really? twenty years ago (when I last worked in the industry) they were forged from titanium, inconel and monel
100% Incorrect
Compressor (cold section) blades are often titanium.
Turbine (hot section) blades (to which you were referring) are often made from the various nickel/cobalt superalloys like Hastelloy and Inconel (capitalize it because it's a proprietary name)... and the turbine blades were castings... not forged. The geometry and need for complex internal cooling passages made casting the only viable method. And those CAST parts survive in an 1800°F degree environment with ten-of-thousands of pounds of force exerted on them for tens-of thousands of hours.
But ignorant people will argue all day long that a forging is better than a casting. Negative, it all depends on the application.
Nothing is inherently wrong with MIM (or castings).
Not all forgings are equal.
The material and material processing utilized is determined by the application.
The proper alloy cast, may be preferable to the incorrect (or cheaper) alloy that's forged...
and I haven't even started on surface treatments, heat treatments, etc.
Again, nothing is inherently wrong with MIM.
Where I worked, a Fortune 100 aerospace company, we used many parts that were PM (powder metallurgy)... which is similar to MIM.
For the 3rd time, nothing is inherently wrong with MIM.
The only concern is whether the process generates a component with the appropriate mechanical properties to perform the desired function.
Any forging used in place of MIM, isn't going to be ANY stronger than it has to be. No engineer is going to "make it better" just for the hell of it.
FWIW, there are several applications where a coarse random cast grain structure may be MORE FATIGUE or CREEP RESISTANT than the small equiaxed grains of a forging. Most failure modes target the weakest part of the grain structure... which *SURPRISE* is the grain boundaries... and guess what... more & finer grains equal more grain boundaries.... so a forging can be more susceptible to failure in many applications.
This is why aerospace companies started experimenting with single crystal alloys years ago... Why not just eliminate the grain boundaries altogether?
MIM is just a process used to generate a component, and it's utilized when it fits the application.