron microscopy and X-ray diffraction analysis. The results indicated that there was no chemical reaction between the elements during the milling process, which led to the direct formation of an amorphous/nanocrystalline structure without any intermediate phase (intermetallic and/or solid solution phase) formation. It seems that the second kind of amorphization process proposed by Weeber and Bakker is governed. It was shown that the formation of amorphous phase was started after 80 h and developed during the milling for 100 h.

The granularity distribution of powder is shown to have the fractal characters. Based on the fractal theory, three algebraic expressions for the fractal dimension, the cumulative probability and the mass distribution of particles were obtained. Three expressions are the functions of the concentration of particles, the diameter of particles, the maximum and the minimum particle diameters. No additional empirical constant is introduced in these expressions. These fractal models contain less empirical constants than the conventional correlations. The fractal behavior about coal particles was discussed in detail. Simulations were also performed by fractal Monte Carlo technique. The proposed technique may provide us a new approach to analyze the granularity distribution of powder.

Boron carbide is one of the advanced ceramic materials which is used in a wide range of applications. However, this material needs a high sintering temperature (~2200°C). Using nano-size powders for producing ceramic parts results in lowering sintering temperature and also enhances toughness and hardness of the material. One of the methods for producing ceramic nano powders is attrition milling. However, as the milling balls and wall are made of steel, some impurities specially iron will be introduced to the powder during milling. Chemical analysis of the milled powder shows that more than 33wt% of the powder consists of iron. These uncontrolled impurities affect the mechanical and physical properties of sintered ceramic parts that are made of such a powder. Therefore, these impurities must be removed from the powder. Hydro metallurgical beneficiation technique with two different solvents has been used for purification of the powder. The result of chemical analysis after purification showed that the weight percentage of iron in powder dropped to 9% and 0.8% (depending on the solvents). Moreover, the sintering behavior of hot-pressed boron carbide powder with different percentages of iron as sintering aid has been studied. The results showed excellent densification and hardness of the sintered parts.

In powder-mixed electrical discharge machining (PMEDM), the application of low-frequency vibrations to a workpiece is considered beneficial to the machining quality. This study evaluates the average surface roughness (Ra) of SKD61 steel workpieces subjected to low-frequency vibrations during PMEDM using a Cu electrode and titanium powder. Specifically, Taguchi’s L25 experimental design method is used to evaluate the influence of the following process parameters: current, pulse-on time, concentration, push pressure, frequency, and amplitude. The analysis of variance technique is used to determine the minimum Ra (Ra${}_{min}$) value. The results show that Ra is most and least strongly influenced by $I$ and $A$, respectively. Further, Ra${}_{min}$ is found to be 1.03 $\mu$m.