043-Fundamental Study on Fabrication Technology of Al-Cu Alloy Layers on Cu Substrates by Laser Additive Manufacturing
Fumihiro Ozawa, Nagoya University
Adding nanoscale pores and surface textures to metal surfaces imparts superhydrophilic properties and catalytic functions not found on smooth surfaces. Selective etching of binary alloys removes base elements, allowing noble elements to form nanoscale structures. However, for applications such as catalysts, nanostructures need to be provided only on the surface. Therefore, we focus on developing a process to create nanoscale pores only on the surface of the Cu substrate by combining laser additive manufacturing and selective etching. In this process, Al-Cu powder is spread on the Cu substrates and irradiated with a laser to form a continuous Al-Cu cladding layer with a homogeneous microstructure. Al is selectively removed by chemical etching to form nanoporous Cu surface. In this study, to clarify the process conditions for fabricating a continuous Al-Cu alloy with a homogeneous microstructure, we investigated the effects of various process conditions (powder composition, Cu substrate area, laser power, scanning speed) on the morphology and microstructure of the cladding layer.
The balling effect was significant when the laser energy density was low, whereas the substrate was significantly melted and deformed under high energy density. By controlling the heat input to the substrate, a continuous cladding layer was fabricated. On the cross-sections of the cladding layers, inhomogeneous microstructure was observed due to the inflow of Cu from the partially melted substrate to the cladding layer. Adjusting laser conditions and powder composition enables the formation of a homogeneous microstructure.
059-Bulk Near-Net Shape Processing of Nanophase Separation Sintering W-Cr Alloy via Direct Current Sintering
Sean Fudger, U.S. Army Research Laboratory
Nanophase Separation Sintering (NPSS) has been demonstrated as an effective method for the rapid consolidation of refractory alloys at significantly reduced temperatures and pressures. In this work, a W–Cr alloy was synthesized via high-energy ball milling and subsequently consolidated using direct current sintering (DCS). Following a series of DCS runs yielding traditional (10mm height) cylinders to optimize the processing conditions, bulk (125 mm height) near net shape components for ultra-high temperature applications were generated. The combined NPSS–DCS approach produced near fully dense (>99%) components while preserving an ultrafine grain structure, enabled by the reduced processing temperature characteristics of both NPSS and DCS. These results suggest that NPSS-processed W–Cr alloys represent a promising alternative to conventional tungsten-based alloys for extreme environment applications.
085-Intelligent Forming Quality Monitoring System Integrating 3D Profile Sensing and AI-Based Decision Support for Powder Metallurgy Pressing Process
Bortung Jiang, Industrial Technology Research Institute
In powder metallurgy (PM) production, product quality heavily relies on the operator’s experience to adjust compaction parameters and conduct periodic manual inspections. This conventional approach often leads to inconsistent quality, time-consuming inspection routines, and limited knowledge transfer.
To address these challenges, this work presents an Intelligent Forming Quality Monitoring System integrating 3D profile sensing, load-cell–based weight detection, and an AI decision-support module. The system enables in-line, real-time measurement of the green compact’s step height and weight, providing digital quality data for immediate assessment.
A regression-based AI decision module analyzes the correlation between forming parameters and measured features, offering parameter adjustment suggestions to assist operators in maintaining stable production conditions.
Experimental validation on a PM forming line demonstrated high measurement precision (±0.008 mm for step height, ±0.01 g for weight). The proposed system shortened inspection time from 5 minutes for 3 samples to less than 10 seconds per part, increased production efficiency from 81 % to 88 %, and improved equipment utilization from 92 % to 100 %. Additionally, it reduced material waste by 3,300 kg per year.
The system effectively digitizes the quality assurance process in PM forming, transforming experience-based adjustments into data-driven decision support, thereby enhancing process stability, product consistency, and readiness for smart manufacturing deployment.
119-Enhancing Toughness of Intermetallic Compounds via Powder Surface Coating in Powder Metallurgy
Akira Umise
Among intermetallic compounds, Heusler alloys have attracted considerable attention as promising functional materials for applications such as spintronics, magnetic refrigeration, and shape memory alloys. Moreover, the electronic structure and magnetic properties of Heusler alloys can be predicted based on their valence electron count, and recent advances in computational materials science have accelerated the discovery of numerous novel functional materials. However, the practical implementation of these materials has been hindered by the intrinsic brittleness and poor workability of intermetallic compounds. Therefore, the development of processing techniques and mechanical property modification is essential for their rapid commercialization. In this study, we aim to impart toughness to intermetallic compounds by coating their powder surfaces with ductile metals during powder metallurgy processing.
201-Laser Assisted Additive Manufacturing of W and W-Re for Fusion Power Application: Material Response in Manufacturing Environment
Katie Estrada, University of North Texas
Tungsten is currently favored for critical applications like plasma-facing components in fusion reactors due to its high melting point, superior strength, excellent thermal conductivity, and low thermal expansion. However, its inherently low ductile-to-brittle transition temperature (DBTT) and the severe conditions it faces in reactors, such as irradiation and thermal cycling, lead to embrittlement and flaking, posing significant challenges to the commercialization of fusion reactors. W and W-based alloys are also extremely challenging to process using traditional metallurgical methods like casting and rolling. This study explores laser powder bed fusion (LPBF) additive manufacturing as a viable alternative to conventional tungsten manufacturing methods, enabling the production of complex, high-performance components. The research involves fine-tuning LPBF parameters, utilizing laser powers of 400W and 900W with a constant scanning speed of 500 mm/s, to optimize the fabrication of pure tungsten and tungsten-5wt% rhenium (W-5Re) samples. Comprehensive characterizations, including density measurements, microstructural analysis, crack density assessments, and scratch-based methods, are to be performed to understand the influence of laser power and the effect of Re addition on the resultant microstructure and mechanical properties will be discussed.
214-Influence of Y2O3 Content on the Microstructure and Mechanical Properties of Oxide-Dispersion-Strengthened Ti-6Al-4V Spherical Powders Produced via an In-Situ Process
Ryun-Ho Kwak, Korea Institute of Industrial Technology
Ti-6Al-4V alloy has been extensively utilized in aerospace, biomedical, and various engineering fields due to its high specific strength, excellent corrosion resistance, and outstanding biocompatibility. However, its limited high-temperature performance and inherently low wear resistance restrict its applicability in environments requiring elevated-temperature stability or resistance to surface degradation. To overcome these limitations, oxide dispersion strengthening (ODS) has been considered as a promising strategy to enhance the alloy’s thermal and mechanical stability. Conventional ex-situ ODS powder processing, however, often results in poor productivity, non-uniform oxide distribution, and powder cracking due to surface coating based oxide incorporation.
In this study, an in-situ powder fabrication was developed to introduce nanoscale oxide particles uniformly within Ti-6Al-4V powders by controlling thermodynamic reactivity during synthesis. ODS Ti-6Al-4V powders containing 0.5, 1.0, and 2.0 wt% Y2O3 were produced using the in-situ process, and bulk samples were subsequently consolidated via spark plasma sintering (SPS). To systematically evaluate the effect of Y2O3 content, microstructural evolution, sintering behavior, and mechanical properties were analyzed and compared. The results demonstrate that the in-situ approach effectively forms a homogeneous nanoscale oxide dispersion, thereby providing a pathway to enhance the high-temperature performance and wear resistance of Ti-6Al-4V based materials.
215-Tungsten and Tungsten-Titanium Sputtering Targets for Semiconductor Manufacturing
Enrico Franzke
Modern semiconductor manufacturing relies on ultra-thin films deposited with atomic precision, primarily through Physical Vapor Deposition (PVD) processes using sputtering targets. As device architectures shrink below the nanometer scale, the demand for materials with exceptional purity, stability, and tailored properties intensifies. Plansee addresses these challenges by developing high-purity sputtering targets made from molybdenum (Mo), tungsten (W), and tungsten-titanium (WTi) alloys. These materials enable critical applications in logic and memory chips, MEMS devices, RF filters, EUV lithography masks, and advanced chip packaging. Key requirements include ultra-high purity (up to 99.999%), uniform microstructure, mechanical integrity, and compatibility with complex deposition systems. By a fully integrated supply chain and advanced powder metallurgy processes high-density targets with minimal particle generation are obtained. In our presentation we supply an overview over current state of the art and tailored solutions for next-generation semiconductor technologies.
217-Investigation of the Froth Flotation Process for Anode Material Recovery from Black Mass
Jinyoung Je, Korea Institute of Geoscience and Mineral Resources
The rapid expansion of electric vehicle (EV) markets has intensified global interest in large-scale lithium-ion battery recycling. In particular, the graphite anode, historically considered a low-value component, is gaining renewed importance due to supply chain instability driven by China’s strong dominance and ongoing polices promoting the domestic consolidation of natural and synthetic graphite production. These trends highlight the need for robust recovery technologies capable of securing graphite resources from end-of-life batteries.
In this study, a froth flotation process was investigated to separate anode and cathode active materials and to recover high-purity graphite from black mass. Froth flotation process is a physico-chemical separation process based on the difference of surface properties between particles. The raw black mass was first characterized in terms of particle size distribution, mineralogical composition, surface chemistry, and impurity content. Based on these characteristics, the experiments were conducted by varying key operating parameters, including slurry pH, impeller agitation speed, collector and frother dosages, and pre-treatment conditions. Particular attention was given to the heat-treatment process, which is critical to remove the binder responsible for converting the naturally hydrophilic cathode surface into a hydrophobic surface. By identifying the optimal conditions and extending them to a continuous process, a process design enabling the recovery of high-purity graphite was achieved.
234-Microstructure and High-Temperature Properties of ODS Ni-Based Superalloy Consolidated by Spark Plasma Sintering Process
Hwi-Jun Kim
Oxide dispersion strengthened Ni-based superalloys have been widely used for high-temperature applications in aerospace, automotive, and power plants due to their superior creep resistance and excellent high-temperature strength. These materials have been cost effective heat-resistant alloys for service at temperatures of above 1,000 °C without adding expensive rare earth elements like Ru and Re.
In this study, we investigated the effect of composition and consolidation parameters on the high-temperature properties of ODS Ni-based superalloys. Bulk consolidates were manufactured by spark plasma sintering process after fabricating ODS Ni-based superalloy powders using Electrode Induction Melt Gas Atomization. FE-SEM and EDS analysis were performed for microstructure analysis, and Gleeble test was performed to evaluate the high temperature mechanical properties. The results showed that the high-temperature compressive strength and Vickers hardness of bulk consolidates increased with increasing the content of Nb5Si3 phase and Y₂O₃ oxide. The optimized ODS Ni-based superalloy consolidate exhibited 133 MPa of maximum compressive strength at 1,050 ℃. Furthermore, the relationship between microstructure and compressive strength was estimated.
238-Production of Nickel Powder from Solvent-Extracted Nickel Sulfate for Electric Vehicle Battery Recycling
Hong In Kim, Korea Institute of Geoscience and Mineral Resources
The rapid growth of electric vehicles has increased global demand for efficient recycling technologies capable of recovering high-value metals such as nickel. This study presents a process for producing nickel powder from high-purity nickel sulfate obtained through a solvent-extraction (SX) refining route applied to spent electric vehicle batteries. Nickel sulfate purified via multi-stage SX was converted into nickel powder through a controlled reduction and precipitation pathway, followed by thermal treatment to achieve the desired particle morphology and purity. Key process variables—including pH, reductant concentration, temperature, and residence time—were systematically optimized to maximize yield and control particle size distribution. The resulting nickel powder exhibited high purity, uniform particulate characteristics, and suitability for powder metallurgy and battery precursor manufacturing. This work demonstrates the technical feasibility of integrating hydrometallurgical SX purification with nickel powder production, contributing to a closed-loop recycling system for critical battery materials. The proposed approach supports resource recovery, carbon reduction, and circular economy strategies for next-generation electric vehicle battery recycling.
242-Cold-Sprayed AMDRY386 Coatings: Parameter Optimization Using Computational Modeling and Experimental Validation
Taala Aboalnaja, King Fahd Univ of Petroleum & Minerals
Amdry386, a Ni-based alloy widely used for repairing high-value aerospace components, is increasingly applied through cold spray due to its solid-state deposition advantages. Despite its relevance, limited data exist on how process parameters influence its deposition behavior and coating development. In this study, cold spray parameters for Amdry386 were selected and optimized using computational tools that provide particle-flow and impact-simulation data predicting particle behavior, plastic deformation, cohesive strength, and deposition efficiency. Particle-flow simulations were performed using the commercial Kinetic Spray Solution (KSS), while impact simulations were carried out in Abaqus/FEA using explicit-dynamics time stepping with Arbitrary-Lagrangian-Eulerian or Coupled-Lagrangian-Eulerian formulations. Computational predictions were validated through cold spray trials on HX alloy substrates, followed by metallographic preparation and characterization. Experimental observations—including coating build-up, particle consolidation, and layer formation—were compared with model outputs and relevant literature to assess the accuracy of the computational approach. This combined methodology enabled systematic evaluation of coating-thickness evolution, densification behavior, and porosity trends under the selected parameters. The outcomes demonstrate the effectiveness of integrating computational modeling with experimental validation to optimize cold spray processing of Amdry386 and provide a framework for future parameter-selection strategies in aerospace repair applications.
256-Direct Size-Analyzing Metal Powder in Gas Atomizing System
Inhee Cho, KITECH
In-situ particle size analyzing is of importance in metal powder manufacturing system since this process consists of counting and variating of those samples in-time. Previous industrial levels hinders one to analyze particles using a stand-alone equipment from direct size-analyzing process so that workers needs several steps including (1) collection, (2) refinement and (3) selection of those samples for size analyzing. Although such system ensures high-precision results with optical (or laser) modules for those samples, but this step-by-step procedures from manufacturing to analyzing do not easily allow for quick feedback and straightforward product verification by operators.
In this work, we developed the simple but adequate particle size analyzing platform that directly attached to the gas atomizing system that can visualize the produced fine and spherical powders. The optimized view port, which is designed to be located in collected samples on factory-scale gas atomizer, was chosen as a optical setup with high-resolution camera and back-stage photonics in vertical direction. When the amounts of particle drops horizontally, the images with 10 frame per seconds(FPS) with staged camera captured and directly converted into the image processing for in-time analyzing particle sizes.
This work would pave the way for the possibility not only for integrating the manufacturing process and the the analyzing one, but also for obtaining the entire process into the digitalization of metal powder productions with additional data acuquisition system
257-Powder Processing, PM-HIP, and Post Processing at The University of Michigan
Stephen Raiman, University of Michigan
This poster will present an overview of severla activities related to powder processing to improve compoennt quality, PM-HIP to produce parts, and HIP post-processing of AM parts to induce facotrable microstructures and thus better performance.
311-Low Activation Tungsten Heavy Alloys for Fusion Reactors
Jordan Yeap, Imperial College of Sci & Tech
The current first wall material for fusion reactors is tungsten. A tungsten heavy alloy (WHA), improves tungsten’s fabricability and thermal-mechanical properties. However, commercial WHAs are prohibited for fusion due to their production of high-level radioactive waste under neutron irradiation. In this research, alternative binder elements including iron, chromium and vanadium were tested. Binary, ternary, and quaternary WHAs based on these elements were produced by pressureless liquid phase sintering. The densification, and microstructural evolution were tracked with dilatometry and thermogravimetry; while the phase evolution was tracked with electron microscopy and X-ray diffraction. Among the binders tested, those containing iron were critical in aiding densification. Chromium and vanadium both supressed intermetallic formation but vanadium was found to promote excessive oxide formation. Subsequent studies have focused on optimising the ratio of iron and chromium to supress intermetallics, and optimising the sintering parameters which include heating rate, dwell time, dwell temperature and sintering atmosphere.
903-In Situ LPBF Monitoring Using A Dual-Wavelength Thermal Camera Calibrated Via Ex Situ Single-Track Width Measurements
Matheus Soares, École de Technologie Supérieure
Real-time monitoring of the laser powder bed fusion (LPBF) process using a dual wavelength thermal camera can be used to improve the process reproducibility. The method estimates the melt-pool temperature without prior knowledge of emissivity by using Wien’s approximation of Planck’s law and considering a pixel-by-pixel intensity ratio between two close wavelengths. However, applying the commonly-used tungsten filament-based calibration method provides unrealistic results when measuring thermal field distributions within and outside the melting pool in LPBF.
To convert intensity images into temperature fields, we developed a calibration method that combines in situ melt-pool thermal measurements and ex situ single-track width measurements, across multiple materials (316L, CoCr, IN625, W, and Mo) and multiple processing conditions. This approach revealed almost 1000 K difference between the commercial tungsten filament-based calibration and the proposed calibration procedure, and resulted in a ~20% more precise assessment of the melt pool dimensions.
904-A Generalized Prediction of Ultrasonic Atomization Outputs Aided by Machine Learning
Logan Winston, University of California, Santa Barbara
In the ultrasonic atomization of metals, discrepancies persist between methods for predicting particle size. Although some processing and material conditions have been considered in previous studies, others, such as substrate properties, remain underexplored. Furthermore, most models require empirical fitting, limiting broad applicability.
To address this gap, we investigated the relationship between atomizing conditions and particle size using waxes of varying properties as metal analogs. A custom ultrasonic atomizer enabled full authority over operational variables, while machine-learning techniques were used to identify correlations. Key parameters, identified from the wax experiments, were then validated on an exemplary metal, stainless steel.
A Bayesian optimization model, grounded in experimentally derived physical relationships, was developed to identify next-best atomization parameters. Ongoing work to correlate the results between two separate atomization setups aims to connect physical parameters existing beyond personalized empirical fitting, and move towards an understanding of the process independent of instrumentation variability.
905-Microstructure Evolution Modeling Framework of Laser Powder Bed Fusion
Foroozan Forooghi, University of New Brunswick
Additive manufacturing (AM) has transformed modern fabrication by enabling the production of complex and customized geometries that are challenging or uneconomical to fabricate using traditional methods. Among various AM techniques, Laser Powder Bed Fusion (LPBF) has gained prominence for its ability to produce high-performance metallic components with exceptional dimensional accuracy. However, the rapid solidification and steep thermal gradients inherent to LPBF lead to complex microstructure evolution within the melt pool, which critically influences the final mechanical properties. In this study, a cellular automaton (CA) model is developed to simulate microstructure evolution during solidification in the LPBF melt pool. The model incorporates nucleation kinetics, thermal gradients, and solidification front dynamics derived from process simulations, enabling the prediction of grain morphology and texture under varying processing conditions. The simulation results reveal the transition from columnar to equiaxed grains with increasing undercooling and illustrate the influence of scanning speed and laser power on grain growth behavior. These findings contribute to a deeper understanding of process–structure relationships in LPBF, offering valuable insights for optimizing process parameters to achieve desired microstructural characteristics in additively manufactured metals.
909-Process Parameter Development and Mechanical Property Evaluation of Pure Tungsten Fabricated by Electron Beam Melting
Cristian Banuelos, University of Texas at El Paso
Processing pure tungsten via Electron Beam Melting (EBM) remains challenging due to its high melting point, rapid solidification kinetics, and susceptibility to cracking and porosity. This study focuses on the systematic development of EBM process parameters—including beam power, scan strategy, hatch spacing, and preheat conditions—to improve densification and reduce defect formation using an Arcam system. Parameter sets were evaluated through density measurements, metallographic cross-sections, and microscopic analysis to characterize lack-of-fusion defects, swelling, and microcracking, and to understand microstructural evolution across varied thermal profiles. Optimized conditions were used to fabricate tensile bars for determining the as-built mechanical properties of pure tungsten, with testing underway to correlate strength and failure behavior with processing history and defect morphology. Upcoming work will incorporate pyrometry as an in-situ thermal monitoring approach to identify localized thermal anomalies and link them to defect-prone regions. The resulting framework advances process optimization for refractory metals in EBM.
910-Process Development for Defect-Free Overhangs in Electron Beam Powder Bed Fusion of Chemically Reduced Tungsten
Sarath Chandra Reddy Karumudi, Mid Sweden University
Powder Bed Fusion using Electron Beam (PBF-EB) has demonstrated great potential for processing tungsten, yet nearly all published work focuses on bulky samples produced from gas- or plasma-spherodized powders, a route that is energy-intensive and costly. In contrast, chemically reduced tungsten powder offers a significantly lower cost and environmental footprint, but its irregular morphology and fine fraction introduce unique challenges for process stability.
This study aims to identify the fundamental process conditions needed to produce stable overhangs using chemically reduced tungsten powder. An overhang development theme is implemented via a gradient strategy across a tiled block grid, systematically varying heating and melting strategies to identify a stable envelope for overhang fabrication. Backscattered electron (BSE) imaging provides rapid semi-automated feedback to guide optimization toward defect-free overhangs.
Results demonstrate that chemically reduced tungsten powder can achieve stable and defect-free overhangs, highlighting a sustainable pathway for PBF-EB processing of tungsten that combines environmental benefits with increased design freedom supporting applications in advanced energy and radiation-shielding technologies
911-Effects of Powder Production Methods on Tungsten Dissolution in Niobium During Additive Manufacturing
Benjamin Labiner, North Carolina State Univeristy (NCSU)
Tungsten containing Niobium alloys are of interest for high-temperature components in the aerospace industry, but are difficult to process due to their mechanical properties and Tungsten separation during solidification. To study the effects of different powder production methods on the solutioning of Tungsten in this alloy system when produced via electron beam powder bed fusion, Nb20W1Zr powders were made by mechanical milling and gas atomization. Microstructural characterization was completed on the powders and additively manufactured parts to observe differences in chemical homogeneity at different stages in the manufacturing process. The mechanically alloyed powder did not effectively blend Tungsten into the Niobium particles, while gas atomized particles were relatively chemically homogenous. Compositional separation in the powders persisted when each was additively manufactured. These findings help to understand viable processing routes to create feedstock of this alloy for continued additive manufacturing studies.
915-Liquid Phase Sintering of Creep-Resistant Cu-Based Alloy (GRCop-42)
Atul Anand, Technische Universität Wien
GRCop-42 (Cu-4 at.% Cr-2 at.% Nb), a copper-based alloy widely recognised for its exceptional creep resistance, is normally printed by selective laser melting. There are very few studies available on the sinter-based additive manufacturing of GRCop-42. Chromium and niobium tend to precipitate out of the Cu solid solution as the intermetallic laves phase Cr2Nb, thereby pinning the grain boundaries. The very Cr2Nb precipitates that make the alloy creep resistant also hinder pressureless sintering. Although pressureless solid-state sintering of GRCop-42 is not possible, the addition of other alloys/elements could enable pressureless liquid-phase sintering of GRCop-42, leading to a composite structure with intermediate mechanical properties and reasonable conductivity. This work investigates the potential of utilising Cu-Sn bronze and Ag as liquid-phase sintering agents that can effectively wet the GRCop-42 skeleton, thereby providing sufficient capillary forces for densification. Liquid-phase sintering also allows a short sintering duration and prevents coarsening of Cr2Nb precipitates at high temperatures.
916-Towards Dimensional And Compositional Accuracy In Binder Jetting: An Investigation Of Process Parameter Optimization And Binder Burn Off
Alexandra Darroch, University of Waterloo
Current challenges in the realm of copper binder jetting (BJT) include high final porosity or altered chemical composition after sintering. These may result from residual binder or premature part shrinkage during densification. In order to produce complex functional copper structures in BJT, understanding the inherent dimensional inaccuracy of the manufacturing process and determining appropriate de-binding and sintering schedules are essential. The first stage of this work will investigate the effect of varying process parameters on the dimensional accuracy of fine features in both the green and sintered states. Binder saturation is one such process parameter which affects the strength of the green parts as well as the achievable resolution of fine features and final carbon content. Dimensional fidelity will be evaluated using image analysis techniques to compare achievable feature size to that of the CAD model. An optimized set of printing parameters will be selected before proceeding to the second phase of the work, which proposes to address the problem of carbon-rich areas within the matrix due to binder residue, commonly resulting in high porosity and decreased thermal or electrical properties of the part. De-binding under inert, reducing, and oxidizing atmospheres will be investigated to determine if superior carbon content removal can be achieved before the final sintering step. Optical dilatometry will be implemented during sintering to observe the shrinkage and distortion of fine features in real time.
917-Tailored Anisotropy in Cold Spray Additively Manufactured GRCop-42: Process-Structure-Property Relationships
Michael Ross, University of California, Irvine (UC Irvine)
GRCop-42 is a high-conductivity, precipitation-strengthened copper alloy with demonstrated performance in conventional liquid-rocket engines, yet its behavior under extreme, directionally biased thermomechanical loadings–such as those of rotating detonation engines (RDEs)–remains largely uncharacterized. The ability to tailor AM processing to exploit inherent deposition-induced anisotropy presents a compelling opportunity to design materials aligned with the directional nature of detonation physics. This work investigates cold spray additive manufacturing (CSAM) of GRCop-42 as a means for engineering anisotropy through controlled variations in cold spray processing parameters. The aim is to engineer application-specific anisotropy by leveraging CSAM’s wide processing envelope–varying gas temperature, standoff distance, robot toolpath, and build orientation. Microstructural evolution, splat morphology, and directional thermomechanical performance resulting from these processing strategies will be presented and discussed in the context of material design for detonation environments.
921-Utilization of Triboelectric Charging for Surface Chemistry Assessment of Additive Manufacturing Metal Powder
Ali Alagha, McGill University
In powder-based manufacturing processes, surface-related phenomena, such as moisture adsorption, oxidation, and contamination, can significantly alter powder cohesion, flowability, and ultimately part quality. Unfortunately, conventional powder characterization techniques often remain costly, time-consuming, or insufficiently sensitive to subtle surface alterations. Triboelectric charging, arising from charge transfer during particle contact and separation, presents a rapid and highly sensitive alternative for assessing powder surface states. Since this charge transfer is intrinsically affected by particle size, morphology, and particularly surface chemistry, it offers a tool to detect variations of electronic and chemical surface properties. This work investigates the role of surface chemistry in governing the triboelectric response of aluminum alloy powders used in additive manufacturing. By correlating triboelectric charging data with X-ray photoelectron spectroscopy (XPS) and work function measurements, we reveal direct links between electronic surface characteristics and charge transfer dynamics. Together, these results establish triboelectric charging as a practical method for characterizing powder surfaces in support of quality control in powder-based manufacturing.
922-Surface Topography Characterization of As-Built And Chemically-Milled LPBF Parts Using Computed Tomography, Stylus and Optical Profilometry Techniques: A Comparative Analysis
Quentin François, École de Technologie Supérieure
Characterizing surface roughness of Laser Powder Bed Fusion parts is a key factor in predicting their service properties, but conventional surface measurement techniques cannot non-destructively capture small or complex internal and external features. Computed Tomography (CT) is relevant to address this issue, but conventional CT surface determination algorithms are not up to this endeavour.
To assess the accuracy and robustness of a novel CT flux conservation-based surface determination algorithm, a full range of ISO surface roughness metrics obtained by two different CT systems were compared with those generated by stylus profilometry, confocal and structured light microscopy. Therefore, titanium and nickel alloy specimens having roughness spanning from 5 to 30 μm (Ra) conditions were used. They were produced with different thicknesses (0.5-2.5 cm), shapes (flat, cylindrical, conic) and build orientations (0-135°). Comparison against alternative methods revealed that the proposed CT algorithm represents an accurate and robust non-destructive surface characterization approach.
923-Optimization of Temperature Distribution in Selective Laser Melted Desulfurization Reactors
Noman Alias Ghulamullah, Kent State University
With the advent of additive manufacturing, it has become possible to design and fabricate complex and intricate designs with ease and low cost. In this work, we designed, printed and assembled an intricate desulfurization reactor for portable applications. One piece and lightweight desulfurization reactor was utilized in onboard desulfurization system to remove sulfur from jet fuel for fuel cell systems. 316L stainless steel alloy was used to print a reactor via EOS M290. The desulfurizer was equipped with Nickel based sorbent and Jet A fuel with 365ppmw sulfur content was treated. The internal intricate and complex geometry was evaluated based on the operational performance, in terms of temperature distribution. The inflow(cold) and outflow fuel (hot) creates a temperature gradient and which alters the temperature and pressure conditions inside the active catalyst bed. Moreover, it also influences the outlet flowrates. To mitigate these effects, a unique heat exchanging mechanism was adopted to reduce the overall all thermal gradients. After several reactor designs and temperature control, we successfully ran desulfurization tests for 100 hours at a fixed outlet flow rate and consistent ~1ppm sulfur content. The temperature monitoring at five key locations demonstrates the effectiveness of the designed reactor and adopted temperature control mechanism in achieving a uniform temperature profile.
927-Functionally Graded Interface to Enable Electron Beam Melting of Tungsten on Ti64 Substrates
Ali Mohammadnejad, University of Waterloo
This study demonstrates the feasibility of printing pure tungsten directly onto Ti-6Al-4V by electron-beam powder bed fusion (EB-PBF). Interface formation was controlled by tailoring electron-beam energy density to overcome the large melting-point mismatch without an interlayer. A single low-energy transition layer produced weak bonding, whereas uniformly high energy increased porosity, residual stress, and warpage. In contrast, a gradual energy ramp yielded robust bonding, suppressed porosity and residual stress along the interface, and reduced cracking risk. The porosity and microcracking formation mechanisms are analyzed by energy-dispersion spectroscopy (EDS), scanning electron microscopy (SEM), and X-ray diffraction analysis (XRD), supported by numerical modeling. The mechanical and microstructural properties of the final sample with a density of 99.96% and no microcracking in the bulk region, are presented.
929-Connecting Metal Powder Atomization to Powder Bed Fusion: Morphology, Rheology, And Printability
Lucas Erich, University of California, Santa Barbara
Atomization is the dominant synthesis route for producing high-quality metal powder for additive manufacturing (AM). There are five major methods of atomization, each giving rise to particles with unique properties that affect processability in powder bed fusion (PBF). This work explores how atomization influences printability under laser-based (L-PBF) conditions. Commercial 316L stainless steel (SS) sourced from water, gas, and centrifugal techniques and Ti-6Al-4V sourced from plasma, gas, and plasma rotating electrode process (PREP) techniques will be examined alongside in-house ultrasonic-atomized powder of each alloy. Morphological/rheological factors will be probed with microscopy and standards. Other characteristics (e.g., laser absorption and porosity) will also be highlighted. Finally, single-track laser scans on individual powder layers will map processability. This work helps bridge the gap between atomization and AM, a connection not yet fully realized. Dense, spherical centrifugal/PREP and ultrasonic powders exhibited the most desirable behavior under L-PBF conditions.
933-Predicting Anisotropic Deformation in Pellet-Extruded Copper MIM Components via Machine Learning
Rawan Elsersawy, University of Regina
This research investigates the anisotropic behavior and dimensional stability of copper Metal Injection Molding (MIM) components fabricated through pellet extrusion-based 3D printing using Copper based feedstock. The study examines how strand orientation during printing affects the final part geometry after thermal processing. Multiple test specimens were containing struts with different slopes and diameters were printed. These specimens went through systematic thermal processing cycles with different debinding and sintering temperature profiles to evaluate the relationship between sintering parameters and dimensional conformity. A comprehensive dimensional analysis protocol kept track of geometric evolution at three critical stages: immediately post-printing, after debinding, and after sintering. Advanced image processing techniques are employed to quantitatively characterize deformation patterns, including directional analysis of warpage, anisotropy, and percentage of dimensional change relative to design geometry. Dimensional data from straight struts specimens across various processing parameters were used to train a machine learning model to predict deformation behavior. The model's predictive capability was then validated by printing specimens with curved struts geometries and comparing predicted dimensional changes against experimentally measured results. This approach aims to establish a predictive framework for optimizing print strategies and thermal cycles for copper MIM components with improved dimensional control and predictable anisotropic properties.
934-Hybridization of Commercial Directed Energy Deposition System for In-situ Repair of Parts
Juan Garcia, University of Texas at El Paso
Metal additive manufacturing (MAM) processes have matured since their inception. Still, limitations regarding the scalability and high energy and material cost for the process have limited it to the fabrication of specialized complex parts. Even then, due to MAM’s proneness to thermal gradients, rough surface finish, and need for support structures, some type of post-processing using traditional manufacturing is required. Combining both additive and subtractive technologies into a hybrid system provides the opportunity to mitigate the limitations of individual technologies and enhance their advantages. Of the available additive (AM) technologies, directed energy deposition (DED) has gained interest for hybridization due to its flexibility compared with other AM processes. Hybrid DED has proven successful in reducing material usage and manufacturing time over pure DED and even subtractive processes. In particular, the repair of existing parts to extend their lifetime has become a field in which hybrid DED excels. Most hybrid DED processes are built by adding an additive component to an existing subtractive system such as CNC, thereby placing an emphasis on the subtractive process. But this can result in a reduction in print quality due to the need for an inert environment for DED processes. By emphasizing the AM process by integrating a subtractive system into a commercial DED system such as RPM Innovations 222XR, an increment in the availability of quality hybrid DED systems can be achieved. To prove this, the quality of the end-product must be ensured. Thus, a GD&T study was performed to determine the reliability of the subtractive process while microscopy and hardness testing on a case study part was performed to asses the success of the machine on the repair of components.
939-Additive Manufacturing of Electric Motor Components Using Silicon Iron Soft Magnetic Powder
Andrew Gillespie, Purdue University in Indianapolis
The THAM (Transverse Holographic AC Machine) is a promising novel electric motor for electric cars and trucks in the transportation industry. In this work, we focus on fabricating electric motor components, such as the stator core, using the laser powder bed fusion (L-PBF) additive manufacturing (AM) process. In order to determine the appropriate AM processing parameters, a series of small silicon iron (Fe-3.5%Si) cube samples is fabricated to evaluate the sample quality. The cube samples are analyzed using SEM (Scanning Electron Microscope) and EDX (Energy-dispersive X-ray spectroscopy) to evaluate the samples' microstructure and compositions, thereby determining the optimal printing parameters for the silicon iron components.
940-Processing and Properties of a Compacted Power-Based Core-In-Shell Design
Sabbir Uddin, Drexel University
In the context of a research project, the need is to design a metallic powder compact (core) fully encapsulated by a compacted polymer layer (shell). Material and design constraints dictate a relatively thick protective outer polymer shell, but processing of this layer in the melt is to be avoided. As a result, a core-in-shell solution was selected. This solution draws inspiration from the tablet-in-tablet design used in pharmaceutical technology.
In this study, we investigate a model system consisting of a compacted aluminum powder core and an external shell of compacted microcrystalline cellulose (MCC). The manufacturing process involved three sequential compaction steps: (i) formation of a dense aluminum core under controlled environmental conditions; (ii) tamping of a primary MCC layer; and (iii) placement of the aluminum core followed by deposition and compaction of a final MCC layer.
Significant challenges associated with metal–polymer bilayer compaction—particularly interfacial debonding and layer separation—were encountered and systematically addressed with a combination of finite element simulations and experimental studies. The processing steps were simulated and optimized in-silico using appropriate constitutive models for the aluminum and MCC powders. Mechanical integrity was assessed via shear testing of the finished tablets at the biomaterial interface. High-resolution nano-CT imaging was employed to characterize the core–shell interface and identify microstructural defects formed during processing.
Collectively, the results provide insight into the feasibility of integrating metallic and polymeric powders in core-in-shell architectures, the conditions under which interfacial failure occurs, and the role of compaction parameters in maximizing density homogeneity of the outer layer surrounding a sufficiently densified core.
941-Upcycling Scrap Aluminum for Automotive Applications: Advanced Additive Manufacturing Strategies to Control Property Degradation in Impurity-Rich Alloys
Fatemeh Zarei, University of Waterloo
Improving the recyclability of aluminum alloys is essential for advancing sustainable automotive applications, yet is limited by impurity-driven degradation of properties in recycled feedstocks. In this work, additive manufacturing via laser surface melting (LSM) is applied to AA6061 aluminum alloys containing varied Fe and Zn impurity levels to upgrade recycled material streams. Recyclability was assessed through optical microscopy (OM), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS), and extensive corrosion testing. Corrosion measurements demonstrated that LSM treatment significantly reduces electrochemical variability between different impurity combinations, resulting in a stable corrosion response compared to conventional processing. Microstructural analysis confirmed refinement of the grain structure and redistribution of impurity phases, with Fe reducing solidification cracking and Zn promoting liquid film formation. Together, these results show that LSM can effectively manage both microstructural and electrochemical challenges associated with impurities, facilitating the development of high-performance, recycled aluminum alloys with predictable and improved corrosion resistance.