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271- Rate-Independent Constitutive Modeling for Powder Compaction Based on Ramberg-Osgood Uniaxial Equation
Gholamreza Aryanpour,University of Quebec

Based on the Ramberg-Osgood’s equation, the material uniaxial behavior is described by assuming a plastic deformation from the beginning of loading. This property is generalized not only to the loading of pre-strained material but also to the porous material loading. This generalization is carried out by applying a proportionality concept. This concept is applied for the case of porous material while the relative density and the equivalent plastic strain are considered as two isotropic hardening parameters. The model is formulated based on a stress-driven loading path and is partially identified by some experimental data available in the literature.

128 - Understanding the Effect of Triaxiality Variation in MPIF Std 10 Specimens
Abhishek Chawan, Amsted Automotive- Means Industries

This work builds upon prior finite element analysis (FEA) studies of MPIF Standard 10 tensile bar geometries, which showed variation in stress and triaxiality, to improve the reliability and repeatability of tensile testing in the powder metallurgy (PM) industry. The stress and triaxiality variations are believed to contribute to specimen failures outside the gage section which are undesirable as results cannot be used, and specimens are wasted. The present research aims to identify geometric features that contribute to stress and triaxiality variations while also offering solutions to reduce the variations. Insights from this work will guide the development of improved tensile bar designs that increase the probability of failure within the gage section thus improving the reliability of tensile testing data, reducing testing costs, and decreasing variability in reported mechanical properties.

005 - Fatigue Assessment of Powder Metal Steels via the FKM Guideline
Ian Donaldson, FAPMI, GKN SInter Metals

The FKM guideline for analytical strength assessment of mechanical components has gained increasing interest for the last couple of decades because it describes a general procedure directly applicable for product design. In general, the FKM guideline requires several model parameters to approximate the material response in terms of mean stresses, stress concentrations, process influences and scatter.  It provides a dependable basis for finite element analysis, making an efficient connection between stress results and a reliable safety margin.  It is based on local stresses obtained by FEA for various materials and loading conditions.  But with respect to powder metallurgy (press and sinter ferrous and aluminum, MIM, and AM) components, the FKM guideline has ignored it until recently.  This paper will discuss work to date and utilization of the guideline with powder metallurgy.

077 - Development of CuAlMn Shape Memory Alloy through Micro Powder Injection Molding 
Abu Bakar Sulong, University Kebangsaan Malaysia

CuAlMn shape memory alloys (SMAs) are promising functional materials due to their reversible martensitic transformation and potential applications in smart and adaptive systems. This study evaluates the feasibility of fabricating CuAlMn SMA using the powder injection molding (PIM) technique and investigates its phase transformation and one-way shape memory behavior. Cu-A-Mn powders were mixed with a binder system composed of polyethylene glycol (PEG), polymethyl methacrylate (PMMA), and stearic acid (SA).  The sintered parts showeda density of 7.039 g/cm³, porosity of 35.25%, and hardness of 213.84 HV, indicating good consolidation and interparticle bonding before heat treatment. X-ray diffraction (XRD) revealed the presence of phases in furnace-cooled samples, which could degrade shape memory performance, while heat-treated and quenched specimens displayed-phase formation and subsequent martensitic transformation. Differential scanning calorimetry (DSC) confirmed transformation start and finish temperatures of 101.61 °C and 171.08 °C for the martensitic phase, and 376 °C and 432 °C for the austenitic phase, respectively. It is possible to attain approximately 4% shape recovery or up to 90.9% strain-recovery efficiency in the CuAlMn alloy by heating the material to 440 °C. The correlation between thermal transformation behavior and strain recovery verifies that the PIM processed CuAlMn alloy exhibits a functional one-way shape memory effect after appropriate heat treatment.

197 - Effects of Hydroxyapatite in 316L-Titanium Metal Matrix Composites Fabricated by Powder Injection Molding for Bone Implant Application
Faiz Ahmad, Universiti Teknologi PETRONAS

Active bone ceramic hydroxyapatite (HA) is added into 316L Stainless Steel-Titanium metal matrix composites to create micro pores through gradual degradation inside the body for creating space for cell growth and tissue regeneration. During sintering, especially under vacuum conditions, HA tends to degrade rapidly at high temperatures. To address this, a two-stage sintering cycle was developed to slow down the degradation process and improve HA retention. In this study, the optimized cycle, which includes a presintering step at 920 °C for 60 minutes, has successfully retained hydroxyapatite up to 1340 °C, yielding a corrosion rate of 0.103 mpy after three days of testing. Mechanical results showed that 3% Ti-reinforced 316L stainless steel sintered at 1350 °C achieved an elongation of 4.82 ± 0.26% and a tensile strength of 444.7 ± 18.8 MPa. Although 3% HA added samples showed reduced elongation of 0.85 ± 0.03% and a tensile strength of 435.4 ± 11.3 MPa. Despite this drop in ductility, the HA-containing sample exhibited a notably lower compressive modulus of 21.51 GPa and a compressive yield strength of 686 MPa, suggesting potential biomedical applications for load-carrying bone implants.

226 - Advancing PIM Technology for Bone Substitute Fabrication Using Beta-Tricalcium Phosphate
Delphine Auzene, Critt-MDTS

The maturity of PIM technology in many sectors, such as the production of aeronautical components for aircraft engines — for example, fuel injectors — is well established. However, it appears to be underutilized in the medical sector, particularly for the injection of tricalcium phosphate (TCP) feedstocks. This biocompatible ceramic was chosen due to the absence, to date, of state-of-the-art studies on the fabrication of bone substitutes using the PIM process.

In view of the future shortage of materials associated with overpopulation, the development of additive manufacturing of implantable ceramic medical systems — especially PIM dedicated to large-scale production — represents not only a collective need but also a rapidly growing market for the coming decades.

Consequently, this research focuses on the development of a feedstock and its rheological characterization, as well as the optimization of injection and post-processing parameters in relation to the binder and the ?-TCP powder. The process–material interactions have been characterized and analyzed throughout the various shaping stages.

153 - Compact Vertical Furnace for Iron Powder Reduction and Annealing: Minimum Floor Footprint, Maximizing Energy Efficiency Using Low Reaction Gas and Ensuring Uniform High-Quality Output 
Ravindra Kumar Malhotra, Malhotra Engineers

Reduction and annealing of iron powder in a Vertical furnace will improve powder quality as compared to a conventional horizontal sheet-belt furnace. In a horizontal furnace the reducing gas hydrogen or cracked ammonia passes over powder bed of fixed height with limited penetration through powder particle spaces. As the reduction and annealing process takes place there is particle to particle bonding which is commonly known as cake formation. In a Vertical retort the powder is completely filled allowing reducing gas to pass through space between all powder particles. In the Vertical furnace gravity and screw feeder assisted powder movement has inherent attrition taking place. This attrition would not allow particle to particle bonding or cake formation. Slight vibration can further increase attrition thereby powder will have more space for gas movement and better oxide reduction of each iron particle. The retort will be heated by cylindrical embedded heaters giving uniform heating around the retort. The four zone  (84kW) furnace will have 3 cylindrical heaters per zone (21kW), The hot shell height can be controlled below 5 meters. The cooling system will also have cylindrical jackets of SS and MS covering a height of less than 4 meters. Spiral path water flow within each jacket will be metered separately. This will ensure adjustable cooling rate to control powder properties. The design temperature of this furnace will be 1000 C for iron powder. With this setup different furnaces can handle variety process cycles of powders on the shop floor. This furnace should give outputs around 8-10 tons per day.

026 - Integrated Production of High-Purity Copper Powder via Novel Vertical Continuous Chip Oxidation and In-Line Reduction for Precision Sintered PM Components
Ravindra Kumar Malhotra, Malhotra Engineers

A novel Vertical Continuous Oxidizer processes machining chips (0.5-3mm) or shredded fine copper wires in to high surface area input for replacing traditional mill-scale used in production of sub-micron reduced copper powder by pulverization-reduction process. Conventional mill-scale a by-product of copper extrusion process has refractory fines and oils as contaminants. This new method using a vertical oxidizer will eliminate any such impurities. There is a distinct advantage in using this method to convert non-usable coarse powder from water atomization plant in to a premium powder grade. The loss making recycling of coarse powder in melting can be diverted as good input for reduced powder production upscaling`. The sheet belt Reduction furnace used in plant can handle both powder types, atomized as well reduced. The dryer section of Reduction furnace can be used for preheating copper scales before reduction and then annealing. The improvised reduction muffle will have hot nitrogen curtains in beginning and end. The reduction hydrogen or cracked ammonia gas will be also preheated. Reduction and Annealing sections will be separated by a reverse parabolic baffle for gas dam. This will ensure reduction side gas will not diffuse in annealing gas thereby purity of reduced powder will be enhanced. The cooling jackets with controlled spiral path water flow will give uniform cooling. Additional nitrogen gas curtains in cooling jackets will protect powder cake color and purity needed for precision PM parts.

185 - Vertical and Horizontal Continuous Hot-Air Shower Burn-Out Furnace Designs for Lubbricant and Carbon Removal to Reclaim PM Green Pre-Mix Scrap Powders
Ravindra Kumar Malhotra, Malhotra Engineers

A novel continuous hot-air shower burn-out process has been devised to safely remove lubricant without any residues, and carbon through partial conversion to carbon monoxide from green part regrind Pre-Mix scrap powder. The resulting low-carbon, low-oxygen powder is subsequently reduced and annealed using hydrogen atmosphere. Thus making reclaimed powder useful for lower-specifications structural parts. Sometimes, green parts are quarantined from proceeding to the sintering process due to detection of some flaws. The high-value pre-mix formed green parts will need salvaging activity with the help of local powder suppliers. However, the lubricant and carbon present in the pre-mix composition become a hurdle to reprocess the powder mix in the conventional reduction furnace. Controlled combustion of lubricant and partial conversion of carbon to carbon monoxide will render the balance alloy to be reclaimed judiciously after reduction and annealing. These processes can be done in-line in a single horizontal setup or in a vertical furnace using gravity and screw conveying. All process steps can be used in a large scale operation. The streamlined recovery process with metallurgical over-seeing can reclaim pre-mix powders thereby preventing their distress sale.

195 - Developing an AM-Grade IN617 Feedstock Powder and Assessing its L-PBF Printability for Next-Generation Nuclear Heat Exchangers
Maz Ansari, InnoTech Alberta

Inconel 617 (IN617) is a leading candidate alloy for heat exchangers and structural components in next-generation nuclear reactors due to its exceptional high-temperature strength, oxidation resistance, and phase stability. Despite these advantages, additive manufacturing (AM) of IN617 remains underexplored, primarily due to the limited availability of commercially atomized powders and challenges related to cracking susceptibility and microstructural control during processing. This research aims to establish a comprehensive material and process development framework for producing AM-grade IN617 powder and evaluating its suitability for additive manufacturing through Laser Powder Bed Fusion (L-PBF).

IN617 powder will be produced from wire feedstock using an ultrasonic atomization system and subsequently characterized for particle size distribution, morphology, chemistry, and flowability to assess feedstock quality. L-PBF process development will be performed to identify optimal combinations of laser power, scan speed, and hatch spacing that achieve high density and stable melt-pool behavior. A heat-treatment matrix—including stress relief, solutionizing, and aging treatments—will be applied to examine microstructure evolution, phase stability, and mechanical property evaluation relevant to nuclear service environments.

This work provides an integrated powder-to-process pathway to enable L-PBF fabrication of IN617 and support the long-term qualification of additively manufactured heat-exchanger materials for advanced nuclear reactor systems."

176 - Low Oxygen Spherical Ni- and Cu- Alloy Powder Production for High Temperature Resistant Additive Manufacturing Applications
Chung-Soo Kim, EML Co., Ltd

This study produced high-purity Ni-superalloy and Cu-alloy powders via EIGA to minimize contamination. CFD analysis of atomization conditions was experimentally validated, revealing their influence on particle formation. The resulting powders exhibited <100 ppm O/N, high sphericity, narrow size distributions, and superior flowability, enabling stable AM layer deposition.

045 - Ultrasonic Atomization: Bridging Process Control and Powder Performance
Roghayeh Nikbakht, McGill University

Ultrasonic atomization (UA) offers a novel route to produce metal powders with exceptional sphericity, flowability, and uniformity. This work focuses on developing process control strategies for UA to ensure its applicability across powder-based manufacturing technologies. To demonstrate relevance, the study benchmarks UA powders against critical specifications for additive manufacturing and thermal spray, including morphology, flowability, and porosity, and evaluates whether UA can meet these requirements. The research investigates the influence of key UA process parameters including vibration amplitude, frequency, current, and feed rate on powder morphology, size distribution, and microstructure across multiple alloy systems. Comparative studies on alloys with varying melting points and surface tension map material-specific responses to UA, supporting robust control strategies. The outcomes are expected to advance mechanistic understanding of UA and enable reliable integration of UA powders into diverse workflows, promoting sustainable and high-performance powder metallurgy.

063 - Surface Roughness Characterization from Computed Tomography Images Using an Enhanced Surface Determination Technique: Case Study of Additively Manufactured Components
Éric Fournier, École de Technologie Supérieure

Quantifying surface roughness in additively manufactured (AM) components using X-ray computed tomography (XCT) remains a significant metrological challenge due to voxel discretization, reconstruction artefacts, and limitations in current surface determination techniques. This paper introduces a novel methodology for extracting surface roughness metrics directly from XCT data. The proposed approach employs a physically-motivated surface determination technique incorporating flux conservation principles based on the divergence theorem. The method introduces a regularization framework that enforces zero net normal flux while maintaining local data fidelity, coupling gradient-based refinements with global conservation constraints to improve noise robustness and prevent systematic volume drift. This formulation enables subvoxel surface localization while mitigating noise sensitivity and directional bias inherent in traditional gradient-based algorithms. The refined surface model allows the direct computation of areal surface texture parameters (ISO25178) within the XCT domain, eliminating the need for complementary optical or tactile measurements.

Validation experiments on representative AM components featuring complex geometries and surface morphologies, demonstrate that the proposed approach provides roughness values comparable, within the margin of error, to those obtained using high-resolution optical profilometry. The proposed framework advances XCT metrology for additive manufacturing by enabling traceable, non-destructive surface roughness characterization directly from volumetric data.

009 - A Method for Evaluating NDT Detectability in Additive Manufacturing Aerospace Parts
Salah Eddine Brika, École de Technologie Supérieure

Additive manufacturing (AM) enables lightweight, optimized aerospace components with complex geometries. However, these designs must meet strict performance standards while remaining inspectable by available non-destructive testing (NDT) techniques. The design freedom of AM, though beneficial, introduces inspection challenges that can impact both reliability and cost.

Given the critical nature of aerospace parts, a high level of flaw detectability is essential. Understanding the detection limits of different NDT methods is key to ensuring reliable qualification and cost-effective production.

This project evaluates the defect detectability limits of three radiography-based NDT techniques: X-ray computed tomography, digital radiography, and film radiography. A Ti-6Al-4V aerospace component produced by laser powder bed fusion (LPBF) includes embedded defects (100–800 ?m) of various shapes, modeled in CAD and integrated into key regions for inspection. A cost modeling analysis then compares the economic relevance of each method. The outcome provides a structured and replicable approach to identify detectability limits and support the selection of the most suitable NDT technique for aerospace AM components.

061 - Implementation of Rapid Fatigue Testing to Evaluate the Effect of Defects and Specimen Thickness on the Fatigue and Fracture Properties of PBF-L/M AlSi10Mg 
Milad Bemani Lirgeshas, Royal Melbourne Institute of Technology (RMIT)

Surface roughness and process-induced defects, especially gas pores and lack of fusion, make additively manufactured parts vulnerable to fatigue and early failure during use. Often, the negative effects of various defects compete, influencing the fatigue resistance of the printed components. While the dynamic mechanical properties are vital in additive manufacturing products, traditional fatigue testing is time-consuming and expensive, posing a significant challenge. Consequently, rapid fatigue methods such as the stiffness method have been developed recently to enable researchers to thoroughly assess the fatigue and fracture characteristics of additive manufacturing products. This study examines the stiffness method for polished and as-built AlSi10Mg specimens produced by laser powder bed fusion. The results indicate that the stiffness method accurately determines the fatigue limit with considerably fewer tests, aligning with standard fatigue data within about 1% deviation. In addition to defect type, size, and position, the geometry of the specimen may influence fatigue performance. Variations in thickness may affect microstructure, defect distribution and type, and stress states, all of which impact fatigue resistance and fracture mechanisms. Findings suggest that rapid fatigue testing can reduce the time and cost of evaluating thickness effects on the fatigue limit by over 90%. Finally, we recommend combining the rapid fatigue test data from the stiffness method with fracture mechanics models to predict the fatigue crack growth threshold in AM specimens.

232 - AI-Guided Development of Crack-Free Cermets for Laser Powder Bed Fusion
Abu Anand, Phaseshift Technologies

The application of Laser Powder Bed Fusion (LPBF) to cermets is persistently hindered by thermal stress cracking, porosity, and the inherent incompatibility between ceramic hard phases and metallic matrices during rapid solidification. This work presents a comprehensive framework to overcome these limitations by coupling AI-driven alloy design with integrated multi-scale simulations, followed by iterative experimental validation. We utilized a physics-informed AI model to screen potential binder chemistries, specifically optimizing for wettability and solidification cracking resistance while simultaneously targeting critical mechanical properties such as hardness and fracture toughness. This virtual screening yielded a tailored binder composition designed to promote robust carbide–binder interfaces and accommodate thermal stresses at high carbide loadings. Following the synthesis of custom powder feedstock, we developed processing maps to balance energy input with defect control. The resulting near net-shape components achieved near-full density with a uniform microstructural dispersion. Tribological benchmarking confirmed that these LPBF-processed parts possess wear resistance comparable to conventional sintered hardmetals and superior performance relative to existing cermet grades processed via Electron Beam PBF (PBF-EB). We will discuss the complete workflow, highlighting the correlation between AI predictions, multi-scale simulations, and the observed failure modes that guided the final material design.

175- Knowledge-Informed Graph Attention Networks Enable Defect-Free Alloy Design for Laser Additive Manufacturing
Hao Yu, Northeastern University

Machine learning offers a promising approach to the design of new high-performance alloys for laser additive manufacturing, by bypassing convoluted physical models and identifying direct correlations among composition, processing, microcracks/porosity and mechanical properties. However, to reliably predict optimal combinations of alloy compositions and processing conditions leading to defect-free high-performance material, conventional machine learning methods face numerous limitations, e.g., overfitting or unreasonable design results, due to their heavy reliance on large, high-quality datasets. Here, we introduce a new generic framework that can operate successfully with smaller experimental datasets, by integrating knowledge-informed graph modeling alongside data uncertainty quantification. In essence, the generic physical metallurgy knowledge and the stochasticity of experimental defect distributions from trial-run produced material are rationally balanced. To validate the approach, we describe in detail the successful development of a new defect-free Ni superalloy possessing excellent laser printability, thermal stability, and high mechanical strength. Mechanism mining revealed a possible origin for the excellent performance, which was confirmed by atom probe tomography measurements. Subsequently, we describe the development of a new laser-printable aluminum alloy through the same approach, highlighting the framework’s potential to accelerate the creation of next-generation alloys tailored for additive manufacturing.

254 - Simulation of Powder Melting Phenomena in Additive Manufacturing Using Lattice Boltzmann Method
Andrew Gillespie, Purdue University in Indianapolis

Powder melting is a critical step in the metal additive manufacturing (AM) process. In this study, a three-dimensional Lattice Boltzmann Method (LBM) based model is developed to simulate the melting phenomena of metallic powder. We analyze the shape evolution of varying particle sizes during the melting process. The results show that neck growth dynamics are primarily driven by surface tension and the associated mass transport. This shows that the initial consolidation plays a critical role in the overall consolidation process, offering a mechanical insight into the melting process for additive manufacturing.

058 - Wear Evaluation of Cemented Tungsten Carbide with Nanocrystalline FeNiZr Binder
Sean Fudger, U.S. Army Research Laboratory

Cemented tungsten carbide (WC) is a traditional machine and cutting tool material due to the extreme hardness and high modulus provided by the WC phase combined with plasticity and resulting toughness contributed by the cobalt (Co) binder.  Due to the health hazards and supply chain concerns associated with Co, there exists a need to replace the binder material while maintaining the mechanical performance in these systems.  Nanostructured FeNiZr is evaluated as a plausible binder replacement to Co since it doesn't exhibit these concerns.  A series of wear tests are performed to compare the performance of the cemented WC with novel FeNiZr binder compared to that of traditional WC-Co material.  Further, machine learning (ML) is utilized to help guide the material development process - particularly focusing on using computational techniques to explore complex multifactorial experiments in addition to data collection and analysis.

198 - Cutting Performance and Wear Evolution of New Generation Cermet Tipped Blades for Handheld Circular Sawing of AISI 304 Stainless Steel
Steven Moseley, Hilti AG

Handheld circular sawing is a high-speed cutting process fundamental to construction sites for cutting structural components, typically produced from steel. Evaluating new cutting tool materials for increased on-site productivity is therefore of high importance. This study investigated the cutting efficacy and tool wear of three modern commercial cermet grades (named CM1, CM2, and CM3) for circular sawing of AISI 304 stainless steel square tubing profiles. A custom test bench was constructed for execution of the cuts. Circular saw blades from each respective grade had 66 cutting teeth brazed onto the steel body. Blades were evaluated for their cutting performance and tool wear up to 50 cuts. Cutting teeth from all three grades remained functional after 50 cuts. The softest grade, CM3, had both the highest cutting speed and estimated specific cutting energy, rendering it the most efficient in terms of time and energy for at least 50 cuts. Dominant wear mechanisms were different amongst the grades in the initial and intermediate wear phases, with the hardest grade, CM1, being prone to early chipping and the softer grades, CM2 and CM3, more susceptible to abrasion. During advanced wear, all grades exhibited severe progressive adhesion and chipping or large edge fractures.

249 - Effect of Femtosecond Laser Chip-Breaker on WC–TiC–Co/Mo and NbC-TiC/TiCN-Ni based Cutting Inserts during AISI1213 Turning
Rodney Genga

Chip control remains a key challenge in the machining of ductile steels such as AISI1213, where long, continuous chips impair surface quality, reduce tool life, and limit automation. This study investigates application of femtosecond laser surface engineering for chip breaker fabrication on sintered WC–TiC–Co/Mo and NbC–TiC/TiCN–Ni cermet cutting inserts. These cermet compositions were produced by liquid phase sintering (LPS) and spark plasma sintering (SPS), and characterized by hardness (HV30), fracture toughness (K1C), elastic moduli, and grain size. The LPS WC–10TiC–10[0.7Co–0.3Mo] cermet had the best combination of mechanical (HV30 ? 16 GPa and K1C ? 9 MPa·m^½) and microstructure properties (grain size ? 0.6 µm) while LPS NbC-10TiCN-12Ni displayed a good balance of hardness (? 13 GPa) and K1C (? 8 MPa·m^½). Femtosecond laser ablation (? = 1030 nm, ?p ? 150 fs) was used to develop a chip breaker on the rake face of the inserts. Laser structuring achieved minimal thermal damage and precise localized geometry control. Post processing analysis by ADF-STEM, TEM SAED, and residual stress was done to assess the impact of the Laser surface engineering. Turning trials on AISI1213 steel showed femtosecond laser-structured inserts achieved up to 100% increase in tool life and reduced flank wear. Surface roughness was also assessed. TOPSIS-based analysis ranked WC–10TiC–10[0.7Co–0.3Mo] (LPS) as the best-performing composition, followed by NbC-10TiC-12Ni. This work presents a viable pathway for post-sintering, high-precision chip breaker fabrication using ultrafast lasers, for Industry machining applications.

277- Production and Characterization of Gas-Atomized Vanadium Alloy Powder as a Foundation for Developing Nanoparticle-Strengthened Fusion First-Wall Materials
Jordan Tiarks, Ames National Laboratory

Vanadium-based alloys are promising candidates for structural components in fusion reactors due to their low activation, high-temperature strength, and excellent compatibility with liquid lithium. This work reports initial efforts toward developing nanoparticle-strengthened vanadium alloys using gas atomization methods. As a baseline, V-4Cr-4Ti alloy powders were produced via gas atomization to establish processing parameters and evaluate powder characteristics, including particle size distribution, morphology, and oxygen content. These powders will be consolidated using friction consolidation techniques to assess microstructural evolution and mechanical properties. Baseline results will be discussed, and an overview will be provided on how these findings will guide the design and processing of next-generation nanoprecipitate-strengthened vanadium alloys aimed at improving high-temperature performance under fusion-relevant conditions.

131 - Tungsten Integration into Fusion Power Plant Systems
Lauren Garrison, Commonwealth Fusion

Fusion offers a clean baseload energy source but comes with extreme conditions for some of the internal components. Tungsten alloys and composites are leading choices for a component called plasma-facing materials (PFM). PFM are the boundary between the high temperature fusion plasma and the structural vacuum vessel, which exposes them to high temperatures, particle fluxes, and neutron radiation. In Commonwealth Fusion Systems’ (CFS) SPARC fusion device, unalloyed tungsten is utilized as the PFM in the highest heat flux areas while tungsten heavy alloy (WHA) is used in other regions. SPARC has 23,400 tungsten and WHA parts with a total weight of 16,200 kg; assembly of the SPARC PFMs is currently underway.  The SPARC PFMs are inertially cooled, experience pulsed temperatures up to 1200°C, and accumulate less than 1 dpa (displacements per atom) neutron dose. In the next CFS fusion device, ARC, which will be a model power plant and is currently in the design phase, the PFM conditions will be more intense, prompting the development of advanced tungsten alloys. In ARC, PFMs will be actively cooled with a molten salt, operate in the ~700-1200°C range, be bonded to the structural vacuum vessel over a surface area of ~500-750 m2, and experience ~20 dpa. The CFS materials development program is thus focused on developing tungsten alloys to prioritize high recrystallization temperature, radiation resistance, and minimizing coefficient of thermal expansion mismatch with the structural material. The current SPARC PFM results will be shared as well as the research and development plan for the ARC PFMs.

079 - Simulation-Based Large-Scale Fabrication of SMART Components via Field Assisted Sintering Technology (FAST)
Yuanbin Deng

SMART materials (e.g., W-11.4 Cr-0.4Zr-0.6Y in wt.%) play a crucial role in advancing the safety and efficiency of future fusion reactors. As plasma-facing materials, they must withstand extreme temperatures, high particle and radiation flux, and radioactive environments. This material serves as a key enabler for next-generation fusion reactors by combining satisfying plasma performance with intrinsic safety through its self-passivating behavior. However, realizing large-scale component fabrication remains a major challenge. To address this, the Field Assisted Sintering Technology (FAST) process is employed as a consolidation method, supported by numerical simulations to optimize process conditions and ensure homogeneous microstructure development. In this study, thermo-electro-mechanical simulation models are developed using experi-mentally determined material parameters in commercial FE software to predict temperature evolution during FAST. The influence of sample geometry with a linear dimension of 100 mm on temperature gradients and microstructural uniformity is analyzed both numerically and experimentally. Based on these results, key process parameters such as current density and heating rate are optimized to achieve homogeneous temperature distribution and reduced thermal gradients. A densification model is then implemented to calculate sintering shrinkage and study the effect of density evolution on heat transfer within the tool-sample assembly. All simulation results are validated against experimental data and used to guide the fabrication of larger SMART components.

610 - Manufacturing and Remanufacturing of Titanium Parts Using Laser-Blown Powder Ded Process
Bhaskar Dutta, DM3D Technology, LLC

Large-scale titanium parts are widely used in aerospace and defense applications due to their light weight. Examples include structural parts in the airframe, landing gear, fuel tanks, compressor sections in the jet engines, casings for the weapons systems etc. However, manufacturing such parts using conventional casting or forging technologies is not only time consuming, but also expensive as the production quantities are small. Additive manufacturing offers an alternate manufacturing route with promises of lower cost and reduced lead time. Direct Metal Deposition (DMD®) is a type of laser-blown powder DED (Directed Energy Deposition) technology that can print large structures. Recent advances in the DMD technology have increased the throughput, enhanced the product quality and traceability and made the technology more cost competitive.  
 
This presentation will begin with a state-of-the-art review of additive manufacturing (AM) of titanium alloys. This will be followed by a brief overview of the DMD technology with an emphasis on large part printing process. Microstructure and mechanical properties of DMD printed Ti-alloys will be discussed. The discussion will also include two case studies; one on manufacturing of a titanium casing, and another on remanufacturing of titanium compressor vane. At the end, some of the challenges that need to be resolved in order to successfully production print large titanium parts will be discussed. 

611 - Assessing Ti-6Al-4V Variability Across Powder Manufacturers for Laser Directed Energy Deposition
Francisco Medina, University of Texas El Paso

612 -  A Thermo-Microstructural-Mechanical Modeling Platform for the Optimisation of DED-Wire Printing Protocols
Mathieu Brochu, McGill University

Titanium alloys have long been of great interest to the aerospace industry because of their high specific strength and excellent corrosion resistance. However, the fabrication of qualified additively manufactured (AM) titanium alloy components still requires a deeper understanding of the process–structure–property relationships for AM Ti‑6Al‑4V, especially when complex or evolving geometries are involved. This presentation introduces a new manufacturing methodology based on protocol‑driven determination, using the required mechanical properties as the input for the framework. The methodology incorporates three mechanistic models that predict and control key variables in the AM process, ensuring that the final components achieve the targeted mechanical performance. With this approach, it becomes possible to obtain homogeneous microstructure and mechanical properties throughout parts that contain evolving geometries—an essential requirement for the qualification of AM titanium components.

516 - The Role of Powder Metallurgy in the Manufacturing of Sintered NdFeB Magnets
Judson Marte, MP Materials

Rare earth magnets are vitally important to achieving environmental sustainability through electrification. The geographic concentration of rare earth magnet manufacturing exemplifies the supply chain risks to achieving that goal. Additionally, the manufacturing process for sintered NdFeB magnets has not been practiced at scale in the United States for many years.  MP Materials has re-established mine-to-magnet manufacturing in the United States.  In this presentation, we will review this manufacturing process with special emphasis on the prominent role that powder metallurgy plays in it.

517 - Considerations for Processing Powders for Rare Earth Permanent Magnets
Miranda Vader, Vulcan Elements

The production of Rare Earth Permanent Magnets, essential for automotive and defense industries, is critically dependent on the characteristics and handling of the constituent metal powders. This talk will discuss some key material and process challenges when forming and handling these specialized powders including reactivity, flow characteristics, particle packing, and the resulting shrinkage behavior during sintering. 

518 - Rare Earth Fluoride Critical To The Permanent Magnet Industry 
Kagya Nyanin, Principal Mineral

The global demand for rare earth permanent magnets is projected to triple reaching more than 176Kt by 2035. Meeting this demand requires secure, scalable production of critical rare-earth metals—Nd, Pr, Dy, Tb, Sm, and Gd—which today rely on fluoride intermediates for molten-salt electrolysis and metallothermic reduction. Rare-earth fluorides therefore remain a foundational midstream material enabling NdFeB and SmCo magnet production. Principal Mineral, in partnership with Ames National Laboratory, is advancing the REMAFS HF-free fluoride technology —an alternative, patented synthesis route that eliminates hazardous hydrofluoric acid while producing high-purity rare-earth fluorides compatible with commercial metallization processes. Recent demonstrations show that REMAFS-derived fluorides successfully produce NdPr metal (99.5%) and Dy metal (99.5%) via established metallothermic reduction pathways, meeting industry specifications for permanent-magnet applications. This presentation will highlight that HF-free rare earth fluoride technology developed Ames National Laboratory has been validated to produce high purity Neodymium Praseodymium metal (99.5) % and Dysprosium metal (99.5%) that meets the specification for permanent magnets. By transitioning REMAFS technology from laboratory innovation to commercial demonstration, Principal Mineral is building a safer, U.S.-anchored midstream capable of supporting future growth in global NdFeB and SmCo magnet manufacturing.