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023 - Essential Isostatic Pressing Technology for PM HIP Components
James Shipley, Quintus Technologies

Following the commercialization of Hot Isostatic Pressing during the 1960’s, Powder Metallurgy Hot Isostatically Pressed (PM HIP) components were developed for difficult and critical applications in the early 1970’s. Focus applications included tool steel production as well as components with complex geometries for the subsea oil & gas and nuclear power generation industries. Equipment and processing technology has seen significant developments, both for compaction of the encapsulated powders, but also for the production of the capsules themselves. This paper will focus on the capsule production, and densification equipment, including essential knowledge for production of small and large scale finished components including examples of materials and material combinations that are commonly produced. Technologies highlighted in this work including hydroforming, hot isostatic presses, focusing on the production of near-net shape components including key insights into the challenges and solutions for successful production as well as examples of applications for this production method.  

068 - Preparation and Microstructural Characterization of Ti55541 Titanium Alloy with Excellent Strength and Ductility
Xiaohao Zhao, Xi'an Sino-Euro Materials Technologies Co., Ltd.

Hot isostatic pressing (HIP) experiments on Ti55541 titanium alloy were conducted at 770°C, 800°C, and 830°C to achieve an excellent combination of strength and plasticity through optimized HIP and post-treatments. Microstructural characterization revealed that samples HIP-treated at 770°C and 800°C exhibited numerous short rod-like primary α phases and prior particle boundaries (PPBs), attributed to the strong affinity between titanium powder and oxygen. In contrast, the 830°C HIP treatment led to a significant transformation to a near full β matrix with a small volume fraction of needle-like α phase and larger grain sizes (70 μm, compared to 43 μm and 51 μm at 770°C and 800°C, respectively). Subsequent solution treatments (830°C, 850°C, 870°C) on 770°C and 800°C HIP samples showed that PPBs persisted at 830°C and 850°C due to oxygen's low diffusion coefficient, impeding grain growth. However, the 830°C HIP sample, lacking PPBs, exhibited larger grain sizes after similar solution treatments. An optimized process was identified: 800°C HIP followed by solution treatment at 870°C for 2 hours (air cooling) to eliminate PPBs and achieve fine grains. Subsequent aging at 530°C for 4 hours (air cooling) resulted in a homogeneous, refined woven needle-like α phase. This optimized treatment yielded excellent tensile properties: an ultimate tensile strength of 1361 MPa and an elongation of 10.5%

143 - PM-HIP Production of Critical Structural Aircraft Components from Alloy Ti-5Al-5V-5Mo-3Cr
Mat Kirsh, The Boeing Company

Powder Metallurgy Hot Isostatic Pressing (PM-HIP) is a manufacturing method which uses high-quality metal powders to produce isotropic material properties in components up to 5 feet in diameter and 10+ feet long. The powder is placed into a shaped canister (typically fabricated using sheet metal processes and welded together), evacuated, sealed, and hot isostatically pressed at high temperatures and pressures to full densify.  The result is a fine-grained metallic structure, which exhibits material properties similar to wrought and superior to castings.  The PM-HIP process, invented in the 1950s, has been used for decades highly critical jet engine rotors and blisks (blade-integrated-disk).  As lead times for large castings and forgings continue to grow and strain fragile supply chains, PM-HIP offers an agile, adaptable and cost-effective manufacturing solution.

In a research project jointly conducted by the Boeing Company and Amaero Advanced Materials & Manufacturing, Inc., PM-HIP production of titanium alloy Ti-5Al-5V-5Mo-3Cr (Ti-5-5-5-3) critical structural aircraft components was demonstrated.  The project has explored multiple types and sources of powder feedstock to understand the effects of powder morphology, rheology and composition on the PM-HIP process.  Computational modelling was used to understand predictive capabilities for near-net-shape (NNS) part production.  This presentation will discuss the current state of the ongoing joint research project and will highlight technical successes and challenges, along with a techno-economic assessment of this innovative manufacturing process. 

124 - Retained Austenite Formation and Its Impact on Mechanical Properties of Sinter-hardened and Heat-treated Low Alloy Steels
Amber Tims, PMT, North American Höganäs Co.

Martensitic transformation is a primary objective for sinter-hardenable and heat-treated powdered metal (PM) materials. Equally important is the stabilization of austenite within the metallurgical matrix at room temperature. Retained austenite can significantly influence impact strength, ductility, and fatigue resistance of PM components. It can also detrimentally affect dimensional stability and hardness due to its inclination to transform to bainite or martensite when subject to thermal variations.  Therefore, precise control over the quantity of retained austenite is essential for optimizing both wear performance and impact resistance in these materials. This paper will evaluate various sinter-hardened and heat-treated alloys to assess the relationship between retained austenite and mechanical properties and the effect of tempering conditions.

155 - Effect of In Situ Copper-Manganese Alloying on Hardenability of Mo-based PM Steels 
S. Sundar Sriram, Sundram Fasteners Limited

Copper steels are commonly used for powder metallurgy (PM) structural parts, with copper powder typically admixed in the blend. During sintering, copper melts at about 1083 degC and infiltrates between iron powder particles, thereby promoting metallurgical bonding and improving strength. Alloying copper with manganese lowers the melting point of the alloy, enabling enhanced diffusion of both copper and manganese into iron powder particles. This results in increased bonding and hardenability.

Molybdenum (Mo) alloyed PM steels such as FL40XX, FL44XX, and FL49XX are widely used in structural applications that require sinter hardening or secondary heat treatment. The addition of copper enhances their hardenability, which can be further improved by replacing elemental copper with copper-manganese (Cu-Mn) alloys. This approach allows simultaneous alloying of manganese into the iron lattice during sintering, improving hardenability without significantly increasing Mo or Cu levels.

The present study examines the role of manganese alloying during sintering in three Mo-based PM steels. A full factorial design of experiments (DOE) was conducted with varying chemical compositions and cooling rates. Metallurgical and mechanical responses, specifically transverse rupture strength (TRS), were evaluated. Based on the DOE results, an optimization exercise was carried out to maximize strength and hardenability with minimized Mo and Cu content.

170 - Influence of Silicone Resin Branching Structure on Magnetic Properties of FeSiAl Magnetic Powder and Magnetic Powder Cores
Jiang Huangyong, NBTM New Materials Group Co. Ltd.

In this study, a novel soft magnetic powder core (SMPC) was fabricated by coating FeSiAl micropowder with three different types of silicone resins. The influence of resin structure on the micromorphology and soft magnetic properties was systematically investigated. Results indicate that all resins form uniform coatings and effectively fill the air gaps between powder particles, thereby promoting densification during compaction. However, the core properties vary significantly with resin branching degree. A highly branched resin leads to high green strength but increased core loss, whereas a lowly branched resin yields low core loss at the expense of green strength. By compounding different resins to utilize their respective advantages, the optimized SMPC demonstrates both superior processability and excellent comprehensive magnetic performance, achieving a core loss of 88 mW/cm³ at 100 mT and 50 kHz.

180 - Sm-Fe-C based Compounds for High Performance Permanent Magnet 
Yusuke Hirayama, National Institute of Advanced Industrial Science and Technology

Sm–Fe–X (X = N, C) compounds are considered highly promising candidates for next-generation permanent magnets, offering a potential pathway beyond Nd-Fe-B magnets. Despite their excellent intrinsic magnetic properties, their practical application is severely limited by low decomposition temperatures, which hinder the fabrication of high-density sintered bodies. Previous studies have reported that Ga doping in Sm–Fe–C can improve thermal stability; however, this effect has been observed only at high Ga concentrations, where magnetic performance is compromised. Systematic investigations in the low-Ga regime, where magnetic properties are retained, remain scarce.

In this study, we explore strategies to enhance the decomposition temperature of Sm–Fe–X compounds through a combined experimental and computational approach. First, we examine phase stability in Sm–Fe–C with low Ga content to clarify its influence on thermal and magnetic properties. Second, we investigate alternative dopants such as Si and Al to identify elements that can improve thermal stability without degrading magnetic performance. Our findings provide fundamental insights into the thermodynamic and electronic mechanisms governing phase stability, offering design principles for developing high-performance Sm–Fe–X magnets suitable for advanced applications.

066 - Influence of Zinc and Calcium Phosphate Reinforcement Powders on the Corrosion and Microstructural Evolution of Magnesium Alloy via Friction Stir Processing
Annayath Maqbool, King Fahd Univ of Petroleum & Minerals

The advancement of biodegradable metallic implants has become a major focus in biomaterials research, aiming to develop alternatives that combine mechanical integrity with physiological compatibility. Magnesium and its alloys offer promising potential for such applications due to their low density, excellent biocompatibility, and favorable mechanical properties. However, their rapid corrosion in physiological environments limits their clinical utility. This study investigates the enhancement of corrosion resistance and microstructural properties of WE43 magnesium alloy through the incorporation of zinc (Zn) and calcium phosphate (CaPO₄) nanoparticles via Friction Stir Processing (FSP). FSP, a solid-state severe plastic deformation technique, was employed to achieve refined microstructures and homogeneous dispersion of the reinforcement powders without the drawbacks of melting or interfacial reactions typical in conventional casting. Two reinforcement ratios (30% Zn–70% CaPO₄ and 70% Zn–30% CaPO₄) and both single- and double-pass FSP conditions were explored to study the influence of powder composition and processing intensity. Microstructural analysis using Optical and Scanning Electron Microscopy revealed significant grain refinement, uniform nanoparticle dispersion, and secondary phase redistribution. Electrochemical testing demonstrated a notable improvement in corrosion resistance for the double-pass FSPed nanocomposites, particularly those with higher CaPO₄ content, due to enhanced barrier formation and reduced localized degradation. 

152 - Laser Powder Bed Fusion of Iron Silicon Soft Magnetic Alloy: Process Optimization and Magnetic Properties
Anatolie Timercan, National Research Council

Recent advances in automotive electrification have driven demand for high performance electric motors, requiring both improved designs and enhanced magnetic materials. Additive manufacturing (AM) offers a promising route to address these needs, enabling the creation of intricate geometries at minimal additional cost and the processing of materials that are otherwise challenging to shape. In this study, laser powder bed fusion (LPBF) was applied to fabricate components using a high silicon content soft magnetic alloy (Fe 6.5Si). Printing parameters were systematically selected and optimized. Cylindrical specimens were produced and characterized for density using Archimedes’ method and micro computed tomography (µCT). Hysteresis measurements revealed a strong correlation between volumetric laser energy density, specimen density, and saturation induction. The most favorable parameter sets were subsequently used to produce toroidal samples for further magnetic testing, such as permeability and core losses. Mechanical properties were assessed through transverse rupture strength (TRS) testing to ensure suitability for the intended application. Results demonstrated that LPBF can produce high density parts with complex geometries and promising magnetic properties. While cracking was observed, it is expected to be mitigated through further optimization of processing parameters and design refinements, paving the way for high performance, additively manufactured motor components. 

060 - Materials, Processing, and Characterization of Multi-Material 17-4PH Stainless Steel and Zirconia Components Produced by Fused Filament Fabrication
Axel Müller-Köhn, Fraunhofer IKTS

Additive manufacturing of metal–ceramic composites via Fused Filament Fabrication (FFF) offers new opportunities to produce geometrically complex and functionally graded components. In this study, multi-material (2K) specimens based on 17-4PH stainless steel and zirconia (ZrO?) were fabricated using a dual-extrusion FFF process. The work focuses on the characterization of the debinding behavior, shrinkage, and dimensional stability of the composite during subsequent thermal processing steps.
Filaments containing metal or ceramic powders in a thermoplastic binder system were produced via compounding and extrusion. Using a multi-material printer, single- and bi-material specimens were manufactured and subjected to solvent and thermal debinding, followed by sintering under controlled atmosphere. The evolution of microstructure, porosity, and shrinkage behavior was analyzed by TGA, optical dilatometry, and SEM.
The results demonstrate the strong influence of the feedstock formulation and processing parameters on the debinding kinetics and the necessary adjustment of the mismatch in shrinkage between the metallic and ceramic regions. Strategies to improve dimensional compatibility and interfacial integrity in 2K- FFF composites are discussed. The findings highlight the potential of powder-based FFF for the fabrication of complex metal–ceramic hybrid components.

114 - Exploring the PBF-LB Processability of a Novel High Strength Low Alloyed Steel
Satya Chaitanya Vaddamanu, Chalmers Tekniska Hogskol

The rapid advancement of additive manufacturing (AM) technologies has increased the need for new alloys tailored for structural applications, where high strength, toughness, and reliability are essential. Conventional ferrous alloys are often unsuitable for AM due to their relatively high carbon content (> 0.3 %), which promotes cracking during processing, particularly when build-plate preheating is not applied. To address this challenge, the present study investigates the processability of a novel high-strength low-alloy (HSLA) steel developed at IPT (C: < 0.1 wt. %, Si: 0.2 wt. %, Ni: 3.5 wt. %, Cu: 1.6 wt. %, Mn: 0.9 wt. %, Mo: 0.6 wt. %, Nb: 0.2 wt. %) using the Powder Bed Fusion – Laser Beam (PBF-LB) technique. The work focuses on understanding the relationships between process parameters, melt-pool dynamics, microstructural evolution, and the resulting mechanical properties. Optimized parameter sets enabled the fabrication of fully dense (~99.9 %) and crack-free specimens across a broad processing window. Microstructural characterization revealed a fine martensitic matrix containing uniformly distributed nanoscale precipitates. Correlations between processing conditions and melt-pool morphology further elucidate the influence of energy input on microstructure refinement. The mechanical response was evaluated through Vickers hardness measurements. Overall, the findings demonstrate that this newly developed HSLA steel can be effectively processed by PBF-LB, offering promising potential for high-strength structural applications.

104 - Investigation of the Flow and Application Behavior of Nanoparticle-Coated Stainless-Steel Powder in PBF-LB/M
Tim Brocksieper, Ruhr-University Bochum.

In the additive manufacturing process powder bed fusion of metals using a laser beam (PBF-LB/M), fine metal powder is spread layer upon layer and in between selectively melted by a focused laser beam. The quality of the powder application strongly depends on the recoater system, the machine settings, and the powder material itself. Previous studies have shown that coating metal powders with nanoparticles can improve their flow behavior. However, conventional flowability tests do not adequately represent the actual powder application in the PBF-LB/M process , because they deviate significantly from the real powder movement in a machine. This study investigates the flow and application behavior of a stainless-steel powder coated with Si3N4 nanoparticles. The real application behavior is examined using a custom-built test rig that replicates the layer deposition in a PBF-LB/M machine and compared with a comprehensive flowability analysis. The recoater speed, supply factor, recoater system, and layer thickness are varied in these experiments  . Powder layers are evaluated with a high-resolution camera system under dark-field illumination, and macroscopic surface measurements are performed using a 3D laser scanner to assess layer homogeneity. The results demonstrate that flow behavior and application behavior must be clearly distinguished. The influence of the nanoparticle coating on the powder flowability differs significantly from its actual application performance in the machine, particularly with regard to its application quality.  

105 - Spreadability of Metal Powders: Combining Powder Characterization and DEM Simulations
Aurélien Neveu, Granutools

Good powder spreadability is essential in powder bed-based AM to prevent the deposition of irregular layers that will induce defects in the built part. Previous studies have demonstrated the link between the Cohesive Index metric [1] of the GranuDrum (Granutools, Belgium) and the irregularity of the layer measured inside an SLM printer.
The interface quality is measured based on the analysis of optical images of the powder bed acquired with the camera device available in the printer. The in-situ evaluation is interesting to get a measure of the global spreadability of the powder but does not allow to go deep in the analysis of the defects shape and size. Discrete Element Method (DEM) has gained a lot of interest in simulating particle-based materials. The main advantage is that the properties of the particles (size/shape, position, velocity) are known at any time of the simulation. We propose an approach using characterization results obtained with the GranuDrum to precisely calibrate the simulations with a digital twin of the GranuDrum system. The calibrated virtual material is then used to investigate the influence of material parameters such as cohesive strength, particle size or shape, and recoater speed, on spreadability. Moreover, the results of the DEM simulations confirm the relation between the Cohesive Index and the spreadability that was previously observed experimentally.

288 - Powder Flowability of Elemental Niobium, C103, and Other Structural Materials for Powder Bed Fusion
Dina Khattab, Purdue University

Adequate powder flowability in laser powder bed fusion is critical important because it enables even spreading of 40-80µm-thick layers of powder in a homogeneous manner. This aids in reducing defects during the melting and solidification process and overall improves component performance. In this talk we will elucidate the influence of surface chemistry and powder morphology on flowability and spreadability using several metrics measured from traditional methods like the Hall flow test and tap density, but also from newer and novel methods such as modified orifice flow, GranuDrum, powder rheometer, and miniaturized powder bed test. To validate interpretation of these experiments, we also present discrete element method (DEM) results that systematically vary powder cohesion and morphology to investigate flowability. While most of this presentation will focus on elemental niobium and Nb-based C103 alloy, other structural materials will be presented including Ni alloy 625, and stainless steel 17-4 PH.

295 - Magnesium Alloy Development for Additive Manufacturing of Biodegradable Implants: The Effect of Powder Size and Morphology on the Sinterability
Ava Azadi, University College of Dublin

The use of biodegradable magnesium (Mg) alloys for bone fixation devices have potential to improve patients’ quality of life by avoiding the necessary secondary operations conducted regularly for the removal of implants fabricated from conventional non-resorbable alloys. Having excellent biocompatibility and biodegradability along with a low modulus of elasticity (decreased bone-shielding) lead to clinical uses as bone-fixation screws (Magnezix®, Syntellix) and coronary stents (Magmaris®, Biotronik). Next generation Mg implants necessitate patient-specific designs which can be realised most effectively via Additive Manufacturing (AM). AM processes based on Powder Bed Fusion have not been widely adopted for Mg-alloys due to safety concerns raising from the intrinsic properties of Mg, such as high affinity to oxygen, low boiling temperature and high vapor pressure. Fused Deposition Modelling (FDM) is a cost-efficient 3D-printing technique commonly used to produce polymer-based components from filaments. Employing FDM that operates at low temperatures (<200˚C) can offer key technological advancement in the customisation of patient-specific Mg alloys with maximum design flexibility. The key limiting factor is the low sinterability of Mg and its alloys. This study focuses on the development of novel Mg-based alloys with superior sinterability. Thermodynamic calculations are used to predict the liquid phase fraction in order to optimise sinterability and porosity levels. Materials characterisation was conducted to validate the thermodynamic modelling results using optical and scanning electron microscopy (SEM/EDS) as well as X-ray Diffraction (XRD). Final porosity levels were determined using X-ray Computed Tomography (CT). Mechanical performance was evaluated in comparison to cast alloys via compression testing.

297 - Laser Powder Bed Fusion of Cutting Tool Components in SSAB AM TS2 Powder: Processability, As-Printed Performance and Industrial Integration
Bruno Guimarães, Palbit S.A.

In the cutting tools industry, additive manufacturing is becoming increasingly used, due to its high design freedom, ability to create more complex parts, and possibility to tailor and enhance internal coolant channels direction to the cutting edge while reducing cutting tool mass.
For this, it is important to properly select the powder material to be used, as this choice will directly influence the component mechanical properties. However, the steel alloys that are typically used need to be heat-treated to achieve the desired mechanical properties, which adds a post-processing stage, increasing lead time, energy consumption and costs.
In this sense, this work intends to evaluate the Laser Powder Bed Fusion processability, as-printed mechanical properties and applicability to cutting tools of SSAB AM TS2, a low-alloyed steel powder with low CO2 emissions that doesn't need to be heat treated, thus contributing for an increased sustainability of the manufacturing process and produced components.
 

007 - Metal Binder Composition Optimization Strategies in Cemented Carbides to Enhance Cutting Performance
Yasuki Kido, Sumitomo Electronic Industries

Cemented carbide is widely utilized as a typical cutting tool material due to its excellent mechanical properties. The combination of the hard phase, tungsten carbide (WC), and the binder phase, cobalt (Co), enables the machining of a variety of work materials. Recently there has been a growing requirement of increased efficiency in machining particularly like heat-resistant alloy, driven by the demand for labor savings and reduced environmental impact. One practical solution is the control of the binder composition; a commercial example is the incorporation of soluble metal binder such as ruthenium (Ru). It has been demonstrated that the binder phase improves mechanical properties as well as cutting performance. Alternative metal binders such as platinum group metals are often discussed in research, however their high costs remain a significant concern. In this study, we examined the damage mechanism sustained during the machining of difficult-to-cut work materials by carbide with modified binder and investigated the essential properties required for the metal binder. Observations revealed that the damage of the tool during cutting led to a transformation of the crystalline configuration of the binder, which appeared to relieve cutting stress. Based on the features, we aimed to propose another metal binder X through computational methods. Evaluating the performance including some types of cutting tests, it was clear that cutting tool requires not only the relief of stress but several properties such as mechanical properties in high temperature and wettability of metal binder.

134- Design of Novel Hardmetal Binders for High-Temperature Applications
Raquel de Oro Calderon, Technische Universität Wien

The performance of hardmetals at elevated temperatures strongly depends on the stability and composition of their metallic binders. In this work, different binder chemistries—Co, CoRu, CoNiCr, and the multicomponent FeCoNiRuCr—were systematically investigated to understand phase formation, chemical composition, and their evolution with carbon content. The results show that carbon variation significantly influences both binder phase composition and elemental solubility, leading to pronounced differences in phase stability and transformation. Heat treatments at 900 °C and 1000 °C for 2 h were performed to evaluate phase stability and potential transformations, such as FCC–HCP transitions. Microhardness measurements revealed notable effects of solid solution strengthening, particularly in the multicomponent systems. The presence of Ru was found to enhance the solubility of other alloying elements in the FCC phase, while Cr-containing binders exhibited increased total alloying content despite reduced W solubility. These findings are crucial for understanding the mechanisms that govern the high-temperature behavior of hardmetals, including phase transformations, carbide formation, and strengthening effects. The insights gained provide a foundation for the rational design of advanced binder systems optimized for improved performance in demanding high-temperature applications.

150 - The Effect of Binder Fraction on Martensitic Transformation in Cemented Carbides with Steel Binders
Saba Mohammadpour Kasehgari

Cemented carbides, composed of tungsten carbide (WC) and a conventional cobalt (Co) binder, exhibit an exceptional combination of hardness and toughness, making them ideal for diverse industrial applications. However, growing sustainability concerns related to cobalt have led to a strong research focus on designing alternative binders with comparable or even superior mechanical properties to those found in WC–Co composites. Previous studies have demonstrated that martensitic transformation in steel-based binders, induced by quenching and/or deformation, contributes significantly to the improvement of the overall mechanical response of cemented carbides. However, the martensite–austenite fraction, which is governed by multiple interconnected factors within austenite grains and adjacent structures, has not been systematically studied. Combining cemented carbides with steels further increases microstructural complexity, as the hard WC skeleton affects dislocation mean free path through multiple mechanisms that remain poorly understood. In this work, the effect of binder fraction, as a parameter controlling the binder mean free path, on the binder structure was systematically investigated.

046 - Additive Manufacturing of Ta-W Alloys: A Gradient Approach to Microstructure and Cracking Behavior
Sila Atabay, Lawrence Livermore NL Lib

Tantalum–tungsten (Ta-W) alloys, or tantaloys, offer a unique combination of ultra-high melting points (Ta: 3017 °C, W: 3410 °C), excellent corrosion resistance, and ductility at W concentrations up to 7.5 wt.%. Their resistance to hydrogen embrittlement makes them promising materials for fusion reactor applications. While most studies have focused on 2.5 and 10 wt.% W compositions, expanding the compositional range is essential for optimizing strength and enabling new alloy design strategies, particularly for additive manufacturing. In this study, a compositionally graded Ta-W alloy was fabricated using laser-directed energy deposition (L-DED) to systematically investigate the influence of W content on cracking susceptibility, microstructure, and mechanical properties. Post-processing via homogenization heat treatment was applied to the gradient material to assess microstructural evolution and property changes relative to the as-printed condition. This approach provides a comprehensive understanding of composition–property relationships in Ta-W alloys and offers guidance for developing robust refractory materials via additive manufacturing.

158 - A Decade of Refractory Metal L-PBF AM
Ryan Anderson, Quadrus Corporation

This presentation covers over 10 years of effort by our team at Quadrus Advanced Manufacturing Division (QAMD) to capitalize on Laser Powder Bed Fusion (L-PBF) Additive Manufacturing’s (AM) capabilities to process refractory metals in geometries and applications previously unobtainable.

Refractory alloys play important roles in the aerospace community due to their ability to survive in extreme temperature areas. Therefore, they are in high demand for our customer base, especially our aerospace customers. QAMD originally entered the realm of refractory AM to produce zero-erosion, run-hot nozzle geometries. Several components have since underwent successful hot-fire. This presentation will summarize the work we have performed to develop L-PBF AM of W-24Re, W-5Re, Mo, C-103, and Re.  QAMD has successfully produced fully-dense and crack-free C-103 and elemental Re. The team also developed >99% density for W-24Re and elemental Mo. W-5Re, with only three parameter development builds, was dense enough to fully consolidate through heat treatment. Overall, QAMD has made great progress in leading the advance in the use of L-PBF AM for refractory components and plans to continue doing so in the coming years.

165 - Tungsten 3D Printing using Electron Beam Powder Bed Fusion
Jonathan Buckley, JEOL USA

Electron beam powder bed fusion (EB-PBF) technology stands out for its capability to 3D print refractory metals such as tungsten and its alloys. Refractory metals such as Tungsten are known for their exceptional properties and resistance to heat, wear and corrosion, which are desirable in industries such as aerospace, defense, medical and nuclear. Join JEOL's presentation to learn more about EB-PBF technology and explore its potential applications in manufacturing tungsten, including EB-PBF's unique preheating capability that allows fully dense Tungsten designs to be 3D printed with excellent mechanical and material properties.

504 - Design and Process Insights in Binder Jet AM
Harsha Jamadagni, Indo-MIM

Additive manufacturing is maturing to become one of the mainstream manufacturing technologies for small, medium and high-volume production. Binder jet metal printing is one such platform to manufacture highly complex and precise metal components for advanced applications.  The increase of binder jet metal printing parts in various applications drives us to think about the dimensional capability in Binder jet metal printing technology which is currently at 1.5% to 2% of the nominal dimensions. When compared to other conventional technologies, the present dimensional capabilities dictate the inclusion of machining operations to achieve tighter tolerances. There are factors which influence the dimensional capability in Binder jet metal printing parts. In the present study, we are going to present the influence design, powder and processing parameters on the dimensional capability of binder jet metal printing parts.

506 - Evaluation of Binder Jetting AM Technology for Fabrication of 10%Co Tungsten Carbide Tools
Hadi Miyanaji, Kennametal

Additive manufacturing (AM) offers considerable economic advantages over traditional manufacturing methods, particularly for producing highly complex geometries with shortened lead times. Consequently, AM has gained traction as a viable route for manufacturing customizable cemented carbide components intended for metal cutting and high-wear environments. Among AM processes, Binder Jetting (BJ) has emerged as a widely adopted technology, and multiple process configurations have been explored to enable successful printing of cemented carbides for cutting tool applications.