In order to expand the choice of materials available for use in additive manufacturing, parameters that consider welding metallurgy, laser powder interaction, and post processing must be developed. This article describes the outcomes of process development for a steel and stainless steel alloy that are not standard materials for laser powder bed fusion equipment.

Flash processing, a new heat treatment for steels based on the concept of rapid thermal cycling, has been shown to achieve new levels of strength and ductility. This article describes the process, its effects on microstructure, and the phase transformations involved. It also discusses current and potential future applications.

Active screen plasma nitriding and nitrocarburizing are relatively new processes in which a plasma discharge is applied to a metal screen surrounding the workload, generating highly reactive gas species that flow to the component surface. The active screen also radiates heat, resulting in a uniform temperature throughout the load. This article provides an overview of the two processes and presents examples of their use on stainless steel piston rings (nitriding) and 4142 and 1045 steels (nitrocarburizing).

Compared to traditional power plant materials, creep strength enhanced ferritic steels require new approaches to nondestructive examination and weld repair. The metallurgical complexity of these steels prompted EPRI to conduct research to define and/or improve the detection limits of ultrasonic testing techniques, explore novel electromagnetic techniques, evaluate the sensitivity and applicability of acoustic emission testing, and conduct studies on improved weld repair procedures.