New Ames Lab Atomizer Develops Materials for Gas Turbines and Fusion Energy

Ames National Laboratory, Ames, Iowa, has established a new refractory metal powder atomization system designed to help researchers develop materials for extreme environments, including next-generation gas turbines and fusion energy systems.

Building on more than 40 years of expertise in metal powder synthesis and metallurgy, the system expands Ames Lab’s ability to produce high-quality powders from high-melting-temperature materials that are difficult to process using conventional methods.

The atomizer can process materials at temperatures up to 3400 °C and produce powder at rates up to one kilogram per minute. This capability addresses a major gap in materials development: researchers have identified promising ultra-high-temperature alloys through advanced computation and AI-enabled design, but often lack access to sufficient quantities of suitable powders for testing and validation.

Refractory metals such as tungsten, molybdenum, niobium, and vanadium offer extremely high melting points, making them attractive for turbine components that could operate at higher temperatures with less cooling and fewer thermal barrier coatings. However, these alloys are difficult to cast, forge, or machine into complex shapes. Powder metallurgy offers a solution, provided the necessary powders can be produced.

Ames Lab’s new system uses a transferred arc plasma process that locally melts feedstock in a water-cooled copper hearth. This approach improves safety, reduces time at high temperature, and helps maintain material purity.

Researchers are currently training with titanium alloys before moving to molybdenum, nickel-based superalloys, and materials for turbine and fusion applications. Funded through DOE ARPA-E’s ULTIMATE program, the atomizer is expected to support U.S. manufacturing, advanced energy systems, and ultra-high-temperature materials innovation.