Linear friction welding (LFW) is a solid-state process capable of joining noncircular parts by oscillating one part under load to create frictional heating. From joining railroad rails to producing strong aluminum-to-steel joints, recent advancements in LFW technology are reducing equipment costs and expanding potential uses.

A new solid-state joining process for medical guidewire applications increases joint strength, provides superior bending properties, and does not require tertiary metals or ferrules. This process may be a superior method to create joints between dissimilar metals such as stainless steel and Nitinol.

This article reports on development of a versatile new technique that fills the need for grain etching in multiple aluminum alloy series. The procedure is a two-step etch that combines an attack etchant with a stain etchant to reveal grain structure of 2000, 5000, 6000, and 7000 series aluminum alloys. This entry won the prestigious DuBose-Crouse Award for unique, unusual, and new techniques in microscopy at the 2022 International Metallographic Contest.

Enhancement of the diffusion bonding process for the development of compact heat exchangers (CHXs) provides an energy efficient solution for high-temperature applications in advanced nuclear reactors and other technologies. However, available information is limited concerning the diffusion bonding (and manufacturing) of CHXs in high temperature applications and associated selection of bonded materials, bonding conditions, mechanical performance, and thermo-fluid characteristics. This article reviews the available knowledge and the ongoing research being conducted to address gaps in information and application.

Field assisted sintering technology (FAST) enables hybrid components for aerospace to be designed with reduced weight and without sacrificing performance. FAST can be used to produce metal, ceramic, and composite components with tailored properties via a powder metallurgy approach. In many cases, it is a one-step, cost-effective manufacturing process for production of net-shape components.

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.

Laser cladding applies thin deposits of hard or corrosion-resistant materials to surfaces susceptible to damage. This article discusses the advantages and drawbacks of laser cladding in comparison to thermal spraying.

The application potential of magnesium alloys as lightweight structural materials in aerospace and especially inside the aircraft cabin are hindered by their high surface reactivity at increased temperatures with particular concerns of ignition and flammability during a potential contact with a flame or other heat source. This article describes global efforts to develop ignition-resistant and nonflammable magnesium alloys. A widely explored avenue involves microalloying magnesium with rare earth metals and other elements having a high affinity to oxygen. As demonstrated by experimental alloys, this approach allows shifting the ignition temperature well above the liquidus, not only easing requirements on protective atmospheres during liquid-state processing, but also increasing the safety margin for possible aerospace applications.

Supersonic spray technology (SST) cold spray enables metal consolidation that can dimensionally restore precision gauges and fixtures made from heat-sensitive aluminum alloys. This case study describes how a manufacturer of high-precision aluminum gauging fixtures used SST cold spray technology to salvage a number of high-value fixtures that were either incorrectly machined or simply worn beyond their useful life.

As copper’s antimicrobial benefits spur new applications, the metal’s other properties are also worth reviewing. Along with strength, fatigue resistance, and ability to take a good finish, the primary selection criteria for copper and its alloys are electrical conductivity, thermal conductivity, corrosion resistance, color, ease of fabrication, and antimicrobial benefits.

Cold spray is uniquely suitable for depositing a wide range of materials over temperature-sensitive substrates. This article is a case study in using cold spray coatings to restore a 1937 Alfa Romeo 8C 2900B racing car.

A new approach aims to fabricate parts with targeted, site-specific properties for a wide range of applications in extreme environments within the aviation, space, and energy sectors.

Concentrating solar-thermal power with thermal energy storage can provide renewable energy for electricity or industrial processes at any time of day. The U.S. Department of Energy (DOE) has made significant research investments to increase the operating temperature of solar-thermal systems, which increases overall efficiency, but materials science challenges remain to affordably manufacture and commercialize key components.

This article reports on a study to better understand the integrity and microstructure of extrusion welding in a magnesium alloy (AM30) hollow section extrudate using light optical microscopy. The article is based on the entry that won the prestigious Jacquet-Lucas Award for Best in Show at the 2013 International Metallographic Contest.

This article describes research leading to the development of a new grade of low temperature bainitic steels, named Kinetically Activated Bainite (KAB) steels. with exceptionally rapid transformation kinetics at temperatures below 200°C. This entry won the Jacquet-Lucas Award for Best in Show at the 2015 International Metallographic Contest.

Recent advances in high velocity oxygen fuel torches in the form of miniaturization, joining, automation, and digitization are increasing the application opportunities for this thermal spray coating technology.

New methods for processing titanium alloys offer the potential to enhance mechanical properties while reducing component cost. This article discusses innovative and potentially lower cost fabrication processes including additive manufacturing (AM), superplastic forming/diffusion, hot isostatic pressing (HIP) near-net shapes from prealloyed powder, injection molding, rapid solidification, mechanical alloying, and thermohydrogen processing.

News about ASM members, chapters, events, awards, conferences, affiliates, and other society activities. Topics include: MS&T 2013 Lecturers Announced; 2013-2014 Student Board Members Announced; Jean Duval Educational Fund with ASM Foundation; Chapter News.

One of the most recent success stories for thermal spray in the automotive industry involves the development of plasma transferred wire arc (PTWA) for aluminum engine blocks. Driven by the demand to increase fuel efficiency, automakers are placing emphasis on decreasing overall vehicle weight as well as improving engine efficiency by reducing internal friction losses. The surface structure of the composite coating created by the PTWA process promotes favorable lubrication, low friction, wear resistance, improved heat transfer, and decreased bore distortion in engine block cylinders.

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.