Search Results for atomized powders

Beryllium won a lengthy competition as the material of choice for the mirrors on the James Webb Space Telescope, set to launch in 2018. This article documents the development history leading up to that decision. It took decades to perfect powder atomization and HIP'ing processes to make optical-grade beryllium components homogeneous, isotropic, polishable, thermally and dimensionally stable, and above all, predictable.

A new single-step plasma-assisted gas atomization process for metal powder manufacturing can reduce carbon footprint by over 99% compared to traditional methods. This technology uses scrap metals as feedstock, eliminating the need for virgin ores while meeting ASTM/AMS powder quality specifications. Beyond environmental benefits, the innovation addresses material scarcity that has historically constrained the additive manufacturing industry while mitigating supply chain delays and market uncertainties. The process supports manufacturers in achieving environmental goals through significant emissions reduction and localized sourcing.

This article, the first in a two-part series, explains how powder metallurgy presents a cost-effective alternative to conventional titanium fabrication processes. It reviews the characteristics of different types of titanium powders and compares and contrasts near-net shape (NNS) production techniques, including conventional press-and-sinter, cold isostatic pressing (CIP), hot isostatic pressing (HIP), CIP-sinter, and CIP-sinter-HIP (CHIP). Other titanium production methods are covered in Part 2, which is scheduled for the October 2012 issue of AM&P .

This article series explores the indispensable role of characterization in the development of cold spray coatings. Electron backscatter diffraction (EBSD) is a characterization technique that enables determination of crystal orientations, texture, boundary misorientations and deformation behavior, and bonding mechanism in cold spray coatings.

This article series explores the indispensable role of characterization in the development of cold spray coatings. Transmission electron microscopy is used to understand powder characteristics, cold spray coating deformation behavior both within splats as well as near the coating-substrate interface, phase transformations in the as-sprayed and heat treated conditions, phase equilibria of the coating under the operating conditions pertaining to the application of the coating, the coating recovery mechanism, and the thermal stability of the coating.

A powder metallurgy and hot isostatic pressing technology offers a new way to manufacture high pressure-retaining components for use in the power-generation industry.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

Temperature measurement, unvented cavities, loose powder, and direct contact of certain metals must be considered during process development for vacuum heat treatment of additively manufactured parts.

This article is the second in a two-part series on cost-saving methods for the production of titanium components. Part 1, published in the September 2012 issue of AM&P , covered a number of powder metallurgy techniques, including press-and-sinter and both cold and hot isostatic pressing. Other near-net shape processes are described here, including additive layer manufacturing (ALM), metal injection molding (MIM), and spray deposition (SD). Examples are also given showing how titanium PM parts compare with cast and wrought components.

The fraction and size of pores present in EBM Ti-6Al-4V specimens varies depending on the melting strategy used, whether linear raster melting or point melting.

Radio frequency inductively coupled plasma (RF-ICP) spraying is shown to be a promising method for producing oxidation-resistant W and W-Cr coatings on plasma-facing surfaces in fission and fusion reactors.

The ability to make components from copper and copper alloys via additive manufacturing is spurring a range of novel applications. Although the high thermal conductivity of copper presents challenges for direct AM processes, fully dense copper components with complex geometries have been demonstrated. Of particular interest is the ability to use AM methods to fabricate internal cooling channels and mesh structures to optimize thermal management. This article describes feasibility studies to evaluate AM processing of copper parts.

John J. Croat and Masato Sagawa simultaneously and independently invented the world’s most powerful permanent magnet, the neodymium (NdFeB) magnet, and established two different manufacturing methods to produce it. Their achievement is recognized by the 2023 Honda Prize, awarded by the Honda Foundation. This article highlights each inventor’s research contributions.

George Pfaffmann was highly regarded as a true leader and innovator in induction heating technology.

High-strength, corrosion-resistant steel is proposed as a cost-effective alternative to titanium alloys due to its high specific strength, high fatigue strength, good toughness, and corrosion resistance.

In cold spray characterization, scanning electron microscopy is used to analyze feedstock powders for particle size, distribution, shape, and chemical composition prior to spraying. SEM is used extensively to characterize coating chemistry via energy-dispersive x-ray spectroscopy (EDS). Coating thickness and interface contour can be characterized in a manner that makes SEM an indispensable and versatile tool for evaluating coating integrity in the as-sprayed condition, as well as in developing an understanding of bonding to the substrate.

This article explains how SEM, TEM, and atom probe tomography are being used in the development of additively manufactured high-entropy alloys (HEAs), revealing critical features such as anisotropic microstructure and metallurgical defects. It also discusses ongoing efforts to improve the predictability and analysis of HEA microstructure using data-driven approaches.

Boriding is performed by diffusing boron atoms into a metal surface and allowing the boron to react with elements present in the substrate to form metal-boride compounds. Upon diffusing enough boron into the surface, a metal-boride compound layer with high hardness precipitates and grows below the surface of the part. This article discusses boriding of ferrous alloys, including a new deep case boriding method that produces wear layer depths comparable to competitive processes such as carburizing, nitriding, thermal spray coatings, and hardfacing.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

Enhanced antiviral performance is associated with antipathogenic copper material consolidations obtained using cold spray processing.