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.
132-Microstructure and Mechanical Properties of Nb-Si based Alloys with Rare Earth Boride Addition Fabricated by Spark Plasma Sintering
Hyeonyoung Choi, Seoul National University of Science and Technology
Niobium (Nb) is the most attractive refractory metals due to its high melting points (~2468℃), ductility, workability and low density (~8.57 g/cm3). However, Nb-based alloys suffer from pesting oxidation, at temperatures above 600℃. In high-temperature oxidation environments, non-protective Nb2O5 forms and volatilizes above ~1000℃, reducing high-temperature mechanical properties and oxidation resistance. To solve these problems, Nb-Si alloys have been developed to form a protective SiO2 scale under high-temperature oxidation.
In addition, current research has focused on controlling the microstructure and enhancing the mechanical properties of Nb-Si alloys by introducing alloying elements and compounds. Among these, rare-earth elements are known to be added to Nb-Si alloys to preferentially form rare-earth oxides, thereby preventing internal oxidation. Boron has been reported to promote Nb5Si3 formation and accelerate the Nb3Si decomposition. Based on these characteristics, previous studies have indicated that the addition of borides such as TaB2 to Nb-Si alloys results in decomposition into Ta and B during sintering, with each element affecting the microstructure and properties. However, the effects of rare-earth borides on Nb-Si alloys are still unknown. Therefore, it is necessary to investigate the addition of rare-earth borides in Nb-Si alloys
In this study, Nb-Si alloy and Rare earth boride powders were uniformly mixed using high-energy ball milling, then mixed powders were sintered by Spark Plasma Sintering (SPS). Microstructure and properties of the alloys were then analyzed.
154-AI-Based At-Line Inspection Cell for Powder Metallurgy Components: 3D Vision for Localization, 2D Surface-Defect Detection, and Six-Axis Robotic Handling
Chuan-Hao Liu, Chin Chih Metal Industrial Co., Ltd.
This study presents an at-line automated inspection cell for powder metallurgy components that integrates 3D vision for part localization, an optimized illumination and camera system for high-contrast imaging, and a six-axis robotic manipulator for picking, repositioning, and sorting. A deep learning model performs surface defect detection and classification, while confidence thresholds and rule-based postprocessing enhance decision stability. The cell supports rapid product changeover and viewpoint reconfiguration, enabling a reconfigurable platform suited to high-mix manufacturing. We describe the system architecture, calibration procedures, and control workflow, and we construct a dataset spanning multiple part families to evaluate performance under varying surface roughness and lighting conditions. Quantitative metrics include mean Average Precision (mAP), Average Precision (AP), true positives (TP), false positives (FP), false negatives (FN), and per-part cycle time. Experiments across multiple part families demonstrate robust detection performance with controlled false alarms and misses, together with stable cycle time compatible with production requirements. The results indicate practical feasibility for quality assurance in powder metallurgy and scalable flexibility for deployment across diverse product lines.
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.
239-Microstructural Changes and Mechanical Properties of TiGr.12-TiN Alloyed Produced by Laser-Cladding Process and Spark Plasma Sintering Process
Jin-Chun Kim, University of Ulsan
Ti and Ti alloys have been used in aviation, chemical industry, and medical fields because of their excellent corrosion resistance and lightness. Among them, Ti-Grade.12 is a material with better corrosion resistance and mechanical strength by adding elements such as Ni and Mo. TiN is a ceramic-based material and has properties such as excellent hardness, wear resistance, and high temperature resistance, so it is used for surface coating of Ti based parts.
In this study, TiN coated-Ti-Grade.12 samples was manufactured through a laser cladding process. To compare these samples, some samples was produced by Spark Plasma Sintering. Microstructure analysis between the Ti Gr12-TiN junction interface of the all samples was performed using an optical microscope (OM) and a scanning electron microscope (SEM-EDS) for the prepared sample. In addition, mechanical properties were evaluated through a micro Vickers hardness test. The results of this study will be used as basic data for laser cladding to improve mechanical properties of chemical industry parts to which titanium alloy materials are applied.
241-Effects of Cavitation Water Jet Peening on Crack Initiation and Propagation in Tungsten
Annalise Gade, University of Michigan
Tungsten is a useful material of fabrication for components used in actinide electrorefining due to its high melting point and resistance to molten salt corrosion. However, in the high temperature corrosive environment it is prone to degradation mechanisms such as cracking, corrosion, and grain boundary deterioration. Surface modification techniques such as peening are a promising strategy for improving the performance of tungsten and other refractory components.
For this work, samples of tungsten were treated by cavitation peening and other surface modification techniques, heat treated and tested mechanically, and characterized. This work discusses the effects of cavitation water jet peening to improve the material’s resistance to crack initiation and propagation, with the main goal of extending the service lifetime of tungsten components in harsh service environments.
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