A number of nickel‐based and iron‐based alloys have been successfully developed for applications at high service temperatures and in corrosive environments. Applications such as diesel particulate filters, heat exchangers, and catalyst supports require open‐cell porous structures with tailored and uniform material and structural properties, a requirement which can be met by high temperature and corrosion resistant metallic alloy foams prepared with compositions similar to those mentioned above. A new technology that transforms pure nickel foam into an alloy foam, and which has now reached the pilot plant production stage, will be introduced. This technique starts from commercially‐available nickel foam, which is uniformly coated with a pre‐alloyed powder using standard powder metallurgical methods, and subsequently transformed into the desired alloy throughout the strut cross‐section in a relatively short time with a carefully controlled heat treatment that utilizes transient liquid‐phase sintering. This process allows for the preparation of a wide variety of foam compositions and structural features, which is important for tailoring material properties to a specific application.

A powder metallurgy route is described as a promising route to produce highly active Raney-Ni electrodes. An expanded Ni mesh was used as metallic substrate on the surface of which Raney-Ni phases were produced via a heat-treatment step using Al powder at different loads. The overpotential at −300 mA/cm 2 as well as the active surface area were determined to evaluate the electrodes. The results reveal that a high Al loading is necessary to achieve a stable electrode and a high activity for the hydrogen evolution reaction.

The most important use of fine spherical iron powders is for metal injection moulding (MIM). For many applications, the high costs of powder based on the carbonyl or atomising production route are a limiting factors. An alternative twostep hydrogen reduction process using a granulated hematite powder, which is a recycling product from steelmaking, has been developed to produce <25 µm spherical powder. The morphology and properties of the powder have been found to depend strongly on the second temperature step of the reduction process. A further important step is enclosed powder processing by milling and sieving to remove agglomerates. The powder properties and sintering behaviour as a function of heat treatment and processing parameters are reported and discussed