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116 - A Multiscale Digital Model of the PM Process Chain
Christoph Broeckmann, RWTH Aachen University

Companies that manufacture powder metallurgical (PM) components by powder compaction and sintering are facing a rapidly decreasing demand for functional components, such as variable valve timing rotors. Hence, PM industry needs to identify alternative fields of application, which often are associated with requirements for high load-bearing capacity. However, the latter is limited by the inherent porosity, which is widely reported to reduce mechanical strength. This is superimposed by the heterogeneous density distribution, which is due to friction acting between powder and tool during compaction, and the complex interaction along the entire process chain, provoking mistrust in PM components among potential customers. Nevertheless, extensive research has been conducted over the last decades, providing comprehensive knowledge on production processes and their numerical description. Consequently, a digital model is proposed in this work that captures the interaction along the production. A macroscale model for powder compaction is used to provide locally resolved information on porosity, which is passed to a generative adversarial network. This model generates realistic images of the local microstructure, whose evolution during sintering is then simulated using a Level Set model that describes the diffusion processes involved. The predicted images are finally used as representative volume elements to deduce information on local mechanical strength, revealing an anisotropic compressive strength with respect to the direction of compaction. The applicability of this framework is demonstrated with a PM gear.

097 - Accelerating Gear Development through Modeling Surface Densification Rolling for PM Gears
Phillipp Scholzen, Höganäs AB

The press and sinter process chain offers a great opportunity for gear manufacturing, including improved material utilization, more sustainable manufacturing, and potentially lower production costs compared to competing technologies. However, residual porosity after pressing and sintering limits the strength of the material. To meet the requirements of high-performance applications, powder metal (PM) gears can be surface densified to meet the performance of wrought steels.
 
This paper presents a method for designing the surface rolling densification process for gears. The objective of the methodology is to reduce development time and optimize solutions through advanced modelling and simulation. The model is validated in terms of geometry, process parameters, and material behavior. The method is exemplified through its application to electric vehicle transmissions, and it is shown how new PM based gear solutions are made feasible with surface densification. The results are discussed in terms of manufacturing processes, load capacity, and noise-vibration-harshness (NVH) performance.

078 - Numerical and Experimental Investigation of Densification, Deformation and Phase Transformation during Hot Isostatic Pressing of AISI H13 Tool Steel
Yuanbin Deng

Newly developed hot isostatic pressing (HIP) units with integrated rapid cooling systems capable of operating at gas pressures up to 200 MPa enable simultaneous densification and hardening of metallic materials. To explore their application for steels with defined micro-structures, this study presents a combined experimental and numerical investigation of the HIP process of AISI H13 tool steel. A fully coupled thermo-mechanical model was developed to predict densification, capsule deformation, and microstructural evolution throughout the heating, holding, and cooling stages. The transient temperature distribution inside the capsule and powder regions was analyzed to reveal axial and radial gradients affecting local densifi-cation and stress development. Austenite grain growth during the high-temperature stage was modeled considering temperature, pressure, and holding time, while grain-size-dependent martensitic and bainitic transformations were simulated during cooling. The influence of capsule geometry, wall thickness, and weld-line profile on densification and distortion was also assessed. The simulation results show excellent agreement with experimental observa-tions, confirming the model’s capability to accurately reproduce both capsule deformation and phase transformation inside capsule. This framework provides a powerful tool for optimizing HIP parameters and capsule design to achieve controlled capsule, reduced distortion, and desired microstructures in near-net-shape HIP components.

075 - Thermal Diffusivity of Common PM Steels
Bo Hu, North American Höganäs Co.

Powder metallurgy (PM) is a thermal process to sinter powder particles together and form designated microstructures through metallurgical phase transformation to achieve desired mechanical and material properties. The process relies on thermal diffusion to disperse heat throughout the body of components, causing atomic or molecular interactions between the base metal, alloying elements, and additives, while the rate of removing heat from the sintered body during the cooling stage of sintering determines the metallurgical phase(s) formed. Therefore, thermal diffusivity plays an important role in sintering of PM components. This paper presents analysis of the thermal diffusivity of common PM steels with different metallurgical phases at a temperature range from 25°C to 500°C. The materials investigated include iron and carbon steels, copper and nickel steels, prealloyed and diffusion-alloyed steels, sinter-hardened steels, and stainless steels. The study also examines the effect of density (porosity) and alloying elements on thermal diffusivity. Understanding the thermal properties of PM materials provides insights to the sintering process as well as post-sintering operations such as heat-treatment and machining.   

016 - Steam Oxidation of FL-5008
Roland Warzel III, North American Höganäs Co.

Steam oxidation is a common secondary operation applied to powder metallurgy (PM) components where a superheated steam-rich atmosphere is used to produce a layer of iron oxide on the component surface and surface of any surface connected porosity. This iron oxide layer seals the surface porosity and can provide improved corrosion resistance. The oxidation layer also increases the hardness, improves wear resistance and increases the compressive yield strength of the material. Steam oxidation is well established and can be applied to ferrous PM alloys through either a continuous or batch process. The FL-5008 steel, which uses Cr-prealloyed powder as the base material, was recently standardized to provide a sustainable alternative to copper steels. As copper steels are a common material which is steam oxidized, the properties of the FL-5008 after steam oxidation are required. In this study, FC-0208 and FL-5008 specimens were subjected to both a continuous and batch steam oxidation process at multiple density levels. The properties of the steam oxidized materials will be presented and compared to published data. 

040 - Improving the Toughness of Hiped Low Alloy Steel Nuclear Pressure Vessel Material By the Use of A Powder Oxide Stripping Process
John Sulley, Rolls-Royce

Hot Isostatic Pressing has been used by Rolls-Royce to successfully manufacture nuclear plant components, the majority of which being manufactured from stainless steels, typically 316L. There are considered to be potential benefits to be gained by manufacturing large nuclear plant pressure vessels via the HIP process, such vessels commonly being manufactured from Low Alloy Steel (LAS) materials such as ASME SA-508. HIPing of LAS presents particular challenges due to the propensity for LAS powder to create a surface oxide, which can subsequently affect the toughness properties of the material. Rolls-Royce has conducted work in this field attempting to achieve properties equivalent to the wrought form. Thus far Rolls-Royce has only been able to achieve equivalent toughness by having an oxide stripping process conducted on the powder prior to HIPing. This paper presents the work conducted showing the material property results of unstripped and oxide stripped powder.

Of note is that although the unstripped powder had a very low oxygen content with the powder being produced by the gas atomised, vacuum melt process, which minimises oxygen pick-up, this did not enable toughness properties to be achieved equivalent to forged material. Oxide stripping of this powder was required to reduce the oxygen content even further to achieve equivalent toughness properties.

230 - High-Density PM and Functional Density Gradients via Advanced Compaction and Sinter-Forging Routes for Superior Strength with Weight Reduction
Sudarshan Palve, Egearz Pvt Ltd

With the advent of technological upgrades, the requirement for higher performance is increasing in many applications. Higher performance in powder metal components indicates the need for higher density levels or controlled density gradients, including near full densities. This paper focuses on advanced manufacturing techniques that enable the achievement of higher density levels, allowing components to be optimized for strength, weight, and cost.
A range of powder metallurgy and hybrid manufacturing methods are studied, including Warm Die Compaction, 2P2S, Ultra-Densification, Sinter Forging, and High-Temperature Sintering. Each process was evaluated for its capability to achieve high density levels, and some were assessed for their ability to generate functional density gradients within a single component.

Results demonstrate that controlled density gradients can deliver substantial improvements in performance while reducing material usage and overall manufacturing cost. The results provide a process-selection framework suited for application driven part design, enabling the development of next-generation components with enhanced reliability, mechanical strength, and tailored functional properties.

096 - Analysis of the Effects of Lubricant and Iron Powder Particle Sizes on Compaction Behavior
Naofumi Takatori, JFE Steel

With the electrification of vehicles, the demand for high-performance magnetic components such as reactors has been increasing. This trend has led to the growing use of iron powders finer than those traditionally employed in powder metallurgy. Lubricants play a crucial role in the compaction process, but the influence of particle size combinations between iron powder and lubricant on compaction behavior is still not well understood. This issue becomes particularly important when fine iron powders are used, as their interaction with lubricants may differ from that of conventional powders.

This study investigates the effects of iron powder and lubricant particle sizes on compaction behavior. Experimental results indicate that green density tends to decrease when finer iron powders are combined with conventional lubricants. In contrast, fine lubricants exhibit minimal sensitivity to the particle size of iron powders.

To elucidate the underlying mechanism, a compaction equation was applied to decouple the effects of particle rearrangement and particle deformation during compaction. The analysis suggests that the reduction in green density is primarily attributed to inhibited particle rearrangement. Furthermore, scanning electron microscopy (SEM) observations were conducted to examine particle rearrangement behavior, corroborating the analytical findings.

229 - Functionally Graded Printed Compaction Tools
S. Sundar Sriram, Sundram Fasteners Limited

Powder-compaction punches require high strength and wear resistance in the working zone, while the non-working body primarily demands toughness and stiffness. This work presents a proprietary Laser Powder Bed Fusion (LPBF) methodology to fabricate Functionally Graded Compaction Punches (FGCPs) using multi-material printing of tool steels and alloyed carbon steels. Two combinations were evaluated: (1) hot die steel with Ni-Mo alloyed medium carbon steel, and (2) high-speed steel with medium carbon Mo alloyed steel. Performance was benchmarked against conventional HSS punches. FGCPs showed  up to 40% higher tool life and 20–30% lower material cost, establishing multi-material LPBF as a strong alternative for next-generation compaction tooling.

020 - The Influence of Particle Size and Morphology on the Hausner Ration in Additive Manufacturing Refractory Metal Feedstocks
Scott Ohm, Elmet Technologies 

Powder flowability is a critical quality attribute for ensuring process stability and final part quality in powder bed-based Additive Manufacturing and other powder-handling industries. The Hausner ratio calculated as the ratio of tapped density to loose bulk density, is a widely adopted, rapid metric used to empirically quantify powder cohesion and flow behavior. This paper investigates the quantitative influence of two fundamental particle characteristics: particle size and particle shape (morphology), on the resulting Hausner Ratio of AM Refractory Metal powders. Molybdenum powder will be examined in 3 standard grades: fine powder metallurgy grade, spherical thermal spray grade, and high density spherical AM grade.  Powders with controlled particle sizes ranges and varying morphologies (ranging from highly spherical to irregular/angular) were characterized using image analysis and standard density measurements. The results will demonstrate the strong effect of particle size and morphology as it relates to the Hausner ratio and will compare the results to the standard test method for the flow rate of metal powder using the Hall Flowmeter funnel.

049 - Effect of Humidity on Commercial Pure Ti Powder Properties
Abdelrahman Khalil, McGill University

The quality of the powder feedstock is critical in minimizing defects in laser powder bed fusion parts. Due to their small size and high surface energy, these particles tend to interact with contaminants, such as moisture, during handling, reuse, and storage. While these phenomena are being studied in Al alloys, the data set on Ti powder remains incomplete. To address this knowledge gap, this project first examined the impact of humidity on the properties of commercially pure (CP) titanium powder. Upon reaching saturation in relative humidity ranging from 20% to 60%, the powder was tested for flowability, apparent and tap density, rheology, and tribocharging. These results were then correlated with the surface composition, which was analyzed using X-ray photoelectron spectroscopy.

287 - Deterioration of Part and Powder Quality Through Multiple Powder Bed Fusion Cycles
Dina Khattab, Purdue University

C103 has gained significant attention due to its high strength and temperature capabilities. Additive manufacturing can produce complex C103 components suitable for various fields, such as aerospace, due to its lower ductile-to-brittle transition temperature than other refractory metals. A challenge with C103 is its low oxidation resistance, which makes it susceptible to oxide formation during the various heating cycles involved in powder bed fusion, even in low-oxygen environments. This study aims to monitor the deterioration of C103 components made with PBF across 14 different print cycles. In addition, powder samples of each build are taken to monitor the powder’s reusability for subsequent usage. Part density, porosity, and oxygen content are analyzed across the various builds, along with changes in mechanical properties. Finally, a strain rate sensitivity analysis is performed to determine the effect of strain rate on wrought vs AM built samples through tensile and nanoindentation testing.

146 - Toward Unified Dynamic Image Analysis Specifications for Metal Powders Across Multiple Alloy Systems
Rajeshree Varma, Purdue University

Characterizing metal powder morphology is important for powder metallurgy and additive manufacturing. In this work, Dynamic Image Analysis (DIA) was used to measure the size and shape of titanium, copper, and steel powders. All powders were evaluated using the same imaging instrument, with settings adjusted as needed for differences in reflectivity and particle appearance.

DIA was used to extract quantitative shape descriptors including form factor (FF), elliptical form factor (EFF), convexity, solidity, and Fourier based curvature metrics. Curvature analysis captured fine surface features such as satellites, uneven edges, and local irregularities that are not well represented by traditional shape factors.

Principal component analysis showed that two descriptors, particle elongation (ARbox) and perimeter complexity (EFF), explained most of the shape variation across all powders. Curvature skew provided additional sensitivity to irregular or partially fused particles.

These results show that DIA can generate consistent and comparable morphology measurements across different metal powders. This supports the development of broader, material independent approaches for powder quality control and provides a basis for linking powder morphology to performance in powder metallurgy and additive manufacturing.

148 - Particle Shape and Packing: A DIA-Based Approach
Rajeshree Varma, Purdue University

Packing behavior in metal powders is influenced by how particles interact, and small surface features can play an important role in how efficiently powders settle under gravity or tapping. This study examines whether curvature-based morphology metrics obtained from Dynamic Image Analysis (DIA) can help predict simple packing responses such as bulk density and tap density.

Metal powders will be analyzed using the Canty InFlow system to obtain quantitative shape descriptors, including form factor, elliptical form factor, aspect ratio, convexity, solidity, and Fourier-based curvature measurements. Curvature analysis is used to capture local surface variations such as satellites, rough edges, and fused regions that may increase friction or hinder particle rearrangement.

Bulk density and tap density will be measured for each powder, and these values will be compared directly with the DIA shape metrics to identify which descriptors show meaningful relationships with packing efficiency. The goal is to determine whether curvature-related features provide useful predictive information beyond traditional shape factors. This work aims to establish a simple experimental framework for linking particle-level morphology to practical packing behavior in metal powders used for additive manufacturing and powder metallurgy.

137 - New Rotating Drum Rheometer Measurements to Better Predict Powder Behavior in AM Printers
Gregory Martiska, Mercury Scientific, Inc.

Rotating drum rheometers are widely used in the powder AM field to characterize powder flow properties. The measurements are used to determine if powders will perform well or poorly in printers and if their flow properties are changing with use. Poor performance can mean the powders produce non-uniform layers, intermittent layers, or no layers at all.  This study introduces new measurement parameters made in a rotating drum rheometer that identify the pattern of powder flow to better predict powder behavior and identify the type of layers powders will produce in printers.

196 - Bringing Components Back to Life from the Broken Dream Graveyards: A Novel Chemical Strategy to Remediate Trapped Powder in Metal AM Internal Cavities and Passages
Agustin Diaz, REM Surface Engineering, Inc.

The rapid expansion of metal additive manufacturing (AM) has enabled exceptional design freedom, especially for components with complex internal features. However, post-processing challenges persist, particularly the removal of powder trapped within enclosed passages, notably in heat exchangers (HXs). Such blockages can occlude flow paths, hamper performance, and lead to high scrap rates when traditional powder-removal methods such as vibration, high-frequency agitation, or high-pressure air/IPA flushing fail in intricate channels. To address this gap, we developed a selectively reactive chemical treatment that targets unfused or partially sintered powder while preserving the integrity of the consolidated metal. The tailored formulation is injected into clogged passages, dissolving loosely bound powder through a controlled self-limiting reaction that strongly favors powder over fused metal. Pressure fluctuations during processing generate turbulence that mobilizes and evacuates the reduced powder. Once declogged, a chemical polishing process treatment can be employed to reduce surface roughness, improve flow characteristics, and tune pressure-drop behavior. Demonstrations on AlSi7Mg, AlSi10Mg, CP-1, IN-718, and Ti-6Al-4V components, show significant improvements in internal cleanliness, surface finish, and restored fluid dynamics. These results enhance performance and economic sustainability, with strong relevance for high-value aerospace and defense applications. This work was supported by the U.S. Air Force (SBIR-FA864923P0707 and FA864922P0969).

147 - Seeing Recyclability: Morphology Mapping of Vacuum Recovered Metal Powders
Rajeshree Varma, Purdue University

Powder collected in vacuum filters from large additive manufacturing systems often contains material from multiple alloys and build cycles, but its condition and reuse potential are not well defined. In our lab, a substantial quantity of vacuum recovered powder was obtained from one of the industrial printers. The material is expected to contain a mixture of low strength carbon steels and high strength alloys, and its morphology has not yet been evaluated.
This project will characterize the recovered powder using Dynamic Image Analysis (DIA) with the Canty InFlow instrument. The planned analysis includes threshold calibration, perimeter detection checks, and extraction of shape descriptors such as form factor (FF), elliptical form factor (EFF), convexity, solidity, and Fourier based curvature metrics. These measurements will be compared against reference powders to identify signs of particle damage, surface irregularities, fines, or fused features that may develop during repeated thermal exposure.

The goal of this work is to determine whether DIA can provide a reliable first-screening method for assessing the recyclability of vacuum recovered powders. Data collection and analysis are currently in progress, and the results will guide the development of simple criteria for evaluating recovered powder before reuse in large-scale additive manufacturing.

019 - Supporting the Royal Canadian Navy by Recycling Critical Materials to Produce AM-Grade Metal Powder
Manuel Martin, Industrial Materials Institute - NRC

Maintaining legacy assets presents a significant challenge for many industries or organizations, particularly when supply chains are stressed, specialized tooling is no longer available, or critical materials are scarce. In response to these issues, the National Research Council (NRC) of Canada has been mandated by the Royal Canadian Navy (RCN) to investigate the recycling of discarded nickel–aluminum bronze components into high quality additive manufacturing powders. This feedstock can then be used to produce replacement parts or to repair worn components. Leveraging its newly developed powder atomization capabilities, the NRC team has demonstrated the technical feasibility of this approach. The work involved optimizing each stage of the recycling process, from atomization feedstock preparation to powder production, followed by laser powder bed fusion trials to assess the quality and performance of the recycled powder. Results confirm that the recycled material processed by LPBF meets the standards for applications, enabling the RCN to secure a reliable source of a critical material. This innovative method not only addresses supply chain vulnerabilities but also offers a pathway to accelerated maintenance solutions, reducing fleet downtime and extending the operational life of naval assets.

191 - Properties of WC-Co with Alloyed Binder
Oladapo Eso, Kennametal Inc.

Alloying is an effective approach to modify material properties such as improving strength, increasing corrosion resistance, and changing thermal conductivity. By combining the cobalt binder in WC-Co with other elements, superior property combinations of WC-Co can be realized. Elements such as molybdenum (Mo), ruthenium (Ru), and rhenium (Re) that form solid solutions with the binder of WC-Co can provide property enhancement. This study presents the mechanical properties and thermal conductivity of WC-Co whose binder is alloyed with Mo, Ru and Re. The effect of the different alloying elements on the mechanical properties and thermal conductivity of WC-Co was investigated. Compositions with optimal properties were identified.

135 - Creep Behaviour of Cemented Carbides — Influence of Binder Alloy Composition and Carbon Content
Ralph Useldinger, University of Luxembourg

This study investigates the high-temperature creep behaviour of cemented carbides in binder alloys comprising pure Co, Co-Ni, and Co-Ni-Cr compositions at temperatures of 800 °C, 900 °C, and 950 °C. The creep behaviour was characterised using compressive high-temperature experiments. This experimental investigation considers a systematic variation of carbon content, with the objective of avoiding the formation of eta phase or free carbon. The aim is to establish relationships between binder composition, carbon content, and creep resistance in cemented carbides. Understanding the role of alloying elements in the Co-based binder and their interaction with carbon variations is essential for developing materials with improved thermal stability and mechanical performance. The investigation explores how Ni and Cr additions to the Co binder influence dislocation mobility, grain boundary stability, and diffusion-controlled deformation mechanisms across the temperature range studied. Special emphasis is placed on identifying the optimal carbon content for each binder composition to maximise creep resistance while maintaining phase stability. The results provide insight into the dominant deformation mechanisms active at different temperature regimes and support material design guidelines for advanced cemented carbides used in cutting tools, wear parts, and high-temperature components subjected to prolonged mechanical loading.

106 - Discrete Element Method Simulation of Three-Point Bending Test for Cemented Carbide
Sota Terasaka

WC-Co cemented carbide is used in a wide range of fields such as cutting tools and wear-resistant tools, and its strength is an important property from the perspective of preventing tool breakage. For the strength of medium-grained cemented carbide, the size of the defect that initiates the fracture origin is crucial, and it is known that the degree of strength increase decreases when the defect size becomes smaller than a certain size. However, the cause of this phenomenon is unclear, and clarifying the relationship between defect size and strength in cemented carbides is an important topic. In this study, a three-point bending test simulation of cemented carbide was performed using the Discrete Element Method (DEM), which enables fracture calculations, by placing particles equivalent to defects within the test specimen. The relationship between defect size and load was analyzed. It was possible to calculate the process by which the test specimen deformed and fractured under load. Analysis of the load-displacement curve revealed that as the defect particle size decreases, the failure load increases, but the degree of increase in the failure load decreases. From these results, the simulation exhibits behavior similar to the relationship between defect size and strength observed experimentally in cemented carbides, suggesting that this simulation is effective for analyzing the fracture of cemented carbides.

224 - Advanced Refractory Metal-Based Composites by Electro-Sinter-Forging: W–Cu and Novel W-free Synaptite Systems 
Sébastien Recalcati, EPoS Technologies SA

Electro-Sinter-Forging (ESF) is an advanced Field Assisted Sintering Technique (FAST) that couples a high-current electrical pulse with rapid uniaxial pressing to consolidate powders in air within milliseconds. This short thermal cycle prevents long-range substitutional diffusion while promoting fast interstitial transport, producing fine microstructures. ESF provides a versatile pathway for producing dense metals and composites with tailored properties while drastically reducing processing time and energy use compared with other sintering routes.

Using ESF, W-Cu pseudo-alloys have been produced from mechanically alloyed powders. Their refined microstructures result in hardness up to 350 HV for W75–Cu—while maintaining electrical conductivity up to 26 MS/m (45% IACS) and excellent machinability. These attributes make ESF-processed W–Cu materials highly suitable for resistance-welding or EDM electrodes, and precision components requiring thermal stability, wear resistance and electrical performance.

In parallel, tungsten-free Cu–Mo–TiN composites “Synaptite”, have been engineered as sustainable alternative. With hardness from 250 to 600 HV, conductivities of 5.8 and 25 MS/m (10–42% IACS), and hot yield strength of 510 MPa at 500 °C, Synaptite materials can surpass the performance of W75–Cu. Their mechanical robustness, chemical stability, and excellent machinability position them as credible next-generation refractory electrodes. Their electro-mechanical behaviour aligns within the envelope of RWMA Class B materials, providing a viable tungsten-free solution for resistance-welding applications.

029 - Exploration of W–Ni–X Systems for Lower-Temperature Sintering of Tungsten Heavy Alloys
Thibaud Hureaux, Plansee Tungsten Alloys

Reducing the sintering temperature of tungsten heavy alloys (WHA) is a key objective for improving industrial efficiency and sustainability while maintaining high mechanical performance. The challenge lies in achieving adequate liquid-phase formation and material densification at lower temperatures without compromising strength or ductility.

A comparative study of several W-Ni-X systems (X = Co, Mn, Ti, etc.) was carried out, combining available thermodynamic data and published findings. This effort focused on identifying alloying strategies that support effective sintering below the temperatures typically required for standard tungsten heavy alloys (> 1500?°C).

Among the investigated systems, the W-Ni-Mn alloy has long been considered a promising candidate since the 1990s but has received limited attention. In this work, several compositions with different Ni/Mn ratios were sintered at various temperatures using pre-alloyed Ni–Mn powders, to examine their resulting microstructures and sintering behavior.

This study, conducted in an industrial R&D context, provides an initial experimental basis for a deeper understanding and future optimization of new cost-efficient WHAs.

233 - 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.

613 - From Microstructure to Processing and Properties: FIB, PFIB, SEM and TEM Characterization of Additively Manufactured Titanium Alloys
Phillippe Plamondon

Additive manufacturing of metals, such as laser powder bed fusion of titanium alloys, produces complex and heterogeneous microstructures that strongly influence the performance of printed parts. Understanding these microstructures requires a combination of advanced techniques such as electron microscopy and focused ion beam (FIB). In this presentation, we show how scanning electron microscopy (SEM), gallium-based FIB, plasma FIB (PFIB), and transmission electron microscopy (TEM) can be combined to characterize additively manufactured materials, with examples from Ti-6Al-4V alloys. The Ga-FIB enables precise preparation of thin TEM lamellae for detailed phase and crystallographic analysis, while the Xe-based PFIB allows rapid milling over large areas, enabling 3D reconstructions and large cross-sectional imaging. Combining these approaches with energy-dispersive X-ray spectroscopy (EDS), wavelength dispersive spectroscopy (WDS) and electron backscatter diffraction (EBSD) provides a complete description of the material’s chemistry, grain structure, and phase distribution. In addition, in situ SEM experiments, such as tensile testing and high-temperature observations, are used to study the evolution of microstructure and deformation mechanisms directly under the electron beam. Together, these techniques offer a comprehensive view of the material’s behavior across multiple scales, supporting a better understanding and optimization of processing parameters and post-treatments in metal additive manufacturing.

614 - Turning Oxygen Embrittlement into an Asset: Strong and Ductile High-Oxygen Ti-O-Fe Alloys
Ma Qian, Royal Melbourne Institute of Technology (RMIT)

This work presents a new class of high oxygen titanium oxygen iron alloys that transform oxygen embrittlement from a long standing liability into a critical asset. By integrating compositional design, laser additive manufacturing, and targeted annealing, we have developed α β Ti O Fe alloys that utilize elevated oxygen content (≥0.40 wt%) together with iron additions (4–5 wt%) to activate pyramidal <c+a> slip and sustain cross phase slip transfer. The resulting alloys exhibit unprecedented mechanical performance: Ti 0.45O 4Fe achieves ≥14% uniform elongation (≥27% total) at a yield strength above 980 MPa, whereas Ti 0.5O 5Fe retains ≥13% uniform elongation at a yield strength exceeding 1075 MPa. The microstructural evolution and underlying deformation mechanisms are elucidated in detail through multi scale characterization.

615 - High Performance Alloys via Advanced PM & Consolidation Processes
Bradley Richards, Materials Implemented

Advanced PM and consolidation processes are playing an increasingly important role in rapid part replacement, sustainment operations, and substitution for complex and inefficient legacy processes. The capability to cost-effectively consolidate cast and wrought performance equivalent components from advanced materials has opened new opportunities. Solid-state consolidated products can now be used in and meet requirements for demanding applications for titanium and titanium alloy components and represent a method to fabricate titanium structures separate from the traditional supply chain. This presentation will provide a deep dive into several different PM / advanced consolidation processes for titanium and review how those deliver material performance and economic benefits with distinct advantages over legacy production methods. The processes that will be discussed include (i) kinetic consolidation via cold spray, (ii) an ultra-fast sintering process compatible with most classes of metals and cermets, and (iii) field assisted sintering of materials. All three process / application combinations that will be reviewed represent key opportunities to replace incumbent processes while offering significant economic, lead time, and capability advantages for the specific components for which they are used. The development of equipment and process capabilities for titanium represents an important and ever-expanding growth vector for PM and solid state technologies.

519 - Strip Casting and Scaling-up Production of Rare Earth Magnet Materials
Sasha Long, Arcast Inc.

Rare earth magnet materials and production is one of the biggest topics in materials in recent years. The headlines are about NdFeB and the efforts to bring this production back to North America and Europe. But these are not the only materials to consider. Rebuilding the know-how and the industrial capital from what was originally lost from the USA when MagnaQuench relocated to China has significant challenges. While good strides have been made to establish small and medium scale processing of these materials there is still much work to be done for large scale production. We will review the challenges and areas to consider for microstructure control, and chemistry control during strip casting and post casting in the collection and handling of the material. We will also explore the state-of the art and what challenges lay ahead. 

520 - Vacuum Strip Casting: Regaining Lost Technology for Future Advancement 
George Bernhard, Consarc Corporation

The rapid solidification of rare-earth-containing alloys by means of strip casting for use in permanent magnets was once an established practice for powder production in North America. For several decades, this method has been all but nonexistent, with furnaces shipped overseas, scrapped, or mothballed. With the recent rise in demand for Western sources of rare earth magnets, the need for Western-produced strip casters has rapidly reemerged. To meet this need, old technology has been resurrected, modern technologies have been integrated, and completely novel aspects of the equipment have been developed to build the magnet production facility of today and tomorrow. 

521 - Bringing Back Magnet Production to the US: Opportunities and Challenges 
Aamir Abid, Retech

As demand for high-performance permanent magnets grows, reshoring magnet powder production has become a strategic priority for advanced manufacturing. Drawing on decades of metallurgical expertise, Retech Systems LLC, explains how advances in vacuum melting, strip casting, and plasma gas atomisation are enabling reliable domestic production of rare earth magnet powders, supporting supply-chain resilience and reducing dependence on scarce heavy rare earths.