Recent advances in manufacture and application of Mg/Mg alloy powder: A comprehensive review

doi:10.1016/j.jmst.2025.10.056

Abstract

Abstract: Magnesium (Mg) and Mg alloy powder, characterized by its low density, high reactivity, and excellent strength-to-weight ratio, have emerged as a strategic material in diverse high-performance fields. This review systematically summarizes the latest research advances in the preparation and application of Mg/Mg alloy powder. We firstly focused on a comparative analysis of various preparation methods, including the solid-phase method, the liquid-phase method, and the gas-phase method, to evaluate their differences and advantages in terms of particle size, morphology, purity control, scalability, and safety. In terms of applications, this review mainly discussed the use and technological breakthroughs of Mg/Mg alloy powder in powder metallurgy, high-pressure molding, and additive manufacturing, as well as comparing the effect of different processing methods on the mechanical properties of Mg/Mg alloy production. Additionally, this review addressed the expanding functional applications of Mg/Mg alloy powder in fields such as superconducting materials, composites, and anticorrosion coatings. Although the production technologies of Mg/Mg alloy powder have reached a certain level of maturity, there still exist some significant challenges regarding safety control, structural stability, and application adaptability. Looking forward to the future, innovations in hybrid preparation techniques, safe handling protocols, additive manufacturing integration, and circular utilization pathways will be the key directions to drive Mg/Mg alloy powder materials towards high-performance engineering applications.

Key words: Mg alloy, Powder materials, Atomization, Additive manufacturing, Powder metallurgy

Yu Cao, Xiaohui Dong, Yulong Zhu, Tao Huang, Bin Jiang, Chenghang Zhang. Recent advances in manufacture and application of Mg/Mg alloy powder: A comprehensive review[J]. J. Mater. Sci. Technol., 2026, 263: 140-155.

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