Iron-based alloy powders and their bulk materials are widely used in the automotive and other mechanical fields, as well as in defense, economic, and social security areas such as transformers, inductors, and magnetoresistive detection due to their excellent mechanical properties, magnetic properties, and lower costs. However, high-performance iron-based alloy powder and its bulk material components mainly rely on imports, severely restricting the development of related national defense and civilian technologies in China. Although China has developed alloy compositions similar to those abroad, there is still a certain gap in the preparation and forming technology of iron-based alloy powders compared to foreign countries. This project has been ongoing for over a decade, supported by related topics, starting with the study of material science mechanisms in powder metallurgy preparation and forming technologies. It aims to reveal the relationship between the preparation and forming process and the structure and properties of materials, overcome key difficulties in powder metallurgy preparation and forming technology, and contribute to the development of high-performance iron-based alloys in China. Innovatively developed a variety of high-performance iron-based alloy powders and bulk material components, as well as their key preparation and forming technologies, which have been applied in the fields of national defense, economic security, and social safety such as criminal investigation, engineering troop equipment, aerospace weapon systems, and automobiles, achieving significant social and economic benefits. The main innovative achievements are as follows: 1. In response to the issue that criminal investigation fingerprint magnetic powders mainly rely on imports, by adopting a combination of gas atomization, solid-state diffusion metallurgy, and subsequent heat treatment methods, high-performance fingerprint revealing iron-based composite magnetic powders were prepared. This has achieved successful application of the composite magnetic powders in revealing fingerprint traces under different conditions. The revealing effect is comparable to that of similar products domestically and internationally, and it is superior to existing domestic and international counterparts in terms of bonding strength and adaptability to humid environments. 2. The nanocrystallization process of iron-based amorphous alloys is a complex dynamic process. A kinetic model for the study of the nanocrystallization mechanism of amorphous alloys by non-isothermal methods was constructed, elucidating the nanocrystallization mechanisms of typical amorphous alloys. Based on this, iron-based amorphous nanocrystalline alloy powders were prepared by mechanical ball milling/alloying and gas atomization techniques, and bulk iron-based amorphous nanocrystalline alloys with high saturation magnetization and low coercivity were produced using ultra-high pressure rapid consolidation technology. This solved the technical difficulties in the preparation and forming of high-performance bulk soft magnetic materials, and based on this, high-performance magnetic core devices were developed, achieving the application of high-performance bulk iron-based alloys in defense aerospace patrol weapons systems and engineering soldier equipment. 3. In response to the technical difficulty that thin-walled multi-step products and helical gears with complex shapes from powder metallurgy are difficult to achieve net forming, this project has developed a powder metallurgy net forming technology for difficult-to-form iron-based alloy products through independently developed molds and powder materials. The application in automotive parts such as engine series pulleys, brake system vacuum pump rotors, and electronic parking system helical gears has solved the problem of subsequent machining required by traditional products, improving production efficiency. 4. In response to issues such as low contact fatigue strength of tooth surfaces and poor tooth profile accuracy in powder metallurgy chain/gear parts, this project has carried out densification treatment on the tooth surfaces of chain/gear parts through surface densification technology, enhancing the performance and lifespan of the parts. This has solved the key technical bottleneck for the industrialization of powder metallurgy chain/gear parts in engine belt drive systems. Upon re-evaluation, the project results have generally reached an international advanced level and are novel and creative both domestically and internationally. 14 patents have been authorized; 58 papers have been published, with 40 being included in SCI (10 of which were published in journals with an impact factor ranking in the top 5% of metal and metallurgical engineering fields), Cited 654 times domestically and internationally, the achievements have been successfully applied in the fields of national defense, social security, and economy. The Shanghai Municipal Public Security Bureau, China Aerospace Science and Industry Corporation, a certain unit of the People's Liberation Army, as well as enterprises such as SAIC Volkswagen and Shanghai Automobile have applied the results of this project, generating significant economic and social benefits. In the past three years, this project has achieved direct economic benefits of 264 million yuan and indirect economic benefits of 2.76 billion yuan. Through the implementation of this project, the level of technology development and application in China's defense industry, people's livelihood, and social security fields has been improved, reducing dependence on foreign imported products and promoting the enhancement of scientific and technological strength in the fields of national defense, people's livelihood, and social security, contributing to national defense and social development.