WorldPM          AMPM        TNT Presentations

041 - Compatibility of Catalytic Debinding Binders with Metal Powders in Metal Injection Molding
Yoshiki Shirai, Asahi Kasei Corporation

Metal Injection Molding (MIM) relies heavily on binder systems composed of various chemical constituents to facilitate powder shaping and subsequent debinding. Among these, catalytic debinding binders—particularly those based on polyoxymethylene (POM)—are widely adopted due to their high processing efficiency and low residual content. POM decomposes cleanly under acidic conditions, making it a promising candidate for catalytic debinding.

However, the interaction between POM and metal powders during mixing presents significant challenges. The premature decomposition of POM in the presence of certain metals can lead to the release of formaldehyde and alter the chemical composition of the sintered body, thereby compromising product quality and process stability.

This study investigates the compatibility between various metal powders and catalytic debinding binders, with a focus on understanding the reactivity and potential adverse effects during the MIM process. Our findings provide insights into binder-metal interactions and offer guidance for selecting binder systems that ensure both safety and performance in industrial applications.

203 - Safer & Greener Catalytic Debinding Technology for MIM and Metal AM
Stefan Joens, Elnik Systems, LLC

Depending on the process, debinding has historically been too slow, imperfect, or dangerous due to hazardous chemicals. It’s been quite challenging to identify a cost-effective solution that is reliable and repeatable. As metal injection molding and metal additive manufacturing technologies become more commonplace in expanding markets (firearms, jewelry, consumer products), so does the need for high-quality complementary tools such as debinding, sintering, machining, and finishing. Furthermore, these new markets are heavily reliant on consumer adoption and require greener and safer solutions that align with ESG (environmental, social, and governance) initiatives. A recent innovation in debinding technology has been the replacement of harmful chemicals, such as nitric acid, with oxalic acid, a proven debinding solution for metal and ceramic parts. 

Stefan introduces the latest technology advancement in catalytic debinding. With decades of experience in debinding, sintering, metal injection molding, and metal additive manufacturing, the Elnik team pushes a technology upgrade that will enable better technology adoption and greener results. 

Compare conventional debinding processes with the latest technology. Understand the speed, safety, and scientific considerations of oxalic acid debinding. 
Explore the technological landscape of oxalic debinding and relevant use cases.  

204 - Sintering for Scale & Lessons Learned from Metal Injection Molding 
Stefan Joens, Elnik Systems, LLC

Debinding & sintering experts, Elnik Systems and DSH Technologies, have over 50 years of industrial sintering experience, specifically in the metal injection molding industry. With the continual development of binder jetting and metal filament fabrication, Elnik has been called upon to help develop a seamless workflow that takes full advantage of the design benefits afforded by AM and the scalability promise that may seemingly rival metal injection molding.  However, sinter-based additive manufacturing is still in its infancy compared to the worldwide usage of metal injection molding, primarily due to technology maturity and lack of experience or knowledge in the field. 

In this presentation from Stefan will share the secrets to sintering for scale and lessons learned in the metal injection molding industry. Unfortunately for most, the tribal knowledge required for sintering to succeed remains difficult to obtain, but Elnik’s mission to further evangelize the technology and standardize the workflow will be on full display. 

Learning Objectives:
Understand the basics of sinter-based additive manufacturing and the similarities with metal injection molding. 
Learn about the material options and operational recipes used in the debinding and sintering process. 
Uncover the lessons learned from metal injection molding, most notably related to the serial production of parts and the need for high fidelity materials and quality management systems.

186- Effect of Vacuum Conditions on the Densification and Chemical Composition of Sinter Based Additively Manufactured Ti-6Al-4V
Giorgio Valsecchi, TAV Vacuum Furnaces SPA

Sinter Based Additive Manufacturing (SBAM) technologies offer a cost-effective alternative to conventional methods for producing complex titanium geometries. However, the thermal processing of reactive metals like Titanium Grade 5 (Ti-6Al-4V) presents severe metallurgical challenges. The material’s high affinity for interstitial elements, specifically oxygen, nitrogen, and carbon, at elevated temperatures necessitates rigorous atmospheric control to prevent alpha-case formation, embrittlement, and loss of ductility.

This study investigates the critical role of sintering atmosphere by processing MoldJet fabricated Ti-6Al-4V green parts under distinct conditions including high vacuum, medium vacuum, and controlled partial pressures of argon.

Comprehensive analysis of the sintered samples included Archimedes density measurements, interstitial chemical analysis, and mechanical testing.
The study aims to define operational windows that minimize interstitial contamination, providing the data necessary to optimize the trade-off between component quality and production costs.

276 - Using Controlled Atmospheres to Maximize Sintering Production Rates Using Less Energy and Lowering Emissions
Daniel Enoch, Messer North America

While using nitrogen and hydrogen atmospheres for sintering is well established, the chemical energy of the hydrogen utilized and vaporized lubricants is most often unused as atmosphere constituents are vented at the furnace exhausts.  Attempts have been made to redirect this energy to help pre-heat parts being sintered, often by adding a small section in advance of the pre-heat section of the furnace.   This paper presents a systematic implementation of such techniques to utilize the chemical energy present in combustible atmosphere constituents, and the benefits a producer achieved.  The paper also discusses how  computational fluid dynamics were used to and precise control was achieved while adhering to industry standards and best practices.

179 - Comparing Various Delube-Assist Systems Used in PM Sintering Furnaces
Harb Nayar, FAPMI, TAT Technologies LLC

The main bottleneck in the PM press and sinter industry is most often the delubing portion of the sintering process.  Many Systems have been developed during the past 50 years to improve the delubing part of the sintering cycle. These delube-assist systems can be broken down into 4 unique systems dependent upon what atmosphere is externally injected into the delube section of the sintering furnace:
1. Wet N2-Developed by BOC
2. Natural gas and Air to produce Exo gas developed by Drever, Sinterite, Abbott, Sarnes & Cremer
3. Pre-Heated air developed by TAT
4. Steam and N2 developed by Abbott

Only category 2 uses natural gas. All others use N2, air or externally generated steam.
Each system has its own pluses and minuses.

Using software developed by TAT, this paper compares the THERMODYNAMICALLY generated gaseous compositions, that the “green” pressed PM parts are exposed to within the delube section of the furnace for each of the four (4) different systems. The same software calculates how much energy is required (or generated) for each of the four (4) systems. The software calculations will show that both the gaseous compositions and the energy values are significantly different for the four (4) systems. Ease of operation and maintenance of each system will also be covered.

034 - Investigation of Initial Workpiece Adhesion on CVD TiN, TiC and Aluminum Oxide Coatings During Stainless Steel Machining
Larissa Sirtuli

Adhesive wear is a common cause of tool degradation during stainless steel machining. This study investigates the adhesion phenomenon during the early stages of AISI 316Ti turning using CVD-coated cemented carbide tools with TiN, TiC and Al2O3 top layers. All coatings were deposited on Ti(C,N) and cemented carbide. TiN and TiC coatings were tested in as-deposited and top-blasted conditions, while Al2O3 was evaluated only in the top-blasted condition. Blasting flattened the surface grains of TiN and TiC, resulting in slightly lower adhesion during turning, while the as-deposited coatings exhibited more pronounced surface asperities that increased mechanical anchoring between workpiece material and coating. TiN and TiC, despite their well-known differences in mechanical properties, showed similar adhesion behavior and regions of cemented carbide exposure after 0.3 m of cutting, suggesting that adhesion is a key factor in their early failure. Although adhesion was also observed on the Al2O3 coating, the Al2O3 area covered by adhered material after 0.3 m of cutting was approximately 40% smaller than that measured on TiN and TiC. Wear on Al2O3 tools was first observed after 1 m of cutting. These results demonstrate that adhesion plays a important role in premature coating wear and highlight the importance of optimizing coatings to improve tool performance in stainless steel machining.

095 - On the Fabrication of Carbide-Reinforced Inconel Coatings Through Laser Processing of Metal-Polymer Films
Carlos Matos, Universidade de Aveiro

The ever-increasing demand for high-performance components, in sectors such as aeronautical and automotive, that are able to sustain harsh oxidative environments at high temperatures, is pushing the development of high-performance coatings that can minimize wear rate and oxidation, while imparting other functionalities. Different materials have been studied and applied for these coatings production, such as the carbides TiC, SiC, WC and B4C. In this work, a novel approach is explored, namely the production of a pliable metal loaded-polymer film, loaded with Inconel alloy and carbide powders, processed through a tape casting technique. The use of these films allows the coating of non-planar surfaces and, most importantly, also enables the opportunity to fine tune coating composition, allowing tailored properties. We demonstrate how laser technology can be used to create the Inconel-based coating on stainless-steel substrates, that are then characterized regarding densification and microstructure.

178 - Analysis and Design of Multi-Element Alloys in Powder Metallurgy 
Ali Akbar Yadollahi Heydarabadi  

This research focuses on the development of multi-element alloys within the powder metallurgy process. The main objective of this project is to enhance the mechanical and resistant properties of alloys through precise design of powder compositions. This study introduces novel methods for powder production and processing, which include advanced compaction and forming techniques. The results demonstrate a significant improvement in the characteristics of the produced materials, highlighting their potential for industrial applications. The findings could contribute to the enhancement of manufacturing processes and the optimal utilization of multi-element alloys in the industry.

247 - Cold Spray Deposition of Soft Magnetic Powders with In-Situ Thermite Reaction for Oxide Network Formation
Fabrice Bernier, National Research Council Canada

Cold spray additive manufacturing is a high-throughput route that can be used to produce complex-shaped soft magnetic components with excellent mechanical integrity. In this work, an oxidized iron powder was coated with aluminum layers of 50 nm and 100 nm to improve deposition efficiency and, during post-deposition heat treatment, initiate an in-situ thermite reaction that generates a continuous oxide network providing electrical insulation to limit eddy currents. Deposition trials at 950°C produced dense, defect-free coatings for both aluminum thicknesses, with the 100 nm layer yielding a higher deposition rate. Heat treatments under nitrogen allowed the identification of the thermite reaction onset near 950°C, producing Al-rich and Fe-rich oxides that form the insulating network, although excessive reaction or iron sintering led to coating discontinuities. Particle size distribution analysis, scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS), and transmission electron microscopy (TEM) observations at each stage from powder modification through component testing provided detailed insight into coating uniformity and microstructural evolution. Magnetic characterization showed permeability improvements after heat treatment, with the best balance of properties achieved when the in-situ reaction was initiated but carefully controlled to preserve insulation continuity. 

056 - Magnetic Properties Optimization and Mechanisms Explanations for Cold Sprayed SmCo Permanent Magnets
Jael Giguère, Ecole Polytechnique

The additive manufacturing (AM) of permanent magnets has gained significant attention in recent years. The possibility for complex geometries and efficient material utilization puts AM as a more sustainable manufacturing method for components containing critical materials such as rare-earth elements and cobalt. While AM of permanent magnets has been studied by many research groups around the world, few studies explain thoroughly the effect of process parameters on the magnetic properties and the underlying mechanisms behind properties degradation. Indeed, it is often observed that the remanence and/or coercivity of the AM permanent magnets are lower than the initial powder feedstock, but the explanation of this decrease is not often presented. This work focuses on the cold spray additive manufacturing (CSAM) of SmCo-based permanent magnets with aluminum or copper binder to optimize the fabrication parameters, and suggest explanations for the decrease of magnetic properties observed: volume fraction of magnetic material in the final magnet, mechanical stress in the deposits, change in the crystal structure of the SmCo hard magnetic phase. The magnets are characterized using optical microscopy (microstructure), vibrating sample magnetometer measurements (magnetic properties), X-ray diffraction (phases) and transmission electron microscopy (SmCo crystal structure). The best as-fabricated magnet presented a SmCo volume fraction of 66%, a remanence of 0.433 T, a coercivity of 730.2 kA/m and a BHmax of 29.89 kA/m.

265 - Rethinking Powder Specifications: Utilization of Wide and Off-Size PSD Powders for LPBF Processing of Ti64
Mahdi Habibnejad Korayem, Colibrium Additive – GE Aerospace

Laser powder bed fusion process is an additive manufacturing process that utilizes a laser to fuse powders in a bed and typically utilizes fine powders with a narrow particle size distribution, in the range of 15–45 ?m. Powder properties such as morphology, mean size and particle size distribution affect the flow properties of the powder, which in turn have strong effects on the performance of the final part. Previous work surrounding metal powders used in additive manufacturing focuses on the relationships between powder particle size distribution and flow properties. However, relationships between powder particle size distribution (PSD) and mean size to mechanical properties such as yield strength, tensile strength, dimensional accuracy, surface roughness, and fatigue have not been explored. This work attempts to determine if “offsize powders”, or coarser powder size distributions can produce viable parts for LPBF. Four plasma atomized powders with various oxygen contents and particle size distributions (PSD) were prepared by introducing powders in the 15–106 ?m range. The powders were characterized for chemistry, and flowability then printed. Parts were characterized for strength, hardness, porosity surface roughness and dimensional accuracy. The offsize powders displayed comparable flowability and flow properties to that of the benchmark or traditionally used powder. The explosivity of the powders significantly decreased by lowering the fines fraction of the powder, resulting in up to an 84 % reduction in explosion severity (KST) and an increase in minimum ignition energy (MIE) of up to 3000 %. Wit

202 - Optimization of the Chemical Composition and Heat Treatment of Ni-Hard Alloys for the Metal Binder Jet Process
Christopher T. Schade, FAPMI, Hoeganaes Corporation

In general, hard materials for tooling and wear resistant applications are very difficult to machine, with the most common forming method being grinding. Utilizing a grinding operation severely limits the shape of the final product which can be achieved.  Additive manufacturing (AM), specifically, Metal Binder Jetting (MBJ) allows for intricate shapes to be formed for most all alloy materials. In a previous paper a Ni-Hard composition typical of castings was introduced for use in additive manufacturing. The chemical composition has now been altered to take advantage of the processing route used in the MBJ process, mainly the sintering process. The mechanical properties of this new alloy are optimized through various heat treatments to optimize the hardness of the carbides along with the matrix. The various heat treatments, microstructures along with the hardness and abrasion resistance are studied in samples produced from the MBJ process.

145 - Influence of Percent Binder Composition and Print Orientation on Green Strength in Binder Jet Additive Manufacturing
Elrik Heaney, Advanced Powder Products, Inc.

Binder jet additive manufacturing enables rapid, high-resolution fabrication of complex metal components, yet low green strength impedes efficient de-powdering and handling. This study quantifies how binder percent and print orientation affect the green flexural strength of printed parts. Test specimens were fabricated using seven binder compositions (1.35–1.97 wt%) and printed in three distinct build orientations, then evaluated via three-point bend tests to determine flexural strength and modulus. At lower binder contents, green strength values across all orientations were tightly clustered, indicating minimal binder-driven heterogeneity. As binder increased, strength rose but variability also expanded. Parts printed perpendicular to the powder-spreading/binder-infiltration plane exhibited a 56% decrease in strength at low binder and a 40% decrease at higher binder relative to the two orientations printed coplanar to the layer plane. Within the coplanar group, printing with the part’s wide edge on the build plate produced a small, non-significant reduction in strength and modulus relative to the narrow-edge configuration. Green strength followed a power-law growth with binder composition, indicating diminishing returns at higher binder ratios and suggesting a binder threshold beyond which additional binder offers little improvement and remains far below sintered properties.

094 - Towards Dimensional and Compositional Accuracy in Binder Jetting: An Investigation of Process Parameter Optimization and Binder Burn Off
Alexandra Darroch, University of Waterloo

Current challenges in the realm of copper binder jetting (BJT) include high final porosity or altered chemical composition after sintering. These may result from residual binder or premature part shrinkage during densification. In order to produce complex functional copper structures in BJT, understanding the inherent dimensional inaccuracy of the manufacturing process and determining appropriate de-binding and sintering schedules are essential. The first stage of this work will investigate the effect of varying process parameters on the dimensional accuracy of fine features in both the green and sintered states. Binder saturation is one such process parameter which affects the strength of the green parts as well as the achievable resolution of fine features and final carbon content. Dimensional fidelity will be evaluated using image analysis techniques to compare achievable feature size to that of the CAD model. An optimized set of printing parameters will be selected before proceeding to the second phase of the work, which proposes to address the problem of carbon-rich areas within the matrix due to binder residue, commonly resulting in high porosity and decreased thermal or electrical properties of the part. De-binding under inert, reducing, and oxidizing atmospheres will be investigated to determine if superior carbon content removal can be achieved before the final sintering step. Optical dilatometry will be implemented during sintering to observe the shrinkage and distortion of fine features in real time. 

055 - Electrical Conductivity of Additively Manufactured Conductors at Cryogenic Temperatures
Alexander Goodall, University of Sheffield

High-performance electrical conductors are crucial for advanced cryogenic applications, most notably in superconducting magnet systems, fusion reactors, and high-efficiency power-dense electrical machines. Exploring future electrical machines for the electrification of aerospace, additive manufacturing (AM) can offer enhanced geometrical complexity, higher slot fill factors, advanced loss management as well as direct thermal cooling of the windings via liquid or gaseous cryogenic fluids. This presentation explores the application of Additive Manufacturing (AM), specifically Laser Powder Bed Fusion (LB-PBF), to fabricate high-purity electrical components from aluminium and copper. Detailed process mapping exploring laser energy density, build angle, and powder quality, is undertaken to correlate resulting material density and defects with electrical properties. X-ray computed tomography was used to observe porosity, which was found to concentrate around the joint between contours and fill hatches, leading to concerns that high frequency properties will be degraded. Direct current electrical characterisation was conducted at ambient temperature and at 77 K in liquid nitrogen, demonstrating conductivities of 420% IACS for aluminium and 820% IACS for copper, within the range of traditionally processed materials. The findings confirm the viability of AM for creating next-generation, high-conductivity components essential for future cryogenic technologies such as electrical propulsion of aircraft.

073 - Laser Powder Bed Fusion of an Al-TM-RE Alloy
Buket Yilmaz, McGill University

The drive to develop laser powder bed fusion (LPBF) for high-strength aluminium alloys is leading to the increasing creation of new compositions containing a variety of alloying elements, as the commonly used high-strength wrought variants are not compatible with the LPBF solidification conditions. These new alloys are mostly designed on a mixture of transition (TM) and rare earth (RE) elements to provide strengthening. This presentation will showcase the results obtained for an aluminium alloy containing nickel (Ni), gadolinium (Gd), zirconium (Zr) and scandium (Sc) as alloying elements. In its as-printed condition, the alloy sample exhibited a microhardness above 200 HV, nearly double that of most high-strength LPBF-designed aluminum alloys. The as-built microstructure was studied to understand the solidification path and phase formation. The same analysis was performed on the initial powder to demonstrate the impact of the cooling rate. Printed coupons were also exposed to various heat treatments to investigate the stability of the microstructure and its effect on microhardness.

207 - Comparison of Material Properties of Additively Manufactured C-Alloyed Molybdenum and TZM up to 1,500 °C
Benedikt Distl, Plansee SE

Utilizing a customized Powder Bed Fusion – Laser Beam (PBF-LB) machine, C-alloyed molybdenum (MoC0.4) can be processed on an industrial scale, reproducing results achieved on a lab scale. MoC0.4 has a unique fine-grained microstructure characterized by a subgrain structure consisting of small nanometer-sized molybdenum cells embedded in a Mo2C-matrix inside the molybdenum grains. This refined microstructure leads to promising mechanical and physical properties, comparable to those of conventionally manufactured TZM, a commonly used molybdenum alloy, up to testing temperatures of 1500 °C. Combined with the design freedom enabled by the PBF-LB process, MoC0.4 is a key enabler for high-tech refractory metal products of tomorrow, especially for structural applications at temperatures above 1000°C.