The next generation of materials and assemblies designed to address challenges in power generation, such as molten salt or supercritical carbon dioxide thermal transfer systems, corrosion, creep/fatigue, and higher temperature operation, will likely be highly optimized for their specific performance requirements. This optimization often involves strict control over microstructure, including homogeneity, grain size, texture, and grain boundary phases, as well as precise alloy chemistry and homogeneity. These stringent requirements aim to meet the new demands for bulk mechanical performance and durability. Some advanced materials, like oxide-dispersion strengthened or high-entropy alloys, necessitate specialized synthesis, fabrication, or welding/joining processes. Traditional methods that involve melting and solidifying can compromise the optimized microstructure of these materials, making non-melting synthesis and fabrication methods preferable to preserve their advanced characteristics. This paper presents examples where solid-phase, high-shear processing has produced materials and semi-finished products with superior performance compared to those made using conventional methods. While traditional processing often relies on thermodynamics-driven processes, such as creating precipitate phases through prolonged heat treatment, high-shear processing offers kinetics-driven, non-equilibrium alternatives that can yield high-performance microstructures. Additionally, examples are provided that demonstrate the potential for more cost-effective manufacturing routes due to fewer steps or lower energy requirements. This paper highlights advances in high-shear extrusion processing, including friction extrusion and shear-assisted processing and extrusion, as well as developments in solid-phase welding techniques like friction stir welding for next-generation power plant materials.

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