Thermal spray coatings are widely used to keep power plants running at full capacity. An example is the application of HVOF-sprayed CrC-NiCr to protect generating and superheater banks from sulfuric and vanadium gases. Other examples include the use of arc spraying to deposit high Cr content Ni alloy to extend the life of coal-fired boiler tubes and to apply amorphous work hardening coatings to surfaces in the flu gas path that are susceptible to high-temperature corrosion and wear.

A hydrogen gas generator plant offers a flexible hydrogen supply solution to the powder metallurgy industry. This article provides an overview of a unique steam methane reformer that uses an integrated heat recovery system to reduce the cost and improve the reliability of hydrogen gas supply.

In the quest to improve the reliability of partial penetration welding validation, advanced ultrasonic testing techniques have replaced other less accurate methods. This case study compares weld penetration inspection results from phased array ultrasonic testing and the total focusing method in a rib-to-deck assembly on the top part of an orthotropic steel bridge deck.

Researchers are supplying the aerospace industry with innovative technologies to support the next generation of more efficient and reliable aircraft. This article describes a novel laser technology for measuring stress and damage in the protective ceramic coatings applied to turbine engine blades to prolong their life.

While today's composites encompass a broad and well-established family of materials, the commercial market for high-performance, structural composites has actually existed for well over 30 years. Adoption in the aerospace industry has resulted in a wide range of static test methods offering reliable results. This article reviews some recent innovations in composites testing, including developments related to fatigue testing, high strain rate testing, thermography, and high capacity test systems.

An ultrafast, efficient industrial-scale boriding process can drastically reduce costs, increase productivity, and improve the performance and reliability of a variety of machine parts. This article describes a novel, environmentally friendly technology that enables treating thousands of industrial components in one batch, without creating solid or liquid waste and gaseous emissions.

Recent advances in thermal spray techniques enable thermal spray aluminum coatings to reliably protect offshore oil and gas platform structures. This article presents a case study of preparing thermal spray aluminum coatings to protect steel structures in the splash zone. Testing and industry experience in marine environments indicate that aluminum coatings are a long-term solution for protection of hot risers in submerged, splash zone, and atmospheric service environments.

Recent advances in thermal spray techniques enable thermal spray aluminum coatings to reliably protect offshore structures in splash zones.

Induction heating is used to produce high quality, reliable aerospace components as well as unique combinations of engineering characteristics.

As powder-based additive manufacturing (AM) processes continue to mature, reliable powder characterization techniques will be key to optimizing both AM processes and final part performance. This article describes advanced metals for assessing powder properties and their influence on AM processing and part performance.

As the engineering systems of the world adapt and change due to the effects of the pandemic on global health and worldwide economies, engineers and scientists provide paths of preservation to ensure safe and reliable operations.

This article presents examples of engineered parts where PEEK (polyether ether ketone) thermoplastics have replaced traditional materials such as stainless steel, aluminum, titanium, and glass.

An advanced, patented probe sensor provides early detection of water infrastructure problems caused by corrosion and harsh atmospheric conditions. Designed to detect graphitization in active pipelines, it identifies areas at risk of major failures early on. By using indirect methods like GIS mapping, in-situ soil resistivity testing, and structure-to-soil potential measurements, high-risk zones can be pinpointed. Once these areas are identified, the probe assesses the severity and depth of graphitization, providing a comprehensive evaluation of the pipeline’s condition. This allows for the implementation of effective corrosion management strategies, including cathodic protection systems, to prevent critical failures. This article describes the sensor system and provides a case study of its use. The technology received the 2024 Engineering Materials Achievement Award from ASM International.

Flow measurement is an increasingly important part of quality control systems in the heat treating industry. This article discusses the most commonly used flow measurement instruments and compares their operating principles.

Accurate and continuous dew point measurement is key to maintaining the atmosphere required to achieve high quality and consistency of sintered products in powder metallurgy processing.

Capable of stopping 50-caliber, armor-piercing rounds, ALON and Spinel are hard and durable transparent polycrystalline materials manufactured using powder based processes. This article describes their unique combination of mechanical, optical, and chemical properties, and reports on recent advances in manufacturing to enable their use for critical defense, industrial, and consumer applications.

This guide outlines recent advances in the various methods of laser technology and appropriate manufacturing applications. Each process has unique requirements and matching the laser source to the project is essential for developing a robust solution.

Use of radiography to inspect insulated generator components without the need to strip insulation offers advantages over other inspection methods to assess serviceability and need for repair. This article outlines some of the considerations involved in using nondestructive radiography techniques to assess component integrity.

This case study reviews the considerations in applying plasma spray thermal barrier coatings on augmenters used in military aircraft turbine engines to extend their service life.

Examining a failed part’s fracture surface is a great source of information as to why and how it failed.