WorldPM          AMPM       Tungsten        Special Interest          TNT Presentations

173 - Closing the Hydrogen Loop in Powder Metallurgy through Recycling and Purification Technologies
Devin ter Braak, Hygear NA Inc.

Hydrogen containing atmospheres are widely used in powder metallurgy for reduction and sintering, yet furnaces are still often operated in once through mode, with spent gas vented after a single pass. This results in high hydrogen consumption, increased operating cost, and unnecessary greenhouse gas emissions. Hydrogen recycling and purification offer a way to close the loop around the furnace and recover hydrogen rich off gas streams.

This technical presentation gives a process focused view on integrated hydrogen recycling for powder metallurgy using Temperature Swing Adsorption TSA, Pressure Swing Adsorption PSA, and staged filtration and gas conditioning. A TSA based recycling system recovers hydrogen nitrogen mixtures from the furnace atmosphere and removes water, oxygen, and other impurities so that the conditioned gas can be returned to the process with stable flow and quality. In parallel, a PSA based purification system upgrades hydrogen containing side streams to high purity hydrogen that is suitable for reuse as a reducing gas or as an energy carrier.

The presentation will address practical integration with furnaces, key design parameters such as gas composition, flow, and dew point, and the role of pre and post filtration for reliable operation. Example cases will illustrate the potential to reduce fresh hydrogen demand, improve atmosphere control, and lower both cost and carbon footprint for powder metallurgy production.

071 - Sustainable Graphite for Powder Metallurgy 
Raffaele Gilardi, Imerys Graphite & Carbon

Graphite plays a crucial role as an alloying element in powder metallurgy. Its incorporation into metal powder blends is primarily driven by its ability to significantly enhance the mechanical properties, particularly the strength, of the resulting sintered parts. Even with an addition of only 0.5-1% to the powder mix, graphite is a key ingredient in creating high-performance components with optimized properties. Graphite exists in various forms, including natural and synthetic, each produced through distinct processes. The CO2 footprint and water consumption associated with each form are influenced by factors such as raw materials, production process and location.

This study investigates different graphite types in iron-copper-graphite powder metallurgy compositions (MPIF FC-0208), including natural and synthetic options, assessing their performance characteristics and environmental footprints. A particular focus is placed on exploring sustainable and renewable raw materials as alternatives to coke for synthetic graphite production. The findings indicate that synthetic graphite derived from biomass residues (recently commercialized as SU-NERGY™ by Imerys) demonstrates comparable performance to conventional coke-based synthetic graphite and exhibits superior properties when compared to natural graphite. This novel biomass-derived synthetic graphite offers a sustainable alternative for developing advanced powder metallurgy components, contributing to the industry's defossilization initiatives.

003- Copper Powders and Processing for Electrical and Thermal Applications
Ian Donaldson, FAPMI, GKN Sinter Metals

Powder metal processing has been an attractive manufacturing method for high volume, precision components in the automotive industry.  As the transition to hybrid and battery electric vehicles (BEV) progresses, there will be less opportunity for typical structural PM components but an increase in components for electrical and thermal management applications.  Quite often, the demanding requirements of these components result in high purity copper being necessary.  Electrolytic copper powder and water atomized copper powder are both excellent choices for electrical and thermal management applications due to their high purity, excellent thermal and electrical conductivity.  Electrolytic has a higher purity level but the higher cost and inferior flow characteristics limit use in conventional PM applications.  Results from various processing conditions are discussed for both electrolytic and a 60/40 mixture of water atomized/electrolytic powders are presented.

282 - Thermal Management and the  Production of Copper-Diamond Composites via PM Processes
Alessandro DeNicolo, GKN Sinter Metals

Copper-based heat sinks are essential components in the cooling of electronic assemblies. In most cases, the aim is to increase the heat-transferring surface area in order to achieve a more efficient heat dissipation by applying Newton's law of cooling and using free and forced convection. However, this overlooks the fact that two different heat transfer mechanisms are interacting here. The base plate has a heat-conducting function to equalize any temperature differences, while the fins – the enlarged heat-transferring surface – transfer the heat to the flowing fluid via free and forced convection. It is therefore advantageous to differentiate between the heat spreader (just the base plate) and the heat sink (just the fin). Extensive computational fluid dynamics simulations have shown that the thermal conductivity is more dominant in the base plate area to minimize local hot spots (sharp temperature differences) while free and forced convection dominates the situation in the fin area, where material properties do not play such a significant role. It is well known that particularly a high thermal conductivity can be achieved with copper-diamond composite materials. However, these are very expensive, which is why it seems appropriate to use them sparingly. A hybrid powder metallurgical production is therefore a suitable option. One idea aims to produce a flat and thin base plate through a continuous powder rolling process. After the sintering, the fins – made of a much cheaper copper-based material – could be applied using an additive manufacturing production process. Initial powder rolling tests were carried out to produce the flat and thin base plate/heat spreader. Production restrictions of the powder rolling process and anticipated problems are briefly outlined.

248 - Enhancing Mechanical And Conductive Properties In HIP-Fabricated Copper--Graphene And CuCrZr Composites: A Comparative Study
Andrén Karl-Johan, MTC Powder Solutions AB 

This study compares the mechanical and thermal properties of three HIP-consolidated copper-based materials—pure copper powder, a copper–graphene composite, and a copper–chrome–zirconium alloy—with a hot worked copper reference.  Microstructural analysis, mechanical properties, and thermal/electrical conductivity measurements form the basis of this comparison. By introducing graphene to the copper powder or alloying copper with chromium and zirconium, the aim is to enhance mechanical performance through dispersion and grain boundary strengthening, while retaining thermal and electrical conductivity close to those of pure copper. Demonstrating such improvements could position HIP-fabricated copper-graphene  composites as promising high-performance alternatives to conventional forged copper and CuCrZr in large-scale scientific instrumentation, aerospace components, and heat-exchange systems.

274 - Stability of Manganese Sulfide Machining Additive
Neal Kraus, Hoeganaes Corporation

Several machining additives are available for use in PM premixes.  The most widely used additive is manganese sulfide (MnS).  MnS is highly versatile as it improves machinability in turning, drilling, milling, boring, etc. by acting as a chip breaker, reducing required cutting forces, and lubricating the tool.  The effectiveness of MnS is highly dependent on its chemical makeup.  MnS can degrade to an oxidized form, thereby reducing machinability.  This paper will examine how and when MnS degrades and what effects this has on PM compacts.

264 - How Can Metalworking Fluids and Lubricants Cause Rust and Corrosion on PM Parts
Brett Utsinger, H.L. Blachford Ltd.

This presentation explores adverse reactions associated with amines used in the formulation of metalworking fluids and lubricants applied in secondary operations by PM manufacturers and subcontracted process providers. It examines how variations in fluid and lubricant chemistries drive these reactions, with emphasis on the root cause: the sensitivity of pH reactive metals commonly present in PM alloys.

Analysis focuses on the detrimental interaction between amines and white or yellow metals. Inclusive lab testing shows that amines degrade protective oxide layers naturally present on white and yellow metals, thus increasing their solubility in reactive metalworking fluids. As these softer alloys dissolve, galvanic cells form in the presence of dissimilar metals. These cells act as precursors to corrosion in ferrous components of PM alloys, as their atomic structures readily bond with ferrous molecules, accelerating oxidation and spreading corrosion to other exposed materials.

Also outlined in this presentation are proper sampling methods for metalworking fluids and detailed ASTM testing protocols. Comprehensive testing data will be presented that confirms adverse reactivity between certain metalworking fluids and the copper present in most PM alloys. These testing protocols will help PM manufactures qualify their metalworking fluids, insuring compatibility with their processes and materials. With this knowledge, PM manufacturers and secondary process suppliers can establish independent testing criteria to evaluate fluid or lubricant performance, preventing the risk of incompatibility with PM materials.

211 - Precise Edge Conditioning with Brushes on Planetary Head
Daniel Rauch

Precision parts like gerotor pump components and gears are often single or double side ground. For components with considerable mass and size the often-used tumbling processes have negative effects. Brush deburring on planetary heads eliminates the risks of parts damaging each other during the conditioning process. In line operations may also allow to feed parts in constant distance from grinding to brushing, cleaning and packing, all to avoid contact and thereby protecting the key features.

A planetary head needs to offer optimized cutting speed ratios, and overall tolerances close to grinding machines. Only with perfect control of the brushing process can the edges be conditioned in the hundreds of mm (as many people talk about microns, maybe that term fits better?). Combined with precision tooling, brushes geared exactly to the process, not only can precision be held constant, but also material removal on the edge can be controlled. 

Machines with a given number of planetary heads will allow processes to be optimized for minimal deburring with finest surface finishing requirement or for higher volume throughput. Even the combination of both is possible, the permanent control of the process with considered soft tooling is the essence of this secondary process.

161 - Manufacturing of NdFeB Magnets by Laser Powder Bed Fusion – a Journey Toward Better Properties
Roger Pelletier, National Research Council Canada

The demand for high-performance permanent magnets with complex geometries is growing, driven by the need for advanced motor designs and devices that leverage intricate magnetic field distributions. Additive manufacturing, particularly Laser Powder Bed Fusion (L-PBF), has emerged as a powerful route for producing dense, net-shape components across a wide range of alloy systems. The NdFeB material family is of particular interest for applications requiring exceptional magnetic performance. However, processing NdFeB via L-PBF remains highly challenging due to several factors, such as the scarcity of feedstock powders with optimal particle morphology, the poor thermal stability of the primary magnetic phase (Nd-Fe-B), and the pronounced susceptibility of the material to cracking under process-induced stresses. This presentation will report our latest experimental results and insights into trying to overcome these limitations. Special emphasis is placed on strategies, such as spheroidization of commercial powders via Inductively-Coupled Plasma (ICP) processing, and the use of tailored post-heat treatments, aimed at enhancing both the microstructural integrity and magnetic properties of L-PBF-fabricated NdFeB magnets.

087 - Gas Flow Mapping Diagnostic Tool for Assessing Gas  Flow Homogeneity PBF-L
René Cooper, Airgas, an Air Liquide company

Laser Powder Bed Fusion (PBF-L) relies on a continuous cross-flow of inert gas to prevent oxidation and to evacuate process by-products like spatter and plume condensation. An inhomogeneous gas flow field across the build plate is a major, often-overlooked source of location-dependent defects like porosity and compromised mechanical properties. Insufficient gas flow velocity allows by-products to redeposit or attenuate the laser beam, leading to a higher concentration of gas pores, affecting mechanical properties of each metal layer.

It is therefore critical for Additive Manufacturers to directly quantify and optimize this crucial factor. This presentation will discuss methods manufacturers can use to map gas flow profiles in virtually any PBF-L print chamber, and tools to capture velocity measurements. The data extracted from a mapping sequence can be used to confirm areas with inhomogeneous gas flows, qualify a machine before it is put into production or as a preventative maintenance tool to ascertain if gas flow homogeneity has been affected by situations such as an inlet nozzle clogged with powder, early wearing of fume filter or turbine failure. Ultimately, mapping gas flow homogeneity allows users to understand if there are low-velocity or "dead zones" of gas flow, potentially indicating the impact of part positioning on final quality.

This novel metrology enables manufacturers to characterize and optimize inlet/outlet designs, drastically reducing flow non-uniformity and, consequently, improving part quality and build consistency across the entire platform.

225 - 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-spheroidized 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.

212 - Evaluating Coarse Ti-6Al-4V Powders for Laser Powder Bed Fusion: Results and Potential Benefits
Arslane Bouchemit, Tekna Plasma Systems

Recent advancements in laser powder bed fusion (L-PBF) systems now allow the use of thicker layers to improve productivity and reduce manufacturing costs. However, although printers have evolved and parts are increasingly produced using larger layer thicknesses, the industry remains tied to legacy particle size distributions (PSDs)—typically 15 - 45 µm or 20 - 53 µm originally developed for thin-layer printing (~30 µm). This study evaluates the printability and performance of coarse Ti-6Al-4V powders produced by Tekna’s plasma atomization process, with PSDs reaching up to -90/+45 µm, across multiple L-PBF platforms. Experimental builds were carried out using layer thicknesses up to 90 µm, followed by heat treatments such as annealing and hot isostatic pressing (HIP).

The results demonstrate that coarse PSD powders can achieve excellent densification (>99.9%) and mechanical properties comparable to standard L-PBF powders after appropriate post-processing. Moreover, the adoption of wider PSD ranges provides significant economic, productivity, and sustainability advantages by lowering feedstock cost, reducing powder waste, enabling faster builds, and improving powder-handling safety.

Overall, the results indicate that high-quality coarse Ti-6Al-4V powders can maintain the required part properties, opening opportunities for broader adoption of metal additive manufacturing in cost-sensitive industries such as automotive and consumer goods.

004 - Feasibility of Laser Powder Bed Fusion of a Ti-22Al-25Nb Alloy Using Low-Capacity Printers: Risks of Process-Induced Cracking 
Aurore Leclercq, École de Technologie Supérieure

Ti-22Al-25Nb is an intermetallic titanium alloy that exhibits excellent physical and mechanical properties at elevated temperatures. However, its limited formability poses significant challenges for conventional manufacturing, making additive manufacturing—particularly Laser Powder Bed Fusion (LPBF)—a promising alternative. While high-end LPBF systems equipped with high power lasers and heated chambers can successfully process this material, the feasibility of using low-capacity LPBF printers without preheated build plates is still an open question.

Firstly, single-track experiments were conducted to analyze the influence of process parameters on the single-track morphology, leading to the identification of a minimum linear energy density required for the acceptable track quality. The attempt to print volumetric samples using the same conditions was hindered by severe cracking occurring systematically during printing. Although adjusting process parameters and adding post-processing heat treatments allowed to induce phase transformations potentially favorable to reduce thermal stresses and produce small-size (20mm-diameter, 15mm-long) crack-free samples, they were insufficient to successfully print larger or more complex parts.

The methodology developed in this work enabled an efficient assessment of the Ti 22Al 25Nb printability and may serve as a framework for the use of more complex, and potentially more successful, printing strategies to process these alloys using low-capacity LPBF printers.

044 - Ti6Al4V-Ag 3D Multi-Materials fabricated by Laser Powder Bed Fusion for Biomedical Applications: Mechanical and biological characterization
Flávio Rodrigues

Biomedical implants often face two major challenges after implantation: post-surgical infections and poor osteointegration.
Recent advances suggest that applying electrical current is a promising strategy to address both complications. In this context, a new implant design is proposed that combines the intrinsic properties of Ti6Al4V and Ag(silver). Ti6Al4V, a titanium alloy, is widely used for implants because of its mechanical properties and biocompatibility, whereas silver is recognized for its antibacterial characteristics and high electrical conductivity.

This study explores the fabrication of Ti6Al4V-Ag 3D multi-materials by Laser Powder Bed Fusion, with emphasis on optimizing processing parameters and controlling the transition zone to ensure metallurgical integrity and reliable functionality.

The obtained multi-materials were characterized in terms of microstructure, phase distribution, porosity, hardness, and other relevant mechanical and physical properties. Silver incorporations provide electrical conductivity that enables therapeutic currents to be applied directly through the implant.

The results demonstrate that this approach is effective in producing Ti6Al4V-Ag 3D multi-material with embedded electrical functionality. This opens a pathway for real-time stimulation aimed at both reducing bacterial activity and enhancing osteointegration. Overall, this work highlights the potential of Additive Manufacturing to deliver next-generation multifunctional biomedical implants combining structural reliability, antibacterial protection, and compatibility with electrical stimulation therapy.

220 - Cold Metal Fusion - Industrial Process Capability in Production
Christian Staudigel, Headmade Materials GmbH

In Cold Metal Fusion (CMF) metal green parts are produced by fusing a metal powder/polymer binder feedstock on polymer laser sintering machines; after solvent debinding and furnace sintering dense metal parts are produced. In this study on a EOS Formiga P110, quality control specimens were printed within every build job over 6 month to evaluate the process capability of Cold Metal Fusion (CMF) for Ti6Al4V. Specimens from each job were assessed for density and dimensional accuracy in the green state and again after debinding and sintering. Measurements were performed across multiple material batches to capture both within build and between batch variability.

Statistical analysis of the collected data demonstrates a robust and repeatable CMF process: green state and post sinter densities show tight distributions with low standard deviation, and dimensional deviations remain within targeted tolerances after sintering. The observed stability in shrinkage behavior and density evolution supports predictable sintering outcomes and reduces the need for extensive qualification. These findings validate the Formiga P110 CMF workflow for producing reproducible, high quality metal parts and provide a practical dataset for process qualification and industrial adoption.

263 - Development of Non-Weldable Nickel-Based Superalloys (939, 738LC) for LPBF Additive Manufacturing: Microstructure and Mechanical Properties
Xinjiang Hao, Globus Metal Powders

Nickel-based superalloy 939 was originally developed as a cast high-temperature alloy for gas turbine components such as blades, vanes, and burner nozzles, with service capability up to approximately 850 °C. Despite its desirable high-temperature strength and oxidation resistance, Alloy 939 is considered non-weldable. During laser powder bed fusion (LPBF), it exhibits extensive solidification, which severely limits its printability.

Through targeted alloy-design modifications - focused on adjusting minor elemental additions and solidification behaviour- we successfully developed a modified 939 composition that eliminates microcracking in LPBF-fabricated parts. This paper presents the alloy-design strategy, optimisation of LPBF processing parameters, and a comprehensive evaluation of the resulting microstructure and mechanical performance, including both room-temperature and elevated-temperature properties. Preliminary LPBF results for another non-weldable cast superalloy, 738LC, are also reported.

284 - Microstructure-Driven Qualification of Sintered Titanium in MIM, LMM, and CMF 
Tim Marter, Element 22 GmbH

This talk examines sinter-based additive manufacturing (AM) of titanium, a reactive metal where interstitial uptake and property sensitivity define qualification limits. Instead of a process-to-process comparison, the presentation maps best-fit use cases and restrictions for Metal Injection Molding (MIM), Lithography-Based Metal Manufacturing (LMM), and Cold Metal Fusion (CMF). While medical devices set the highest qualification barrier, the findings are positioned to build confidence in titanium PM components across sectors by prioritizing microstructure and mechanical validation over oxygen content as a standalone proxy. 

ASTM F2885-17 provides requirements for Ti6Al4V produced via MIM, but no equivalent standard exists for LMM or CMF. The talk presents benchmarks for density, surface condition, and static/dynamic mechanical performance, and highlights fine-grained sintered titanium as a pathway to robust performance through refined microstructures and low porosity. Overall, the work supports process-aware qualification strategies and future standards tailored to sinter-based AM.

252 - HiPIMS Coating of Laser-Grinded Hard Materials for Improved Performance
Efrain Carreño-Morelli, University of Applied Sciences and Arts Western Switzerland

High Power Impulse Magnetron Sputtering (HiPIMS) is a PVD technology, which uses  very short but intense voltage pulses to the cathode with a resulting increase in the plasma density. In this work HiPIMS of aluminides and nitrides is used to coat tungsten cemented carbides and titanium carbonitride based cermets. Pico-second laser grinding was used for surface texturing and cutting edge sharpening of hard material tools before coating. Part microstructure, coating characteristics, wear resistance and tool lifetime are characterized and compared with reference materials.

110 - WC- and Co-Free TiC/NbC–Fe/Ni Cermets for Wear in Mining: From Microstructure to Abrasion Behavior
Johannes Pötschke, Fraunhofer IKTS

To mitigate criticality and price volatility of tungsten (W) and cobalt (Co) in mining wear parts, we investigated WC- and Co-free cermets: TiC-Fe-based and NbC-Ni-based cermets processed by conventional powder metallurgy. Cermets were liquid-phase sintered to ≥99% relative density with controlled carbide size (~ 3 µm). Pre-selected Fe-Ni-Cr-Binder provided both work-hardening and enhanced wetting. Phase analysis by XRD/EDS confirmed suppression of eta and brittle oxycarbides and revealed a homogenous microstructure.

Mechanical properties were benchmarked against various WC-Co based reference materials. Testing comprised Vickers macrohardness (HV10), Palmqvist toughness (B-value, N/mm) as well as low-stress (ASTM G65) and high stress (ASTM B611) abrasion tests. Both TiC and NbC-based cermets reached hardness above 1200 HV10 and fracture toughness above 1100 N/mm. TiC based cermets showed better properties in high stress abrasion tests while NbC cermets had a much lower volume loss in low stress abrasion tests. In direct comparison to currently used WC-Co grades, the new WC- and Co-free cermets showed comparable low stress abrasion similar results.

123 - Development of WC-Based Cemented Carbides with Ternary Alloy Binder and Chromium Carbide and Molybdenum Carbide Additives by Spark Plasma Sintering
Nthape Mphasha, University of the Witwatersrand

This study focuses on the development of sustainable WC-based cemented carbides using a cobalt-lean ternary binder system (Co–Ni–Fe) and grain growth inhibitors (Cr3C2 and Mo2C), consolidated by spark plasma sintering (SPS). Powders with the nominal composition of 92 wt% WC, 1 wt% Cr3C2 1 wt% Mo2C, 2.5 wt% Fe, 2.5 wt% Ni, and 1 wt% Co were milled and subsequently sintered at 1300°C, 1400°C, and 1500°C under an applied pressure of 50 MPa for 5 minutes. The sample sintered at 1400°C achieved the highest relative density (96.7%). The use of SPS, combined with the additions of Cr3C2 and Mo2C, resulted in high hardness (HV₃₀ = 20.26 GPa), and fracture toughness (KIC = 13.59 MPa·m¹/²). Sliding wear testing revealed that wear resistance is inversely proportional to fracture toughness. For instance, the sample sintered at 1400°C exhibited the highest coefficient of friction (0.514), even though it showed the highest combination of hardness and fracture toughness compared to samples sintered at 1300°C and 1500°C, which had hardness and fracture toughness combinations of (HV30 = 14.96 GPa and KIC = 7.53 MPa. m1/2) and (HV30 = 14.96 GPa and KIC = 7.53 MPa. m1/2), respectively. These findings demonstrate that Co-lean bonded WC-based carbides can offer comparable performance to conventional WC-Co based cemented carbides. 

279 - Sustainable WC–Co Recycling: Reviewing Progress and Pathways Forward
Xu Wang, Kennametal Inc.

The sustainable recycling of cemented tungsten carbide (WC–Co) is a strategic imperative for the hardmetals industry due to the scarcity, supply-risk, and environmental burden of primary W and Co production. Established industrial routes — notably the thermal zinc (PRZ) process, pyrometallurgical recovery, and emerging electrochemical methods — reliably recover mass but still struggle to deliver consistent, virgin-equivalent powders for high-performance applications. This critical review synthesizes historical and recent advances across different recycling routes and assesses their strengths and limitations with respect to three persistent bottlenecks: (i) impurity control and trace contaminants, (ii) powder microstructure and sintering behavior, and (iii) predictive, application-relevant quality-assessment metrics. We highlight promising hybrid and green flowsheets that combine powder re-engineering, AI-supported digital process control, and insights from recent life-cycle analyses. Finally, the review reframes reclaimed WC–Co not as an inferior substitute, but as a feedstock whose value is unlocked — a shift essential to enabling modern sustainable materials management in hardmetals.

278 - Stress–Strain Characterization of WC–Co Hardmetals at Room and Elevated Temperatures Using Profilometry-Based Indentation Plastometry
Xu Wang, Kennametal Inc.

Accurate mechanical property data, including yield strength and flow behavior, are critical for the design and optimization of WC–Co hardmetals. Their high hardness and brittleness, however, make conventional tensile testing challenging due to premature fracture and demanding specimen preparation. In this study, we employ the novel Profilometry-Based Indentation Plastometry (PIP) technique to derive stress–strain curves for WC–Co grades (WC–10Co, WC–14Co, and WC–25Co) over a temperature range of 23°C to 800°C. PIP measurements of WC–25Co exhibited excellent repeatability, while fine- and coarse-grained WC–14Co  were successfully characterized up to 600°C. Testing of the hardest grade, WC–10Co, was limited by indenter fracture and, at 800°C, severe surface oxidation, consistent with known high-temperature tungsten behavior. These results demonstrate PIP’s potential as a straightforward and rapid method to obtain mechanical constitutive data for cemented carbides, particularly for grades or temperature ranges where conventional tensile testing is difficult. With further optimization, including indenter design and oxidation control, PIP could become a practical tool for materials development, quality control, and temperature-dependent property evaluation in hardmetals.

525 - Special Tooling Considerations for Rare Earth Magnet Production
John Gurosik,Gasbarre Products, Inc.

As demand grows for high-performance rare earth magnets—particularly for electric motors, aerospace systems, and emerging energy technologies—the industry faces increasing pressure to design tooling that can reliably form highly abrasive NdFeB powders with minimal defects despite low green strength. Yet publicly available guidance is limited, leaving manufacturers to navigate complex mechanical, material, and magnetic interactions largely on their own. This presentation outlines the key considerations that should inform tooling development for rare earth magnet production, emphasizing why advanced simulation tools and accurate materials data—not trial-and-error—are essential to achieving consistent near-net-shape performance.

Rather than disclosing proprietary designs, the talk focuses on the engineering framework required for success. Topics include the impact of NdFeB powder on tool steel and carbide selection, the need for BH and mechanical property data across both standard and non-standard tooling materials, and the competing requirement to minimize lubricants while still enabling manufacturability. The session also highlights the types of simulation environments required to model magnetic field interaction and stress distribution, as well as the significant software investment typically necessary for predictive accuracy.

526 - Axial Press Systems for Aligning and Shaping of Magnet Powders in an Inert Atmosphere
Greg Wallis, Dorst America, Inc.

For more than 40 years, Dorst Technologies is developing and supplying press and spray dryer equipment for applications within the magnet industry. This includes mainly axial presses of different kinds and sizes for manufacturing of soft ferrite, hard ferrite, rare earth magnets, and soft magnetic composites. Spray dryers are available for material preparation in the ferrite industry.

The recent developments in geopolitics have created a desire for reshoring technologies along the production chain from the raw mineral to the finished magnet within the western world.

During the last couple of years, DORST has served an unprecedented run on equipment for the compaction on NdFeB powders and gives an insight into the latest state of its modern magnet presses incl. integrated solutions for inerting & particle alignment.

527 - Next Generation Densification of High-Performance Rare Earth Magnets and Elimination of HREE
Kalen Fitch, Gasbarre Products, Inc.

Neodymium magnets are central to the performance of electric vehicle motors and many advanced technologies, yet traditional manufacturing methods limit material efficiency, particle size reduction, and achievable magnetic properties. The emerging Near Net-Shape Pressless Process (NPLP), developed by Nihon Denji Sokki (NDK) in collaboration with Dr. Masato Sagawa, represents a transformational shift in magnet production. Unlike conventional Axial Die Pressing (ADP) or Transverse Die Pressing (TDP), NPLP eliminates mechanical pressing entirely. Instead, magnets are formed by manipulating fine magnetic powders within molds containing internal magnetic fields. This enables precise control of particle alignment, supports powders with diameters approaching 1 μm—well beyond the limits of existing pressing technologies—and allows complex shapes to be produced with minimal machining.

By enabling such fine-particle processing, NPLP offers a pathway to high-performance, heavy-rare-earth-free magnets, reducing dependence on costly and scarce elements such as dysprosium (Dy). Early research indicates the potential for significant gains in magnetic performance. This presentation will introduce the principles behind NPLP, highlight its advantages in waste reduction, near-net-shape capability, and magnetic performance, and discuss implications for the next generation of electric motors and related applications.