Development of wear-resistant hardfacing materials using powder metallurgy/hot isostatic pressing technology offers an alternative to today's cobalt-based materials and those that suffer delamination damage. Ongoing research and development at the Electric Power Research Institute (EPRI), detailed in this article, examines the application of wear-resistant hardfacing materials using the PM/HIP process. The hope is to eliminate weldability and residual stress challenges associated with some hardfacing alloys, as well as to provide a wider range of potential alloy solutions to reduce cobalt use and to address delamination issues with incumbent materials.

Beyond weight savings, aluminum products offer corrosion resistance, weldability, and ease of maintenance for a wide range of marine vessels. Aluminum was recognized as a promising material for marine construction from the early days of the industry. The development of 5xxx alloys and large production capacity made aluminum use more technically and economically possible beginning in the 1950s. The variety of aluminum vessels ranges from small fishing boats and fast ferry catamarans to cruise ships and military vessels. All benefit from aluminum's relatively light weight, low maintenance costs, and easy repairability. Other benefits of using aluminum in marine applications include formability, corrosion resistance, and availability in various product forms.

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.

A new high-strength steel developed for cold stamping addresses the challenges presented by materials traditionally used to manufacture electric vehicle components.

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.

The National Research Council of Canada has teamed up with industrial partners to investigate the challenges of aluminum lightweighting. Project coverage areas include manufacturing of advanced aluminum components, assembly of aluminum and multi-material components, and durability and performance evaluation and solutions.

In North America, renewable power sources and gas turbines are often in the news, but globally, steam turbines generate the largest portion of electricity, and they will remain a predominant power-generation technology for many decades. Because steam turbines represent a preponderance of our power-generation base, it is essential to continue to drive turbine technology development. Until now, the main technical barrier limiting large efficiency improvements was the temperature constraint imposed by available materials. Today, the game is changing. Due to advancements in materials, we now have a chance to make unprecedented improvements in steam turbine power plant efficiency by raising the inlet temperature hundreds of degrees through the use of new tailored superalloys.

Case studies from a range of industries illustrate how advanced additive manufacturing capabilities optimize both material performance and value. The materials discussed are Inconel 718, Ti-6Al-4V, aluminum F357, and Hastelloy X.

From wartime use to cutlery and building facades, the stainless steel industry began to experience dynamic growth from the 1920s on, especially following World War II.

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.

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 .

Among the structural materials developed in the 20th century, titanium and its alloys have played a leading role in improving component performance. This article provides background on the extraction and primary processing of titanium.

During the past 30 years, enormous research has been devoted to developing titanium-base intermetallics for use in gas turbine engines as lightweight alternative to nickel-base superalloys. This article presents a brief history of Ti 2 AlNb and efforts to mature this material for commercial component production. The article includes processing experience insights gained from a current R&D program in China.

This communication is a response to the April 2015 Metallurgy Lane article, Titanium, Part II, by Charles Simcoe. This present piece offers differing historical evidence about the development and commercialization of titanium alloys, including discussion of the patent office proceedings that resulted in the Ti-6Al-4V alloy patent.

Integrated computational materials engineering has proven effective in shrinking materials development timelines and accelerating the implementation of new materials in manufactured components. This article presents examples of aerospace alloys developed using ICME techniques and provides a glimpse of future applications.

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.

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.

A recent metallographic and historical analysis of two parts from the Buenos Aires to Pacific Railroad railway looked at possible manufacturing techniques of the parts in question. The information collected is useful for comparison with techniques and materials used at that time as well as with current techniques. The analysis questioned whether the material itself has varied or evolved from the metallurgical point of view, and confirmed the quality of raw material used to construct the historic railway line.

Conventional manufacturing from wrought bar stock typically involves extensive machining, creates significant material waste (scrap metal), and requires numerous steps to obtain the final part geometry. As a more efficient alternative, powder metallurgical (PM) processes are now available to cost effectively fabricate both simple and complex shapes with minimal material waste. Combustion driven higher pressure powder compaction (CDC) for near-net or net shape manufacturing was recently developed. It offers a unique way of forming near-net or net shape high-density powder metal components both cost effectively and at relatively higher compaction pressures than other PM processes.

Given the demonstrated antimicrobial properties of copper, it is incumbent upon materials scientists to design potent antimicrobial copper-containing stainless steels as an economical option.