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189 - Fabrication of Near-Full-Density 316L Stainless Steel with Mirror-Finish by Powder Design and MIM Process Control
Lanlan Liao, NBTM New Materials Group Co. Ltd.

With the growingly urgent market demand for mirror-polished dense 316L stainless steel components, MIM still faces challenges such as porosity, oxide inclusions, and grain boundary liquation during the fabrication of such parts. Furthermore, the single HIP process fails to eliminate microstructural inhomogeneity, hampering product qualification and application expansion. To address these issues, this study proposes a multiscale optimization strategy integrating powder design, process refinement, and HIP regulation. The underlying mechanisms were systematically elucidated: (1) Inclusion control: precise adjustment of carbon and oxygen content in the powder significantly reduced matrix oxygen, suppressing oxide segregation at grain boundaries; (2) Grain boundary liquation suppression: optimization of Ni/Mo equivalents improved compositional stability, while strict control of P, S, and Si impurities effectively inhibited elemental segregation and liquation; (3) Microstructural homogenization: Ni content regulation enhanced austenite stability, preventing excessive ferrite precipitation at austenite grain boundaries and eliminating surface relief defects caused by dual-phase structural differences; (4) Densification enhancement: combined HIP treatment eliminated residual micropores, achieving near-full densification (>99% relative density). 

177 - Neutron Scattering and Thermodynamic Modelling of Transition Metal Dopant Effects in Cemented Carbides
Ahmet Bahadir Yildiz, Scatterin AB

Alloying with transition metals such as V, Ti, and Cr in cemented carbides can modify phase equilibria, alter the WC/Co interface structure, and inhibit WC grain coarsening. This can accordingly influence the mechanical properties and performance of cemented carbide tools in demanding applications. In this study, we combine in-situ small-angle neutron scattering (SANS) with thermodynamic-based modelling to investigate the competitive nanostructure evolution in V-doped hard metals during heat treatments at relevant sintering temperatures up to 1500 °C.

The in-situ SANS measurements provide real-time information on formation and evolution of nanoscale carbides, i.e. interfacial layers, at the WC/Co interface, enabling direct correlation between experimental observations and modelling predictions of phase stability. Furthermore, complementary room temperature neutron diffraction investigations on Ti- and Cr-doped fine-grained grades reveal how these dopants influence the magnitude of residual stresses and promote microstructural refinement.

The combined insights demonstrate that dopants not only control the evolution of nanoscale features but also affect the residual stresses in cemented carbides. These findings contribute to an improved understanding of the coupled thermodynamic and mechanical effects of alloying in cemented carbides and provide guidance for the design of next-generation hard materials with optimized performance and reliability.

052 - Integration of Rheological Measurement into Piston-based Material Extrusion for Metal and Ceramic Injection Molding
Lennard Hermans, Fraunhofer IAPT

Piston-based Material Extrusion (pMEX) is a complementary shaping process to Metal and Ceramic Injection Molding (MIM/CIM) production routes, enabling additive manufacturing of small-series parts from standard MIM/CIM feedstocks. Analogous to a high-pressure capillary rheometer (HPCR) with a round die, pMEX uses a piston to displace a molten feedstock melt and extrude it through a nozzle. This mechanical similarity enables both part fabrication and in situ rheological characterization of standard feedstocks on the same platform. While printing capability has been validated, systematic rheological measurements and their correlation to HPCR data remain limited. In this study, pressure-flow data from pMEX are used to calculate apparent shear rate dependet viscosities, which are then corrected via Bagley and Weissenberg-Rabinowitsch methods to yield true shear viscosities. Benchmark measurements on an industrial HPCR, matched in shear-rate and temperature ranges and accounting for differing nozzle geometries, provide the basis for correlation analysis. With regard to entrance losses and pressure measurements (including transducer placement) a comparative analysis between HPCR and pMEX-based rheology is conducted to assess accuracy and industrial applicability. This study assesses the suitability of pMEX-based rheometry for precise feedstock characterization within MIM/CIM production routes, enabling rapid feedstock quality assessment alongside the capability to print green parts.

102 - “Gettering” Improved Magnetic Properties in Fe-based Soft Magnetic Composites (SMCs): Magnetic Properties Enhancement via an In-Situ Coating Approach
Vignesh Mohan, TU Wien

The behavior of soft magnetic materials at high frequencies (above 100 kHz) is a lucrative topic for high-frequency transformers, renewable energy, power electronics, medical devices, electric vehicle charging, telecommunications, and many other applications. While metal-based Soft Magnetic Composites (SMCs) offer higher magnetic saturation, their low electrical resistivities make them greatly susceptible to high eddy current losses at high frequencies. This makes coating metal-based SMCs with stable electrically insulating materials a topic of great scientific and commercial interest. “Gettering” is the removal of atoms and molecules from the gas phase by chemical reactions on an active surface. In a mechanically alloyed or pre-alloyed system, when the alloy elements ‘‘getter’’ the oxygen from the “internal” atmosphere, they form more stable oxides that can only be reduced at higher temperatures, and this is called the “Internal Getter Effect”. In this work, ring cores compacted from prealloyed Fe-Si powder were coated using an in-situ coating approach based on the internal getter effect. Tests show a reduction in energy loss (~5.87%) even at 1MHz frequency. Variation in heat treatment conditions results in a significant reduction in energy loss (~25.55% compared to uncoated samples). However, the biggest gain from this coating technique is the increase in magnetic permeability (~11.35% compared to uncoated samples). The results are discussed further. The significance of this work lies in the widespread use of electrical steel (Fe-Si alloys) and the potential for significant energy loss reduction.

While the fracture mechanical properties exhibited no significant variation between the two conditions, a measurable increase in hardness was observed in the specimens treated with the additional holding stage. These findings suggest that subtle microstructural adjustments during the transformation gap can beneficially modify the mechanical response of HSS, offering valuable insights for optimizing industrial heat treatment strategies.

099 - Development of Soft Magnetic Composite Materials for Innovative Circuit Designs in Miniaturized, High-Efficiency DC–DC Converters
Minami Akazawa, Diamet

As the demand for miniaturized and high-efficiency electronic devices continues to grow, improving the energy conversion efficiency of power converters has become a key challenge. Conventional DC–DC converters commonly use ferrite-core transformers; however, ferrite materials are prone to magnetic saturation, which limits both downsizing and efficiency, particularly under high-current operation.

To address this issue, we propose a novel power conversion circuit employing soft magnetic composite (SMC) cores. SMC cores offer excellent DC bias characteristics and a high saturation magnetic flux density, enabling both compact design and high efficiency. In this study, we have developed an improved SMC material with a relative permeability of 60 at B = 0.3 T—higher than the conventional range of 45–50—while also achieving reduced iron losses.

By integrating the improved SMC material with the newly developed circuit topology, significant miniaturization and enhanced efficiency were achieved compared with conventional circuits employing ferrite cores. This synergy between advanced magnetic materials and optimized circuit design demonstrates the potential of soft magnetic composite (SMC) cores for next-generation power electronics operating at high frequencies and high currents.

082- Performance Enhancement of Soft Magnetic Composites for Passive Applications Using an Innovative Water Based Coating Concept
Axel Persson, Höganäs AB

The development and implementation of new coating concept for soft magnetic composites (SMCs) have resulted in improved magnetic core losses, durability and productivity through improved mechanical strength. This study aims at showing the coating’s advantages for passive electromagnetic applications.

The concept has been applied on pure Fe powders with a mesh size of 200 and the results can be compared with the available Somaloy 110i 5P with same kind of base powder. A TRS value of 56 MPa can be obtained, relative 42 for Somaloy 110i 5P, and a resistivity well above 100000 µ?m, compared to slightly above 10000 µ?m for the reference material. Such components have a substantially lower maximum relative permeability of 156 compared to 220 for the reference, while having similar losses of 48 W/kg at 0.1 T and 20 kHz. The new concept hence boosts DC-bias stability while retaining low losses. Also, its thermal durability results in less than 5% increase in the losses at 20 kHz and 0.1 T.

The increased green strength of new developed material enables incorporation of higher concentrations of harder alloyed Fe-powders, such as FeSi or Sendust, mixed with pure Fe and compacted at moderate pressures so that the high frequency core losses and DC-bias stability are improved.

228 - Optimization of Sinter-Brazing Process Parameters for Repeatable High-Strength Joints for Mass-Produced Complex PM Components
Sudarshan Palve, Egearz Pvt Ltd

Sinter-brazing is an efficient technique for assembling multiple complex components together.

Combination of Sintering and Brazing into a single thermal cycle, enables efficient joining of complex components with reduced process time and cost.
However, achieving consistent Brazed joint quality, mechanical strength and controlled dimensions of the components is challenging.
This paper presents a systematic approach to improve the Sinter-Brazing process by optimizing key parameters such as RM selection, atmosphere control, thermal profile and joint design.

Experimental trials were conducted using modified furnace parameters, improving wetting behavior to enhance Brazed-joint integrity. Advanced characterization techniques including metallography and Breaking load performance evaluation were used to assess the effectiveness of the improvements. The optimized process demonstrated significant enhancements in bond strength with improved dimensional stability and repeatability.

The outcome of this study provides a practical framework of a robust and efficient sinter-brazing process.

269 - Binder Enrichment on Carbide Tools to Improve Wettability
Guruprasath Jayachandran, Kennametal

Cemented carbide cutting tools are often brazed to steel substrates prior to industrial use. Successful brazing requires tool surfaces that exhibit strong wettability with industrial braze alloys. Although the cobalt binder in cemented carbides inherently promotes good wetting, forming a consistently binder-enriched surface layer remains challenging. This study investigates the metallurgical mechanisms that enable the development of such a binder-rich layer and its influence on brazing performance.

A range of cemented carbide grades were evaluated with respect to chemical composition, sintering process, grain size, cooling rate, decarburization behavior, and sintering temperature. Experimental trials were conducted to isolate the effect of these variables, and resultant samples were characterized using microstructural analysis and X-ray fluorescence (XRF) to quantify surface chemistry.

The results indicate that finer WC grain size, slower cooling during sintering, and greater localized surface decarburization significantly promotes binder migration toward the surface. Carbide grades that achieved clear binder enrichment were subsequently tested for wettability and contact angle with common braze alloys, as well as transverse rupture strength (TRS) to ensure mechanical integrity.

This work provides a systematic understanding of the processing conditions that enhance surface binder enrichment, ultimately improving brazability and enabling more reliable carbide–steel tool assemblies.

160 - Investigating the Mechanical Performance and Microstructural Evolution of Functionally Graded (FG) and Non-Functionally Graded (NFG) Titanium Alloys Produced Through Field-Assisted Sintering Technology (FAST)
Joseph Hopkinson, University of Sheffield

Investigation of the mechanical performance and microstructural evolution of FG and NFG diffusion bonds formed between two titanium alloys during the FAST process. Billets with NFG and FG regions, composed of Ti-64 and Ti-6246, or Ti-6242 and Ti-6246, were consolidated from powder at 900°C, 965°C, or 1100°C. Three tensile specimens were machined for each condition and tested until failure. FG samples generally outperformed NFG samples in UTS and elongation. The 900°C dwell temperature was superior to higher temperatures for both NFG and FG conditions. Fractography revealed predominantly ductile failure modes. NFG samples failed in the weaker alloy, while FG conditions failed towards the central FG region. Microstructural analysis showed full consolidation of the powder for all samples. NFG conditions showed a gradually more diffuse bond with increased temperature, while FG conditions exhibited a mixed composite microstructure at lower temperatures, which gradually became more homogeneous with increasing processing temperature.

136 - Surface-Engineered AM Inconel: PVD Coating Strategies for Enhanced Performance in Severe Operating Conditions
Abul Fazal Arif, King Fahd Univ of Petroleum & Minerals

This study focuses on Physical Vapor Deposition (PVD) coating as a surface-engineering strategy for additively manufactured (SLM) Inconel 718 components intended for high-temperature and corrosive environments. Although additive manufacturing (AM) enables complex geometries, the as-built SLM surfaces exhibit high roughness and microstructural heterogeneity that limit environmental durability. PVD coatings offer a promising route to overcome these challenges by providing a dense, adherent, and oxidation-resistant surface layer.

In this work, Inconel 718 samples fabricated by Selective Laser Melting (SLM) were coated with hard nitride and ceramic films (TiAlN, AlCrN) using optimized PVD parameters. The influence of the as-built surface morphology on coating adhesion, microhardness, and oxidation resistance was systematically investigated. Surface and cross-sectional characterization using SEM, EDS, and XRD confirmed uniform coating deposition and strong metallurgical bonding. Adhesion and oxidation tests demonstrated significant improvement—coating adhesion > 20 MPa and ~2× higher oxidation resistance compared to uncoated SLM surfaces.

The results establish PVD coating as an effective surface-engineering route for AM Inconel components, bridging additive manufacturing and coating technologies toward hybrid manufacturing frameworks for aerospace, energy, and hydrogen-infrastructure applications.

140 - Enhancing the High-Temperature Performance of SLM-Fabricated Inconel Components Using Cold Spray Coatings
Abba A. Abubakar, King Fahd Univ of Petroleum & Minerals

Geometrically complex Inconel components for high-temperature energy and aerospace applications can be produced through additive manufacturing (AM) with selective laser melting (SLM). However, surface porosity, oxidation susceptibility, and poor fatigue resistance under thermal cycling are common problems with Inconel parts made using SLM. To improve the high-temperature performance and surface finish of Inconel 625 alloys made using SLM, this study investigates the use of cold spray (CS) coating as a post-processing technique. In this study, kinetic spray simulations (KSS) and finite element analysis (FEA) were used to predict the particle velocity, deformation behavior, and coating build-up efficiency under various spray parameters prior to coating. The best process parameters were found using these simulations to achieve strong bonding and high deposition efficiency. Using optimized parameters, Ni-Al₂O₃ coating was deposited on SLM-fabricated Inconel substrates using a low-pressure cold spray system. SEM, EBSD, and EDS were used to examine the microstructure and interface morphology of the resultant coatings. Adhesion strength was evaluated using scratch tests and ASTM C633 pull-off tests, and mechanical integrity and thermal stability were evaluated using microhardness and oxidation tests. The findings show that, in comparison to uncoated SLM parts, cold-sprayed coatings resulted in dense microstructures, outstanding adhesion strength, and superior oxidation resistance to SLM.

172 - Effect of Process Parameters on the Wear and Corrosion Behavior of Cold-Sprayed Nickel with Aluminum Oxide Composite Coatings on SS304
Raihan Goriya, King Fahd Univ of Petroleum & Minerals

Cold spray is an emerging solid-state coating technology widely used for surface repair, coatings, and additive manufacturing. It enables the deposition of metallic and ceramic particles without melting, minimizing thermal damage and preserving material properties. For metal matrix composites, selecting appropriate process parameters is essential for achieving high-quality coatings; therefore, this study employed a computational tool to optimize key variables and reduce experimental effort. Ni–Al2O3 composite coatings were deposited on SS304 stainless steel under systematically varied gas temperatures and pressures to assess their effects on microstructure, wear, and corrosion performance. Microstructural examination showed a strong link between process parameters and coating density, porosity, surface morphology, and particle bonding. Optimized conditions produced better particle deformation, lower porosity, and improved cohesion. Mechanical testing confirmed that coatings produced at higher gas temperatures achieved superior adhesion strength and reduced wear. Electrochemical analysis further revealed improved passive film stability and enhanced corrosion resistance under optimized spraying conditions. Overall, the results demonstrate that careful tuning of cold spray parameters significantly enhances the wear and corrosion behavior of Ni–Al2O3 coatings. These findings offer practical guidance for developing durable protective coatings for harsh environments, particularly in chemical processing and oil and gas applications.

021 - Eliminating Thermally Induced Porosity: Advances in HIP and High-Pressure Heat Treatment
Chad Beamer, Quintus Technologies

Thermally induced porosity (TIP) is a well-documented phenomenon originating from distinct mechanisms affecting multiple material systems, including cast, and additively manufactured (AM) metallic components. In castings, TIP primarily results from solidification dynamics, whereas in powder-bed fusion (PBF), entrapped gas can form voids. Heat treatment plays a crucial role in TIP evolution, often leading to pore growth and expansion, which degrades mechanical properties such as strength, fatigue resistance, and ductility which ultimately impacts product performance.

This presentation will explore TIP in castings and additively manufactured metals, emphasizing its evolution during heat treatment. Various mitigation strategies will be discussed, including the use of advanced hot isostatic pressing (HIP) technology and a novel High-Pressure Heat Treatment (HPHT™) strategy, which not only eliminate porosity but also prevent its re-emergence and expansion.

025 - Additive Manufacturing-Enabled Electroforming for Hot Isostatic Pressing (HIP) Can Production for Near Net Shape
Vanshika Singh, Oak Ridge National Laboratory

Powder Metallurgy-Hot Isostatic Pressing (PM-HIP) for near net shape (NNS) production is an advantageous alternative compared to traditional processes such as forgings and castings for complex alloy systems and geometries. Other alternative methods utilized for such complex part construction such as fusion-based Additive Manufacturing (AM) processes often induce hot-cracking due to stark thermal gradients. To de-risk cracking issues, solid-state processes like PM-HIP might offer a potential route to process such complex alloy systems. However, HIP can production is one of the most tedious and challenging variables in the entire PM-HIP process. Here, we propose leveraging electroforming for producing HIP cans of pure Ni material and infilling with metallic powder for HIP-ing. Electroforming is an electrochemical process to create metallic components by depositing metal ions onto a negatively charged mandrel. We propose to electroform pure Ni onto mandrels manufactured via Fused Filament Fabrication (FFF) – based processes to produce leak-free HIP cans. The cans are then filled with metallic powder and HIP-ed to produce solid components. This work will investigate HIP processing parameters for complex alloy systems for fully densified parts.

211 - Cold Metal Fusion - Eliminating Laser Sintering Porosity in Green Parts via Cold Isostatic Pressing
Christian Staudigel, Headmade Materials GmbH

In Cold Metal Fusion (CMF) metal green parts are produced by fusing a metal powder/polymer binder blend on polymer laser sintering machines; after solvent debinding and furnace sintering, parts typically reach ~97–99% theoretical density, implying residual porosity on the order of 1–3%. Even small residual porosity from the laser sintering step can limit final sinter density and influence mechanical properties.

This work investigates Cold Isostatic Pressing (CIP) of CMF green parts as a route to remove laser sintering porosity prior to thermal debinding and sintering. We present a process chain where CMF green parts are depowdered and cleaned, then subjected to CIP at pressures optimized for the binder metal composite to achieve uniform, isotropic compaction without damaging geometric fidelity. Microstructural characterization (optical microscopy, CT) and density measurements (Archimedes and image analysis) quantify porosity reduction in the green state and after sintering. Mechanical testing evaluates the influence of green state CIP on final properties.

Results show that CIP reduces green porosity enabling higher final sinter densities, which results in improved mechanical properties compared with non CIP. These findings align with prior studies combining selective laser sintering and CIP for ceramic and metal systems, which report enhanced densification and strength when green parts are isostatically compacted before sintering. The study also discusses practical considerations for integrating CIP into CMF production, including tooling, allowable feature sizes, and binder removal compatibility.

164 - Improved Mechanical Properties of Metastable Beta Titanium Alloys with Bi-Lamellar Microstructure via Additive Manufacturing
Jingzhe Niu, Northwest Institute for Nonferrous Metal Research

Metastable beta titanium alloys is one of the important types of titanium alloys that widely applied in aerospace and aviation industries. With the demand of complex parts and rapid near net shaping been proposed these years, the performance of these alloys under additive manufacturing (AM) methods are gained more attention. However, due to the relatively low phase stability of -matrix, such alloys are suffering from extreme fine precipitate and low elongation in laser based AM technics and require complex post-processing treatments to satisfy the design performance. In this study, two typical AM processes including Direct Energy Deposition (DED) and Electron Beam Melting (EBAM) with different energy input are carried out to study the mechanical performance as well as strengthening mechanism of high strength Ti-5Al-4Cr-4Mo-4V-3Zr alloy. By utilizing high energy input and low cooling rate during the EBM process, samples manufactured via high-energy electron beam melting (HE-EBAM) developed a bi-lamellar heterogeneous microstructure, resulting in an averaged ultimate tensile strength of 1152±22 MPa with an elongation of 13.8±1.3%. These mechanical properties are comparable to those of the alloy in its forged state after solution and aging treatment. The overall findings could provide further insight for the future AM techniques and applications of near- and titanium alloys.

168- Study of Microstructure and Mechanical Properties of Metastable Beta Titanium Alloy Manipulation by Electron Beam Powder Bed Fusion
Xuezhe Zhang, Northwest Institute for Nonferrous Metal Research

The Ti-1Al-8V-5Fe (Ti-185) alloy, a leading ultra-high-strength metastable ?-titanium alloy, was first developed in the 1950s in the United States. Conventional melting techniques frequently result in iron segregation and the formation of "? flecks," which severely compromise the alloy's mechanical performance. To address these issues, multiple remelting cycles, hot deformation processes, and subsequent heat treatments are typically employed. While these methods reduce compositional segregation, they also increase production complexity and costs, particularly for manufacturing intricate components. In contrast, additive manufacturing (AM), characterized by its localized melting pool and rapid cooling rates, provides an opportunity to fabricate Ti-185 alloy with a uniform composition. This presentation explores the preparation of Ti-185 alloy via electron beam powder bed fusion (EB-PBF), focusing on its microstructure and mechanical properties, including room-temperature tensile performance and work-hardening behavior. Additionally, targeted alloy composition optimization was undertaken to directly achieve high-strength Ti-185 alloy.

013 - Fatigue Properties for High Productivity L-PBF with Ti-6Al-4V
Kevin Janzen, Fraunhofer IAPT

Laser Powder Bed Fusion (L-PBF) enables the production of complex metallic components but remains limited by low productivity and high cost. Increasing scanning speed can improve throughput but often reduces density and mechanical performance. This study examines the use of hot isostatic pressing (HIP) to restore mechanical integrity and fatigue strength in Ti-6Al-4V parts produced at elevated scanning speeds.

Components with initial densities 95% were HIP-treated to achieve >99.8% density and subsequently tested under cyclic loading. Despite the initial porosity, HIP-treated parts showed fatigue performance comparable to conventionally processed L-PBF specimens. Microstructural analysis revealed complete pore closure and enhanced mechanical properties. The combination of high-speed L-PBF and HIP thus expands the process window, enabling higher productivity without compromising fatigue resistance, and improving the economic feasibility of additive manufacturing for demanding applications.

027 - Effect of WC Extracoarse Grains on the Sinterability of WC-Fe-Ni-Co Cemented Carbides 
Tomás Soria Biurrun, CEIT-BRTA

This study explores the effect of extra coarse WC grains on the sinterability and microstructural evolution of WC-Fe-Ni-Co cemented carbides. Samples were produced via conventional powder metallurgy using WC particles with average sizes of 10 and 20m, and sintered under controlled conditions. The use of extra coarse WC grains was found to reduce the driving force for densification due to their lower surface area and slower grain boundary diffusion. Additionally, the Fe-Ni-Co binder system exhibited poorer wetting and diffusion behavior compared to traditional cobalt binders, further limiting sinterability. Despite these challenges, microstructural analysis revealed smoother WC grain morphologies and a suppression of abnormal grain growth and reprecipitation phenomena. These features contribute to a more stable microstructure and potentially improved toughness. The results suggest that combining extra coarse WC grains with a Fe-Ni-Co binder can produce cemented carbides with balanced mechanical properties, particularly suitable for mining applications demanding high impact resistance and thermal stability. 

139 - Formation Mechanism of Plate-Like WC Grain in WC-Co Cemented Carbides Fabricated by Plasma Milling
Min Zhu

The promotion of hardness typically comes at the expense of toughness, posing a challenge for the creation of high-performance WC-Co hardmetals. In this study, a recently developed milling method known as plasma milling, along with its fundamental principles, was introduced. Furthermore, the application of plate-like WC crystals, based on plasma milling technology, in the preparation of high-performance WC-Co cemented carbide was summarized. In this study, WC-10Co cemented carbide with plate-like WC grains was directly fabricated by sintering a mixture of plasma-milled WC and 10 wt% Co powder. Owing to the characteristics of WC powders prepared by plasma milling—such as high specific surface area, broad particle size distribution, and the formation of nano-sized WC grains with prismatic and basal planes—these features facilitate the rapid growth of nano-sized WC grains into plate-like WC seeds at 800–1000, as well as the formation of large plate-like WC grains at 1100–1300. Furthermore, the morphology and size of plate-like WC grains can be regulated by controlling the plasma milling time, and the influence of plate-like WC grains with different morphologies on the mechanical properties of cemented carbides was revealed.

069 - Low-Voltage SEM Observation near Fracture Origins in Ultrafine-Grained Cemented Carbides
Masaru Kawakami, Fujidie. Co., Ltd

Fracture surfaces of cemented carbides after transverse rupture strength (TRS) testing consistently reveal characteristic defects that act as fracture origins. In ultrafine-grained cemented carbides, which are generally subjected to hot isostatic pressing (HIP) during manufacturing, pores are effectively eliminated and therefore not observed as fracture origins. Instead, coarse or agglomerated WC grains are identified as the fracture origin. These microstructural features are of particular interest in understanding the fracture mechanisms of such materials. In this study, we performed low-voltage scanning electron microscopy (SEM) observations to closely examine the regions surrounding WC grains associated with fracture origins. This technique enabled detailed visualization of grain boundary morphology and interparticle bonding conditions. Although the direct influence of these features on fracture behavior is still under investigation, the observations provide valuable insight into the local structural characteristics near fracture origins. The findings are expected to contribute to a more comprehensive understanding of fracture processes in ultrafine-grained cemented carbides and to support future efforts aimed at improving their mechanical reliability and performance.

192 - Critical Factors Affecting Tungsten’s Ductility through Microstructural and Mechanical Analysis of Annealed Rolled Tungsten 
Zhigang Zak Fang, FAPMI, University of Utah

This work focused on the critical factors controlling tungsten's ductility. Mechanical and microstructural analysis were performed on a set of rolled and annealed tungsten samples with annealing temperatures up to 1400 C. Results showed that the ductility of rolled tungsten can be maintained with some improvement during annealing up to 1200 C, but suffered severe degradation after recrystallization at temperatures above 1350 C. Rolled tungsten had a clear {100}<011> -fiber texture with a preponderance of edge dislocations and low angle grain boundaries. The texture and the proportion of low-angle grain boundaries diminished after recrystallization above 1400 °C. Based on experimental results and analytical modeling, the critical factors contributing to tungsten's ductility include the extent of microstructural texture, the fraction of low-angle grain boundaries, and the edge dislocation density.

107 - High Ductility in As-Sintered Mo Produced by Pressureless Sintering 
Ian Dowding, Foundation Alloy

Powder metallurgy and mechanical alloying offer a powerful pathway for improving the ductility and processability of molybdenum and other refractory metals traditionally constrained by intrinsic brittleness. Through controlled non-equilibrium alloying and fine-scale microstructural refinement, these techniques enable property enhancement beyond the limits of conventional powder metallurgy routes. This work examines a processing sequence combining mechanical alloying, cold isostatic pressing, and pressureless sintering to achieve dense, ductile molybdenum-based alloys. Emphasis is placed on how powder characteristics, defect structures, and phase distributions evolve through each step and their collective influence on mechanical response. Results demonstrate that carefully tuned processing conditions can produce high-performance refractory alloys with improved ductility and manufacturability suitable for extreme environments.

194 - Small-Scale Mechanical Testing of Novel Tungsten Alloys for Alternate-Energy Applications
Blake Emad, University of North Texas

Tungsten and its alloys are prime candidates for plasma facing materials (PFMs) in the first fusion devices due to their ability to withstand extreme working conditions such as high operating temperatures, ion and neutral particle impact, and related sputtering events. However, the intrinsically low ductility of tungsten, due to non-planar screw dislocation core structure, in addition to weak grain boundary cohesion resulting from powder metallurgy, pose major challenges in application. Rhenium (Re) alloying, potassium (K)-doping, and thermo-mechanical processing can significantly improve the ductility of tungsten and lower its brittle-to-ductile transition temperature (BDTT). Here, we report on the structure-property relationships in tungsten-rhenium alloys with and without K-doping and compare with thermo-mechanically processed unalloyed tungsten. K-doping led to substantial grain refinement with average grain size of ~ 2 µm, an order of magnitude lower compared to the tungsten-rhenium alloy and unalloyed tungsten. The Vickers hardness for the tungsten-rhenium alloy was ~ 10% lower than the unalloyed tungsten, consistent with previously reported solid-solution softening effects associated with Re addition. However, potassium doping effectively mitigated this softening and led to extensive grain refinement, enhanced activity of mixed character dislocations, and increased fracture toughness. Electron channeling contrast and TEM were used in alloy structure determination. 

604 - Scaling Titanium Alloy Sinter-Based Manufacturing with Spark Plasma Sintering (SPS): Commercial Pathways for High-Performance, U.S.-Based Production
Eric Eyerman, California Nanotechnologies

California Nanotechnologies (Cal Nano) is deploying Spark Plasma Sintering (SPS/FAST) to enable scalable, high-performance production of titanium alloy components for aerospace, defense, energy, and advanced industrial applications. As demand accelerates for domestic titanium part manufacturing, SPS offers a commercially viable alternative to traditional press-sintering, HIP, and subtractive routes delivering faster cycle times, higher densities, and significant reductions in machining and scrap.
•    This presentation will highlight Cal Nano’s production-oriented approach to sinter-based titanium manufacturing, including:
•    Consolidation of Ti-6Al-4V and advanced Ti alloys into near-net-shape parts 300+ mm diameter using industrial 85 kA MSP-5 system.
•    Cycle times under one hour, enabling rapid iteration, low WIP, and higher asset utilization compared to conventional furnace sintering.
•    Demonstrated pathways for reducing downstream machining, tool wear, and material waste.
•    Integration of cryogenic milling when required for powder refinement, homogeneity, or alloy development.
•    Cost, throughput, and quality considerations for transitioning from prototype parts to multi-hundred-unit production orders.
•    Key application spaces where sinter-based Ti components offer a competitive advantage, including hypersonics, space structures, armor systems, and thermal-mechanical hardware.
Cal Nano’s experience bridging R&D programs into repeatable manufacturing provides a practical roadmap for organizations seeking U.S.-based, scalable Ti alloy production using sinter-based methods.

605 - On the Mechanical Performance of Functionally Graded Titanium Alloy Powder Consolidated Through Field-Assisted Sintering Technology (FAST)
Martin Jackson, University of Sheffield

Titanium components are typically composed of a single monolithic alloy with a largely homogeneous microstructure throughout the component, limiting the range of mechanical properties. Different sub-component regions can experience different primary failure mechanisms, so components are over-engineered based on the most extreme conditions any sub-component region experiences. A component with regions of distinct mechanical properties, due to a tailored alloy chemistry and microstructure could enable designers to drive down component weight through enhanced material optimisation.

This paper investigates the mechanical performance of both functionally graded (FG) and non-FG (NFG) diffusion bonds between dissimilar titanium alloys generated during field-assisted sintering technology (FAST). FAST utilises a pulsed DC and a uniaxial pressure to fully consolidate powders within its reusable graphite tooling. Two alloy combinations were examined: Ti-64 // Ti-6246 and Ti-6242 // Ti-6246, both sintered at dwell temperatures around their respective beta-transus temperatures. Tensile specimens for both FG conditions, alloy combinations, dwell temperatures, and the respective monolithic alloys were tested until failure. This was followed by a thorough microstructural and fractographical analysis of the specimens.  

606 - Material Extrusion Based Additive Manufacturing of Ti-6Al-4V Alloy
Animesh Bose, FAPMI, Shaping Innovations LLC

Additive Manufacturing (AM), which allows the fabrication of complex shaped parts without any tooling, offers the possibility of enabling the creation of novel designs at a quicker pace (shorter time to market) and a lower cost. Complex near net shaped parts fabricated by AM reduces material waste by eliminating the need for extensive bar stock machining of an expensive material like Ti-6Al-4V alloy which is also difficult to machine. In this material extrusion (MEX) process, the geometric shaping step and the final consolidation step (using sintering) are separate steps. The MEX process does not use loose powders during the shaping step of the process leading to the ability to print the material close to ambient temperature. The MEX process, other than the printing part, has other steps that are similar to the MIM process. The major processing steps in MEX include forming the feedstock, printing the 3-D shape, debinding (removal of a significant part of the organic binder), followed by sintering. Several different peak sintering temperatures have been explored. This presentation discusses the processing, microstructure, and properties of Ti-6Al-4V alloy using the MEX process utilizing a metal injection molding (MIM)-based feedstock.

510 - Latent and Ubiquitous AI: The Future of Machinery
Steve Schmid, University of North Carolina Charlotte

511 - Practical Integration of Machine Learning in Powder Metallurgy and Additive Manufacturing:  Methods, Challenges, and Sustainability
Simon Gelinas, Laval University

Advances in the field of artificial intelligence (AI) and machine learning (ML) are providing researchers with new tools that facilitate the development of cutting-edge materials. These increasingly accessible innovations support a wide range of aspects, from identifying the factors that influence the properties of tool steel powders for additive manufacturing, to optimizing the chemical composition of new grades and characterizing their microstructures. Using concrete examples of ML applied to PM and AM research, along with open-source programs and Python libraries, this presentation provides a clear overview of the steps involved to set up, run, and interpret results from an ML pipeline for those without a data science background. Special attention will be given to practical challenges, best practices, and common pitfalls when applying ML to materials research. By exploring real-world AI applications, including their environmental implications and comparisons with more traditional approaches, this talk invites researchers to consider how these technologies can be integrated responsibly into PM and AM research.

512 - An Intelligent Framework for Alloy and Process Development: Toward Tailored Tool Steels for Laser Powder-Bed Fusion
Justin Plante, Laval University

Additive Manufacturing by Laser Powder-Bed Fusion (LPBF) offers innovative pathways to enhance the performance and functionality of tooling components. However, processing of tool steels such as H13 via LPBF remains challenging. Originally designed for conventional manufacturing routes, these alloys are not adapted to the rapid solidification and thermal cycling characteristics inherent to LPBF. As a result, cracking is frequently reported, significantly limiting the reliability of LPBF-processed tool steels and hindering their broader industrial adoption. To address these limitations, new tool steels specifically tailored for LPBF must be developed.

Recent advances and the democratization of machine learning (ML) provide powerful tools to address these challenges. ML enables data-driven approaches that can efficiently process large and diverse datasets to uncover patterns and correlations among variables. In materials engineering, these capabilities can accelerate both alloy development and process optimization. In this work, various ML techniques are employed to gain insight into the complex relationships among alloy chemistry, processing conditions, and cracking behavior of LPBF-processed tool steels. This framework supports the development of more robust alloys and optimized manufacturing strategies, contributing to improved reliability and wider industrial deployment of LPBF for tooling applications.