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100 - Surface Modification of Pure Iron Materials Using Iron-High Carbon Alloy Mechanical Alloying Powder
Shigehiro Kawamori, Tamagawa University

In this laboratory, we fabricated spark plasma sintered (SPS) compacts using Fe-30 vol% (10.9 mass%) alloy mechanical alloying (MA) powder (Fe-30 vol% C powder), a high-carbon Fe alloy containing more carbon than carbon steel. The results showed that these compacts are lighter and harder than conventional steel materials, and exhibit superior lubricity and wear resistance. Therefore, as a prototype, Fe-30 vol% C powder was coated on pure Fe plate using the SPS method. This improved lightness and surface hardness, but the adhesion between the coating layer and the pure Fe plate was poor. In this study, Fe- high C/Fe laminates with high adhesion between the coating layer and pure Fe material were fabricated by varying the carbon content of the Fe- high C alloy MA powder coated on the Fe sheet metal and the sintering temperature during SPS processing. The surface modification effect and adhesion mechanism were investigated.

015 - Process-Specific Binder Development for Sinter-Based Manufacturing
Sebastian Hein, Fraunhofer IFAM

In the past years, the field of sinter-based manufacturing has seen several new processes that often compete and are being pushed towards industrial application. Each process is unique and comes with specific demands on the materials that are being processed by it. In this work, we investigate several processes and compare those demands, and what that means for material development, specifically for the binders being used.

The term “binder” implies the binding function to keep particulate materials in shape. But there are many more demands a binder must fulfil, some of which are independent of the processes, others process-specific. All binders should be as cleanly removable as possible prior to the sintering step. A high green strength is always welcome, as it facilitates part handling. From the processing side, binders may have to induce high melt flowability for a proper injectability in metal injection molding (MIM), show shape retention after being pushed trough a die in powder extrusion molding (PEM) or must have inkjet printability and curability as for metal binder jetting (BJT).

Such demands directly influence and limit the potential binder material choice for each process. We compare binder concepts for MIM, PEM, BJT, material extrusion additive manufacturing (MEX) and others, show how this impacts factors like green strength and debinding properties, and give some examples of possible novel binder concepts that tackle some of the associated issues or enable further processing options.

188 - A Metallographic Study of TiFeMn Hydrogen Storage Powders Manufactured Using Multiple Methods
Thomas Murphy, FAPMI, Hoeganaes Corporation

The intermetallic compound TiFeMn has been used successfully in the creation of interstitial hydrides for solid-state storage of hydrogen.  The effectiveness of the compound to both absorb and release hydrogen is controlled by the chemical compositions and locations of the phases in the microstructure.  In addition, the presence of oxides or unwanted phases may inhibit the first hydrogenation of the compound and require additional thermal or mechanical treatments to increase the storage capacity.  For this study, several TiFeMn powders were produced using different manufacturing methods, which included multiple cooling rates that resulted in variability in the distribution, size, and location of the precipitated phases.  These attributes are examined using various metallographic methods, including imaging using both light and electron microscopy, image analysis/stereology, energy dispersive chemical analysis on localized areas, and others.  Attempts will be made to correlate the generated data with the ability of the individual powders to store hydrogen effectively and efficiently.

098 - An Investigation of Component Manufacturing Processes on the Properties of new Developed SMC Material   
Zhou Ye, Höganäs AB

A pure Fe-based soft magnetic material with an innovative water-based coating represents a new generation of Soft Magnetic Composite (SMC) which has low core loss, good mechanical performance and low carbon-foot print. This SMC material can preferably be used for various electrical machines and other inductive components designed for higher operating frequencies up to several kilohertz (kHz).   Component manufacturing processes play very important role to get suitable component performances for specific applications. This paper investigates the effect of the manufacturing processes, including compaction pressure, die temperature, lubricant content as well as heat treatment, on the final properties of the SMC component. A more detail investigation of heat treatment in pure nitrogen is carried out and discussed in the paper. Finally, a proposal of an optimised process and quality control method for the manufacturing of Somaloy^® 7P components is proposed.

089 - Development of Multiple-Recyclable Soft Magnetic Composite that Contribute to a Sustainable Society  
Kosuke Izumiya, Sumitomo Electric Industries, Ltd.

In recent years, it is required to consider environmental impacts and achieve a sustainable society. It is well known that electrical motors consume about half of the world's electricity, making it essential to realize higher efficiency, use materials that emit less CO₂ during manufacturing. Furthermore, the increasing demand for motors has led supply chain issues for their components, such as core materials, copper wires, and Permanent Magnets (PMs). As a result, this situation has gradually heightened the demand for recycling these components. In correspond to this challenge, we have developed an Axial Flux Machine (AFM) that uses a high-performance Soft Magnetic Composite (SMC) as the core material, instead of traditional Laminated Steel Sheets (LSS). LSS are used as core material in conventional motors. AFM is expected smaller and flatter than conventional Radial Flux Machine (RFM), and can achieve higher torque density. Additionally, one of the advantages of SMC is its lower CO₂ emissions during manufacturing. Moreover, it is easily recyclable. Therefore, we conduct the research about the recycle of SMC, and will report two achievements in this paper. Firstly, we attained the SMC using the raw material after recycling (Re-SMC) that have no performance degradation in terms of both iron loss and strength. Secondly, Re-SMC showed no performance degradation after multiple recycling as well in Re-SMC.

275 - Sintered Soft Magnetic Alloy Magnetic Properties
Neal Kraus, Hoeganaes Corporation

Sintered soft magnetic materials are used for sensors and yokes in electric motor applications.  FF-0000 and FY-4500 are the most common material systems.  The mechanical strength is much higher for FY-4500 as compared with pure iron.  The MPIF standard for these materials, however, also indicates the magnetic performance is also much improved.  Pure iron is highly magnetic and should have excellent response in magnetic fields.  This paper will explore the magnetic response of these materials using different purity base irons and different processing conditions.

083 - Sintering of Bronze & Iron Thin-Wall Bushes via Hot-Air Debinding, Embedded Heaters, Preheated Atmosphere in Low-Height Muffle and Spiral Path Water Flow Controlled Cooling System   
Ravindra Kumar Malhotra, Malhotra Engineers

Thin-Wall, 2< mm Bronze and Iron-Copper-Carbon bushings are used in EVs despite a high rate of sintering rejection. Bronze, Cu-10Sn is sintered at 880 C and Fe-Cu-C parts at 1050 C. This dual process Sintering furnace gives sinter to finish bushings of both compositions. Temperature uniformity is within 2 C across Inconel sheet belt of 1.5 mm thickness. Hot-Air debinding gives soot-free, clean shining parts. Sintering muffles is of low 70-80 mm height. The 200 mm wide belt furnace has 5 heating zones of 18-21 kW each using thyristor control. The Nitrogen-Hydrogen atmosphere is preheated externally to 800 C before introducing in sintering muffle. This preheated atmosphere avoids thermal variation at gas entry to prevent distortion of parts after sintering soak section. The sintering muffle has reverse parabolic baffles to increase atmosphere dwell thereby uniformly heating the parts in the pre-sintering and sintering sections. An end to end mullite tiles 16 mm thick bed resting on both sidewalls in sintering section will support muffle such that there are no piers within the zones. Embedded heaters will ensure seamless zone to zone heating without radiation hot spots. The first cooling jacket will be SS fabricated and rest of jackets will be MS with spiral path water flow. Provision of water in and out temperature measurement will be in all jackets. Belt speed, temperatures, water and gas flows will be measured and recorded in Sintering furnace monitoring system. Furnace parameters analysis and paperless audit will be possible. A quarantine logic ensures segregation of faulty processed parts.

142 - Optimized Design of a 1,200 °C, 240 kW, 450 mm Mesh-Belt Sintering Furnace for High-Volume PM Valve Seat Production 
Ravindra Kumar Malhotra, Malhotra Engineers

High volume Valve Seat production is feasible in a mesh-belt sintering furnace via multi-layer loading of 6-8 valve seat stack with infiltration copper rings in between. A 450 mm belt is selected for optimized loading on Carbon fiber plates of 400 mm width and 300 mm length, with 10 mm gap between them. Hot-Air debinding system ensures residue free pre-sintered, porous yet well bonded parts for complete copper infiltration, in a dedicated infiltration zone, at 1080 C. Each zone of this sintering furnace will be 30 kW with top and bottom heaters separately controlled by their thyristors. Two zone debinding 600-750 C, two zone pre-sintering 950-1050 C, one zone copper infiltration 1080 C, three zones for constant temperature soaking 1120-1180 C, will be provided in this novel 240 kW furnace. Highest temperature in soaking will be 1200 C, to cover any high alloying element sintering. The furnace will use Nitride bonded Silicon Carbide muffle in the sintering section. Embedded heaters will be used to maintain temperature uniformity of 5 C across belt. The nitrogen-hydrogen atmosphere will be preheated before introduction in the sintering section. Four spiral water path cooling jackets, one SS and 3 MS, will be used with nitrogen curtain at end of each jacket. Process dew point and all other parameters like temperatures, gas flows, water flows, belt speed, will be monitored and recorded. Water in and out temperatures will be monitored along with each jacket water flow, for adjusting individual jacket cooling rate. A quarantine logic will be used to separate faulty processed valve seats.

017 - High Temperature Mesh-Belt Sintering Furnace Design With Hot Air Debinding and Refractory Embedded Heaters for Iron and Stainless Steel PM Parts 
Ravindra Kumar Malhotra, Malhotra Engineers

Powder Metallurgy offers unique opportunity to mass produce complicated parts of iron and stainless steel with desired composition of alloying elements. The PM parts properties are enhanced as we go for higher sintering temperatures for iron parts. High temperature sintering furnaces like Pusher, Walking Beam or Roller Hearth are currently used for stainless steels and alloyed iron PM parts. Although Pusher, Walking Beam and Roller Hearth sintering furnaces allow high temperatures up to 1,300 °C they have certain limitations. Any breakdown requires a long shutdown which hampers operations of the PM plant. There are compromises on part sintering outcomes due to design of odd chamber sizes and heaters placement. The heating elements mounted on side walls in a Walking Beam furnace affect part geometry significantly. Large sintering chamber volume requires time to reach operating dew point. Maintaining part symmetry needs post sintering corrections or extra machining allowance. This defeats the purpose of bringing these parts to PM from conventional manufacturing routes. Therefore, pushing the mesh-belt sintering furnace design to surpass 1,150 °C to 1,250 °C can be a good endeavor. Refractory embedded heaters have been operating successfully in a vertical sintering furnace at 1,250 °C. Hot air debinding system is proven to give clean PM sintered parts. Therefore, Lab scale 150 mm mesh-belt sintering furnace using 90:10 Argon-Hydrogen protective atmosphere in a ceramic muffle with embedded heaters holds promise for delivering high temperature sintered iron and stainless-steel parts including SS filters.

012 - Exploiting the Potential of Metal Binder Jetting for Medical Technology and Beyond
Kevin Janzen, Fraunhofer IAPT

Demographic change and the associated trend towards an ageing population is leading to increasing demand for customized medical solutions that meet the specific needs of this patient group. Additive manufacturing, in particular metal binder jetting (MBJ), offers considerable potential for the production of customized endoprostheses and other medical devices. In future, this innovative technology can offer precise and flexible manufacturing that meets the specific requirements of patients. With a combination of improved powder conditioning, optimized curing strategy and effective recycling, MBJ is positioned as a viable manufacturing solution for the production of patient-specific implants. The results of this research suggest that MBJ can revolutionize the production of customized medical devices, contributing to improved healthcare and increased efficiency in medical manufacturing.

222 - Cold Metal Fusion – Applications of nickelbased Alloys in Oil & Gas and Energy
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 particular CMF is well suited to nickel-base alloys, which are often challenging for selective laser melting and casting. CMF reduces thermal gradients, residual stresses, and build-induced defects while enabling complex geometries and internal features without extensive tooling and support structures.

An overview of nickel-based materials currently supported in CMF is presented, summarizing typical compositions, achievable sinter densities, and post-sinter mechanical.
Selected application examples illustrate CMF strengths: hot-section and turbine components with internal cooling channels, corrosion?resistant valves and fittings, and low-volume parts for power-generation and oil & gas equipment. Economic comparisons highlight lower capital expenditure and reduced per part cost for small to medium series, plus simplified qualification for legacy geometries.

The presentation shows that CMF is a competitive, scalable alternative to SLM and casting for demanding nickel-base alloy applications in the energy sector and beyond.

117- Effect of Rare Earth Distribution on Mechanical Properties of Non-Pressure Sintered Al with Low-Rare-Earth-Addition
Yuji Shigeta, National Institute of Advanced Industrial Science and Technology (AIST)

Aluminum is lightweight and has high specific strength, making it suitable for transportation equipment and structural materials. In recent years, additive manufacturing (AM) has been attracting attention as a method capable of reducing costs and energy consumption by producing parts with higher yield and lighter weight. However, aluminum has a stable oxide layer on its surface, resulting in poor sinterability and making it difficult to apply to binder jetting which has excellent mass-productivity among AM methods.

We have reported the successful development of a novel Al powder capable of pressureless sintering. The key lies in the addition of rare-earth elements, which form Al–rare-earth liquid phases that significantly enhance sintering behavior. This breakthrough enables the fabrication of dense Al-based components without any pressure, expanding the potential of AM technologies for lightweight structural applications.

This presentation will detail the role of rare-earth elements and the mechanical characterization of sintered Al. Our findings offer new insights into sinter-based AM of Al and open pathways for its broader use in advanced manufacturing.

018 - Simulative Investigation of an Aerostatic-Bearing-Integrated Setter Plate for Friction Reduction During Sintering
Heiko Blunk, Fraunhofer IAPT

During sintering of binder-jetting parts, anisotropic shrinkage often causes distortion because friction between the part’s underside and the sintering baseplate restricts free contraction. To suppress this friction, we study a porous aerostatic bearing that injects a thin film of inert gas during the sintering cycle, thereby levitating the parts and reducing contact forces and warpage. Building on an existing experimental data set that reports flow rates, pressure drops and sliding-friction coefficients, the present work generalizes those findings, evaluates five alumina restrictors (permeability 2 × 10?¹ – 2 × 10¹³ m²) with three-dimensional CFD, and performs extensive parametric sweeps of gas-film thickness (10–40 µm) and supply pressure (4–24 kPa). The simulations reveal that load capacity and stiffness rise with increasing permeability and pressure, while gas consumption can be reduced by tailoring the film thickness to the measured surface roughness. At furnace temperatures up to 1350 °C the required argon mass flow drops by up to 70% without compromising load, underscoring the bearing’s efficiency for in-situ sintering. Additional analyses confirm that pressure distribution is insensitive to part position and to the simultaneous levitation of multiple parts. 

231 - Numerical Modeling of Permeability in LPBF-Fabricated Porous Structures with Process-Induced Porosity
Aazim Lone, King Fahd Univ of Petroleum & Minerals

Laser Powder Bed Fusion (LPBF) enables the fabrication of porous metallic components by exploiting process-induced porosity through controlled selection of laser power, scan speed, and hatch spacing. This study examines the permeability of SS 17-4PH samples produced by LBPF under low volumetric energy density (LED) conditions ranging from 14.22 to 19.30 J/mm³, yielding porosities between 32.37% and 41.40%. A numerical model using ANSYS Fluent was developed to simulate fluid flow through the porous structures and estimate permeability and pressure drop, which were validated against experimental measurements at three flow conditions. Permeability increased from 1.39 to 9.41 × 10¹¹ m² as LED decreased. CAD-based numerical predictions showed strong agreement with experiments, with errors below 10% for all samples. Although CT scans were not performed in this phase, future work will integrate micro-CT data to enhance geometric fidelity and strengthen validation. The pore networks demonstrated full connectivity and mesh-like morphology, resulting in anisotropic flow and directional permeability. Overall, this study demonstrates the capability of using process-induced porosity as a functional design feature in LPBF components for filtration and thermal management applications. Future efforts will focus on combining controlled porosity with architected TPMS or lattice structures to achieve enhanced control over permeability, mechanical performance, and heat transfer efficiency.

206 - Physics-Informed Machine Learning Framework for Prediction and Control in Additive Manufacturing
Tariku Sinshaw Tamir, King Fahd Univ of Petroleum & Minerals

Additive manufacturing (AM), as a pillar of Industry 4.0 and a driving force behind Industry 5.0, has transformed how complex components are designed and fabricated. Through its layer-wise production process, AM enables unprecedented freedom in geometry and material usage. However, persistent challenges, such as thermal instability, process control limitations, and structural defects continue to affect the precision and repeatability of AM processes. Addressing these challenges requires intelligent frameworks that can both predict and control process behavior in real time. This study introduces an integrated physics-informed and data-driven machine learning (PIML-DPML) framework that unifies two complementary approaches: a PID-embedded physics-informed neural network (PID-PINN) for real-time thermal control, and a data-driven physics-assisted ML (DPML) model for warpage prediction and process optimization. The PID-PINN architecture incorporates PID control logic directly into the neural network, enabling dynamic control of the volumetric heat source during selective laser sintering (SLS). In parallel, the DPML model leverages high-fidelity Digimat-AM simulations to classify and minimize warpage using key process parameters such infill amount, toolpath pattern, layer height, print speed, and extrusion temperature.

122 - Development of the 440 Stainless Steel Series through the Metal Binder Jetting Process
Tim Kriete, Hoeganaes Corporation

440A, 440B, and 440C are part of the martensitic stainless steel series. They have excellent mechanical properties including high hardness and tensile strength. This study focuses on developing these steels through the metal binder jetting (BJT) process. Parts made from 440A, 440B, and 440C powder were printed, sintered, heat-treated, and tested for their physical and mechanical properties. 

112 - Impact of Layer Thickness on the High Cycle Fatigue Properties of a PBF-LB Processed High Strength Steel
Satya Chaitanya Vaddamanu, Chalmers Tekniska Hogskol

Additive manufacturing (AM) in the form of powder bed fusion laser beam (PBF-LB) is rapidly evolving, but the number of materials available for structural applications remains limited. Low-alloyed steels have garnered attention due to superior mechanical characteristics and great versatility. However, the low building rates during PBF-LB, at the current state-of-the-art, limits wider utilization of low-alloy steels for the cost-sensitive structural applications. One of the most effective approaches to increase productivity is by increasing layer thickness. This study aims to investigate the effect of increased layer thickness (from 30 µm to 90 µm) on the fatigue response of a high strength  steel (C: 0.21 wt.%, Si: 1.03 wt.%, Cr: 1.04 wt.%, Mo: 0.20 wt.%, Mn: 0.72 wt.%). Samples processed at varying layer thicknesses were subjected to high-cycle fatigue (HCF) testing. Scanning Electron Microscopy (SEM) analysis of the fracture surfaces and specimen cross-sections was performed to correlate failure mode with defect populations and microstructure. Results show that increased layer thickness results in a decrease in fatigue life of the samples and higher standard deviation due to the presence of a smaller fraction of larger irregular defects in the samples processed at higher build rate.

246 - Microstructure and Mechanical Properties of Hadfield Steel Produced by Additive Manufacturing
Kerri Horvay, Hoeganaes Corporation

Conventionally manufactured Hadfield steels have exceptional toughness, high ductility, and excellent wear resistance. This steel is widely used in applications requiring high wear resistance, however due to its poor machinability the geometries of the components that can be made are limited. By utilizing this alloy with additive manufacturing more complex geometries can be achieved. For this study, both additive manufacturing techniques, laser powder fusion and metal binder jet printing, were used to process the Hadfield steel. Microstructural and mechanical properties were evaluated for heat treated samples. Standardized wear testing was performed to correlate the wear resistance to the hardness of the material. Charpy impact testing was also used to evaluate the toughness of the material. 

118 - Interrelation of Secondary Carbides, Sintering Atmosphere, and Crack Propagation in Ti(C,N)-Based Cermets
Angel Biedma, Universidad Carlos III de Madrid

Understanding how processing variables affect the microstructure and mechanical response of Ti(C,N)-based cermets remains essential for improving their structural reliability. This study examines the influence of secondary carbide additions and sintering atmosphere on the microstructural development and fracture behavior of Co-free Ti(C,N)-based cermets. Compositions containing additions of just 5 wt.% WC or 5 wt.% Mo-C, as well as both 5 wt.% WC and 5 wt.% Mo-C, were fabricated by conventional liquid-phase powder metallurgy using a Ni-based binder. Sintering was performed in Ar and Ar–N- containing atmospheres, followed by a sinter-HIP step. Microstructural characterization by SEM/EDS, XRD, and EBSD was carried out to analyse grain morphology, rim evolution, and secondary phases. EBSD-assisted crack tracing enabled the quantification of crack path tortuosity and the identification of transgranular and intergranular fracture modes, which were correlated with measured fracture toughness. The results reveal that both the secondary carbide type and the sintering atmosphere affect the evolution of the core-rim microstructure and fracture mechanisms. This systematic analysis contributes to understanding the processing–microstructure–property relationships in Ti(C,N)-based cermets and provides insight into the key parameters controlling their fracture response.

133 - Mechanical Microscopy of Hard Ceramic–Metal Composites: From Conventional WC–Co to Alternative Sustainable Systems
Fanny Marvaldi, Universitat Politècnica de Catalunya

WC–Co cemented carbides are widely used in cutting tools for their outstanding hardness and wear resistance. However, concerns about criticality and sustainability have driven interest in alternatives that partly or fully replace WC and Co as the hard and binder phases. WC-based systems incorporating a-phase (mixed cubic carbides) and cermets have emerged as promising substitutes, offering potential for improved performance and reduced reliance on critical raw materials. Yet, systematic studies are still required to understand how composition and microstructure affect mechanical behavior, which is essential for optimizing design and reliability. Although mechanical microscopy has been widely applied to WC–Co composites, comparable insight into alternative systems remains limited.

This study systematically evaluates the micromechanical response of a WC-based composite with mixed cubic carbides and a Ti(C,N)-based cermet, using a conventional WC–Co grade as reference. The investigation examines intrinsic hardness and elastic modulus of each phase to reveal relationships between composition, microstructure, and mechanical properties. Nano-scale hardness and modulus are obtained via high-speed massive nanoindentation combined with statistical analysis using a rotated multivariate Gaussian fit to 2D histogram data. Correlations between microstructure and micromechanical properties are established by overlaying Field Emission Scanning Electron Microscopy (FESEM) images with hardness and modulus maps, providing a robust framework for phase-level property assessment and sustainable tool material design.

090 - Crystallographic Investigation on Molybdenum/Nickel/Boride-Based Hard Materials
Satofumi Maruyama

The Mo2NiB2–Ni cermets are boron-based hard materials, which possess superior hardness and wear resistance.  The hard phase, Mo2NiB2, exhibits a transformation in its crystal system from orthorhombic to tetragonal upon substitution with Cr or V. This transformation is accompanied by a reduction in particle size of Mo2NiB2 phase and enhancement in mechanical strength.  However, crystallographic investigations focusing on the Mo2NiB2 hard phase itself are limited, and the structural changes induced by Cr and V substitution remain insufficiently understood.

Since the crystal structure is one of the key factors governing the mechanical properties, this study investigates the effect of elemental substitution on the hard phase from a crystallographic perspective by substituting 3d transition metals (Co, Fe, Mn, Cr, Ni) for Ni-site in Mo2NiB2 phase.

The samples were prepared by weighing the raw materials to achieve the nominal compositions of Mo2Ni1-xMxB2 (x = 0, 0.25, 0.5, 0.75, 1) and synthesizing them via a powder metallurgical process. X-ray diffraction analysis of the obtained samples revealed that Co substitution resulted solely in the formation of the orthorhombic Mo2Ni2-phase. In contrast, for elements not adjacent to Ni in the periodic table (V, Cr, Mn, and Fe), an increase in x in Mo2Ni1-xMxB2 led to the appearance of the tetragonal Mo2NiB2 phase.  More detailed results of the crystal structure analysis will be presented at the conference, accompanied by a discussion on the factors governing the emergence of the tetragonal phase.

199 - Recycling Refractory Metals: Economic and Environmental Benefits of Plasma Atomization
Michael Jacques, Retech Systems LLC.

Reducing the manufacturing costs of Refractory and reactive metal powders plays a critical role to expanding their contributions to the Aerospace, DOE & DOD sectors.  The affordability to complete research and development trials of emerging technologies weighs heavily on decisions due to budget constraints and rising costs.  Beyond the costs of manufacturing comes the flexibility and supply chain lead time constraints.  The ability to recycle material and reduce environmental impact from mining materials.  This also leads to reduced reliance on foreign material supply.  This study will investigate in what way a PGA system can have significant economic and environmental benefits by using revert and recycled scrap materials over other manufacturing processes.

076 - Characterization of EIGA-Atomized Tungsten Heavy Alloy Powders
Arun Chattopadhyay, Amaero Advanced Material & Manufacturing, Inc.

This paper investigates the EIGA-atomization of a Tungsten Heavy Alloy (WHA) having a tungsten content of 96.5 wt% (Class 4 WHA) with the remaining composition consisting of nickel and iron.  Early investigations showed that EIGA-atomization of WHAs with a tungsten content below 95 wt% was easier than that of Class 4 WHAs.  For EIGA-atomization, tungsten, nickel, and iron powders in the desired composition were fabricated into electrodes using the powder metallurgy (PM) technique.  A microstructural characterization of the EIGA-atomized WHA powders showed that the nickel and iron form a phase that is separated and is trapped in tiny pockets, often along the grain boundaries between relatively pure tungsten particles.  Compositional measurements by XRF confirmed that the electrode composition is preserved in the atomized powder.  

200 - Plasma Atomization of Refractory High-Entropy Alloys
Michael Jacques, Retech Systems LLC.

Plasma Gas Atomization has grown to be a highly selected method to manufacture High-Entropy alloys due to its capability to fully homogenize and eliminate segregation high melting point alloys.  When combining elemental or pre-alloyed materials with various melting points and densities, input power to obtain enough superheat and mix via stirring methods to promote homogeneity requirements.  Localized non-homogeneous powder can lead to downstream AM printing or spray coatings with reduced mechanical properties.  This study will evaluate the feasibility and homogeneity, uniform microstructure results of cold hearth skull melting and PSD atomized powder characteristics when processed using discrete melt parameters.  

607 - Novel Approach in Design of Multi-Scale Porous Metamaterials Using Laser Powder Bed Fusion
Renee Lam, University of Waterloo

Multi-scale porous metamaterials can be fabricated via laser powder bed fusion (LPBF) and deployed in the next generation of orthopedic implants. The motivation behind this work is to address stress-shielding effects, which remains an ongoing challenge in metallic implants and occurs due to the mismatch of mechanical properties between the implant and human bone. Common alloys used for implants such as Ti-6Al-4V, SS316L and CoCr are magnitudes stronger and stiffer than bone, causing issues such as implant loosening and failure due to stress-shielding. Strategically introducing voids into implant structures can help tailor mechanical properties of these alloys to improve biocompatibility. Lattices manufactured using LPBF have been studied for this application, however, they are unable to reach the target mechanical properties of human bone. This study leverages LPBF processing parameters to create strategic voids, a novel approach to manufacturing porous materials for implant applications tackling the stress-shielding effect. Process-driven porous structures are created by altering parameters in the LPBF process, such as hatch spacing and rotation angle. This results in structures with broad ranges of porosities (0 - 70%) and pore morphologies (stochastic and columnar). Multi-scale porous structures can be designed by combining the process-driven and deterministic lattice approaches, resulting in a structure with various surface textures, pore sizes and mechanical properties. Mechanical testing of deterministic (latticed), process-driven (stochastic) and a combination of the two have been conducted, and results show differences in mechanical response depending on the architecture. This work highlights the ability to tailor the response of porous structures through design and manufacturing to bridge the gap in performance requirements for implants.

608 - Low Cycle and Ultra Low Cycle Fatigue Testing of Thin-Wall Ti–6Al–4V Fabricated by Laser Powder Bed Fusion
Javier Arreguin Zavala,
AP&C, a Colibrium Additive Company

This investigation focuses on the fully reversed flexural fatigue bending for Ti-6Al-4V thin-wall specimens fabricated by the laser powder bed fusion (LPBF) process. The experimental matrix focused on acquiring the number of reversed flexural cycles to failure (Nf) for thin-wall design thicknesses for mill annealed (MA), and hot isostatic pressing (HIP) conditions. The studied variables were microstructure, porosity, surface roughness, and the presence of tungsten particles. The delineation between low cycle fatigue and ultra-low cycle fatigue was performed as a function of the strain imposed and sample thickness. The study demonstrated that a combination of porosity present near or at the surface and surface roughness forming notches dictated the fatigue life. The micro-void coalescence explained the crack propagation. 

513 - Cross-Modal Intelligence and Digital Twins: Machine Learning for Monitoring and Optimizing Metal Additive Manufacturing
Mathieu Brochu, McGill University

Machine learning is playing an increasingly central role in improving the reliability and efficiency of metal additive manufacturing (AM). This talk presents a cohesive view of how ML can support different stages of the metal AM workflow from anomaly detection to process monitoring and system optimization. The talk covers both Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) AM processes. First, we introduce ML-powered vision systems for detecting powder spreading anomalies in LPBF processes. Then, we explore multimodal in-situ monitoring in LPBF and DED using synchronized visual and acoustic signals, enabling real-time classification of melt pool behavior and defect signatures. To enhance scalability and generalizability, we apply domain adaptation and transfer learning techniques that enable knowledge transfer across different AM processes. Finally, we demonstrate how predictive models of process–structure relationships can support the development of digital twins for metal AM processes. Together, these contributions illustrate how machine learning can enhance monitoring, improve quality control, and guide process optimization in metal additive manufacturing.

514 - Physics-Informed AI Improves Profitability by Optimizing Tooling for Tungsten Carbide Manufacturing
Tevis Jacobs, Surface Design Solutions

Artificial intelligence is dramatically changing the PM industry, enabling data-driven optimization of production efficiency and profitability. Here we present a use case in the polishing of complex punches for the press and sinter of carbide components. A large manufacturer was struggling with variability in performance and lifetime of complex tools after refacing. Even with an expert machinist, some punches exhibited poor performance; the problem was even worse when one of the senior machinists retired and was replaced with a newer hire. Punches were returned for repolishing, and there was a backlog at the polishing step. The solution to this problem was to use a rapid optical measurement of the surface after polishing, coupled with physics-informed machine learning. The critical result was the discovery of how surface finish influenced key production metrics like parts-per-hour and tool life. This enabled accurate assessment of tools before they went into service, and an improved process to guarantee higher-performing tools and more efficient production. 

515 - Using AI in Feedstock Development
Bill Thorne, BASF

The integration of artificial intelligence (AI) into the production of Metal Injection Molding (MIM) feedstocks offers a transformative approach to traditional manufacturing challenges, primarily by significantly enhancing product quality and process consistency. Traditional quality control methods often rely on manual data analysis, which is slow, prone to error, and inadequate for handling the massive datasets generated during modern production systems. AI tools, such as the Sonata platform, leverage advanced machine learning and data analytics to process and interpret this extensive data in real-time, enabling proactive quality management and defect detection. This data-driven approach facilitates rapid and accurate root cause analysis and the implementation of corrective actions, drastically reducing resolution times from months to mere days. By optimizing production workflows and providing near-instant access to actionable insights, AI not only minimizes waste and operational costs but also elevates overall product reliability and efficiency, providing a sustainable advantage in the manufacturing industry. This presentation explores the application and benefits of AI-driven quality control in MIM feedstock production, highlighting how intelligent systems are redefining quality assurance and operational performance.