This paper describes a novel technology for a mercury-free metallic di
rect filling material, a substitute to dental amalgams. The consolidat
ion relies both on cold-welding that takes place under moderate pressu
re between suitably surface-treated silver particles and on silver-tin
intermetallic compound formation at ambient temperature. A dilute aci
d is used for removing the silver surface oxide layers, thereby promot
ing the cold-welding process. The condensability, namely the ability o
f a loose powder to undergo consolidation within a short time duration
, at body temperature and under moderate pressure has been investigate
d for a variety of mixtures of silver, tin, and prealloyed silver-coat
ed intermetallic powders. The resulting metallic composite material di
splays transverse rupture strength values higher than those of amalgam
s and somewhat lower values of compressive strength and Knoop hardness
.