Optimization methods in powder metallurgy for enhancing the mechanical properties: a systematic literature review

Abstract Powder metallurgy offers several advantages over traditional manufacturing methods, such as improved material utilization and waste reduction. The powder metallurgy process involves four primary steps, metal powder preparation, mixing, compaction, and sintering, followed by secondary operations such as forging, rolling, and extrusion. However, existing studies have predominantly focused on refining the primary processes, neglecting secondary processes that could further enhance mechanical properties. A systematic literature review following the Preferred Reporting Items for Systematic Review and Meta-Analysis method identified twenty-three relevant articles over a ten-year period, highlighting three main optimization methods, that are, the Taguchi method, Taguchi-based Grey Relational Analysis, and Response Surface Methodology. These methods effectively reduce experimental trials and optimize key parameters like compaction pressure and weight percentage, which significantly influence mechanical properties. The review emphasizes the key powder metallurgy process parameters that have a significant impact on mechanical properties, becoming the primary targets for optimization. It offers a focused examination of which process parameters require thorough investigation for optimization and the suitable optimization method to achieve optimal outcomes, whether for single or multiple responses, thereby enhancing the manufacturing process. However, inconsistencies in parameter significance across studies indicate the material-dependent nature of powder metallurgy materials. The review also identifies a gap in the literature regarding secondary process optimization and comparative analyses of optimization methods. Future research should explore optimizing secondary processes in powder metallurgy, conduct comparative studies of different optimization methods, and develop novel approaches for optimization to further enhance mechanical properties and process efficiency.