Enhanced mining tool performance is achieved through the use of reclaimed NiCrBSi-WC powders in laser metal deposition. Collection, analysis, and reuse of spilled powder lowers production costs and reduces environmental impact.

Wire arc directed energy deposition (WDED) is a robust alternative for large-scale metal printing. It offers high deposition rates, excellent material and energy efficiency, and reduced waste material compared to conventional manufacturing processes. This article describes a study that employed a combination of standard and advanced characterization techniques to assess the mechanical behavior of WDED titanium samples. This entry won first place in the light microscopy category of the prestigious 2023 International Metallographic Contest.

The integration of artificial intelligence for predictive modeling and adaptive learning allows manufacturers to achieve unprecedented levels of efficiency and precision in ceramic additive manufacturing products.

This article provides a brief overview of the many ways that artificial intelligence and machine learning are being used for materials and manufacturing research. Several case studies show how the discovery, development, and deployment of novel materials are being dramatically accelerated through automation and data-driven models.

Architected materials are a class of engineered materials carefully designed with an intricate arrangement of their internal structures. These materials leverage specific geometric patterns and configurations to impart tailored mechanical, thermal, or electromagnetic properties, giving rise to emerging functions and characteristics. This article reviews the characteristics and potential benefits of architected materials and describes a case study in which 3d printing was used to create lightweight aircraft runway mats with architected structures.

The benefits and flexibility of using additive manufacturing (AM) open up new possibilities for lithium-ion battery design and performance beyond the limitations of traditional manufacturing methods. In particular, AM offers the ability to build on-demand complex geometries and shape-conformable battery components with tailored properties. While 3D printing offers significant potential, challenges include considerations related to feedstock consistency, printing parameters, and electrochemical performance of the printed components.

This article summarizes the outcomes from a NIST-sponsored workshop that examined the additive manufacturing (AM) data management pain points experienced by small- and medium-sized enterprises in interacting with larger organizations and government procurement agencies. Three prominent themes emerged: cost of compliance, technology gaps associated with uncertainty and AM process qualification, and a desire for government leadership to address these issues. The article includes lists of specific action items proposed at the workshop to address these challenges.

The 15th World Conference on Titanium included papers on titanium alloy development, efforts to reduce Ti powder costs, additive manufacturing, and computational materials modeling tools. This article reviews some of the key advances reported at the conference.

Several key materials processes and techniques positively impact weight reduction and reusability of parts designed for travel to the moon, Mars, and beyond. This article addresses how advances in technologies such as additive manufacturing, friction stir welding, and surface analysis, can help further enhance design and fabrication of space systems.

This article presents highlights from a panel session held at International Materials, Applications & Technologies (IMAT) 2023. Experts from ASM affiliate societies shared insights on the impact of new materials and manufacturing technologies in their respective fields. The panel was moderated by David Furrer, Pratt & Whitney. The panelists were Thomas Ackerson, Blue Origin LLC (representing the Failure Analysis Society); Arvind Agarwal, College of Engineering and Computing, Florida International University (Thermal Spray Society); Marvin Barnes, NASA (Heat Treating Society); Jay Demarest, IBM (Electronic Device Failure Analysis Society); and Laura Moyer, Lehigh University (International Metallographic Society).

Additive manufacturing techniques give the mining industry a chance to revolutionize the conceptualization, prototyping, and production of mining tools, including using WC-Fe, Ni-based matrix coatings that display exceptional properties. The article includes a case study involving the successful utilization of WC-NiCrBSi mixed powder as a protective coating on AISI 9310 steel components to enhance wear resistance and durability for mining tool applications.

The manufacture of electric motors using additive methods offers potential advantages of increased efficiency, weight reduction, and customizability over traditional processes. This article describes some key developments and challenges related to additively manufactured electric motors in terms of manufacturing, materials development, and design.

This article reviews additive manufacturing technologies that can be used for manufacturing ceramics and ceramic-based composites. Stereolithography and associated techniques offer the possibility of producing ceramic components with finer resolution. Powder-based techniques like binder jetting and indirect selective laser sintering can be used for designing porous ceramics. Selective laser melting offers practitioners the option of manufacturing ceramics with minimal post-processing requirements, although further research is needed to decrease its cost.

Osaka University established the Center for Dissimilar Custom Design and Additive Manufacturing Research & Development to connect research-based AM with industrial implementation. It recently established another specialized AM research group at its new Anisotropic Design & Additive Manufacturing Research Center, which will further develop AM technology via an industry-academia collaboration. In this article, Hideyuki Kanematsu talks with Takayoshi Nakano, director of Osaka University’s newest research hub, about the center’s goals as well as the latest prospects for AM technology in Japan.

Ultrasonic additive manufacturing (UAM) originated from ultrasonic metal welding, first developed in the 1950s. Modern applications include welding of battery tabs, thin foil packaging, and electronic wire production. The article reports on a unique UAM method that excels at mixed metal applications. The technology won the 2022 ASM Engineering Materials Achievement Award.

This article starts with a synopsis of machine learning (ML) and explores the characteristics of ML algorithms. It then reports on the results of two recently completed research projects investigating the potential use of ML to establish additive manufacturing materials property allowables. Although continued research and development work is required, the results are very promising.

This article reports on the development of additive friction stir deposition techniques that use secondary feedstocks such as machine chips and damaged components to make in-field repairs at the point of need. The focus of the initial research was aluminum alloys. Preliminary studies show significant promise for the adaptation of these techniques to hard alloys including steel castings, wrought high strength steels, and titanium alloys.

Vat polymerization uses ultraviolet light to harden liquid photosensitive resins into medical products such as surgical models and artificial limbs.

Binder jet 3D metal printing is the ultimate bridge between prototypes and production of metal injection molded parts.

A look at how companies in regulated industries can test materials to produce higher quality metal components with additive manufacturing.