The advantages and disadvantages of bulk powder vary depending on the specific application and material, but generally include considerations of production methods, physical properties, and practical applications.

Key Insights

• Advantages:

  • Versatility in Production:
    • Powder metallurgy allows for the creation of bulk amorphous alloys with larger dimensions, complex shapes, and near-net shapes across a wider composition range compared to rapid solidification
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    • Spray drying can achieve high powder collection yields and maintain the physical stability of monoclonal antibodies, making it suitable for biologic drug substance storage
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  • Enhanced Properties:
    • Nanocrystalline MgB₂ bulk superconductors prepared by mechanical alloying and hot compaction exhibit high critical current densities and improved pinning properties due to the large number of grain boundaries
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    • Additive manufacturing of Al-based metal matrix composites (AMMCs) results in significant differences in microstructure and properties compared to conventional processes, offering potential improvements in mechanical properties
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• Disadvantages:

  • Cost and Scale:
    • Spheroidization methods for producing powders required for laser powder bed fusion (LPBF) are costly and typically sold in large quantities, which may not be feasible for all applications
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  • Environmental Sensitivity:
    • The leakage current in bulk micro-MEGAS detectors increases with storage and test humidity, and the introduction of powder in the avalanche region further exacerbates this issue
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  • Material Limitations:
    • Metallic glasses, despite their unique properties, suffer from poor plasticity and limited dimensions, which restrict their large-scale industrial applications
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Conclusion

Bulk powder offers significant advantages in terms of versatility in production methods and enhanced material properties, making it suitable for various advanced applications. However, challenges such as high production costs, environmental sensitivity, and material limitations need to be addressed to fully leverage its potential.