018 - Smart Inspection System for Powder Metallurgy Gears with AI Defect Detection
Chang Kenghao, Industrial Technology Research Institute
Powder metallurgy offers several advantages in gear manufacturing, including the ability to produce complex shapes, flexible material selection, minimal cutting operations, high precision dimensional control, and suitability for mass production, making it one of the key methods for manufacturing high-performance gears. However, powder metallurgy gears often exhibit porous surfaces after sintering, which appear rough and granular under high-resolution cameras. Traditional machine vision inspection methods are prone to errors and missed detections in such cases. To address this issue, this system was developed in collaboration with the Industrial Technology Research Institute and Chin Chih Metal, incorporating advanced artificial intelligence defect detection technology to significantly improve inspection accuracy and efficiency. Through deep learning and advanced image processing techniques, the intelligent inspection system can accurately identify surface defects in gears and provide high-precision inspection results, even when faced with challenges such as porous or rough surfaces. This system not only measures the dimensions and geometry of gears with precision but also provides timely defect warnings, significantly improving product yield. Its efficient inspection process and reliable defect identification capabilities make it a critical technology in the powder metallurgy gear manufacturing process, effectively reducing the costs and time of manual inspection. It is especially suitable for large-scale production environments, enhancing production line efficiency and product quality.
033 - Effect of Rapid Cooling on Thermoelectric Properties of (BiSb)₂Te₃ Alloys Fabricated via Cold-Water Assisted Atomization
Ha Jiwon, Kongju National University
This study systematically investigates the influence of cooling rates on the thermoelectric properties of BiSbTe alloy powders prepared through a water atomization process. By rapidly cooling molten BiSbTe with high- and low-temperature water, powders were produced, screened to 75-125 µm, and their morphology analyzed using SEM. Powders cooled with low-temperature water displayed finer, irregular particles with a higher oxygen content, attributed to the rapid cooling and resulting increase in specific surface area. This structural change led to a significant reduction in thermal conductivity, measured at 0.91 W/m·K, which contributed to an improvement in the thermoelectric figure of merit (ZT) to 1.3—an enhancement of approximately 6% compared to powders processed with high-temperature water. These results indicate that rapid solidification via low-temperature water cooling effectively reduces thermal conductivity and enhances thermoelectric efficiency, supporting its potential scalability in manufacturing processes for large-scale thermoelectric device applications.
900 - Investigating Process Parameters of WA IN740H in PBF-LB
Sarah Birchall, Carnegie Mellon University
This work focuses on the fabrication of water atomized (WA) IN740H parts by exploring various process parameters. The use of water atomized (WA) metal powders has become a cost-effective alternative to gas atomized (GA) powders in laser powder bed fusion (PBF-LB) additive manufacturing (AM). WA powders contain high amounts of surface oxygen and are highly irregular in shape; however, GA powders are more spherically shaped making them more commonly used in PBF-LB. This project investigates several process parameters being tested to produce highly dense parts with good creep resistance and high yield strength. As a baseline, the WA IN740H parts are compared to GA H282 parts for mechanical property requirements. This talk will include results from multiple builds of WA IN740H consisting of porosity measurements and mechanical testing and the analysis of these findings.
902 - SLM Inconel 625 Metal Matrix Composite with TiC Reinforcement for Forging Die Coatings
Gokalp Cetin, Lehigh University
H13 hot forging dies are designed to endure high temperatures; however, their performance is often constrained by wear, mechanical fatigue, and plastic deformation from prolonged use or extreme service conditions. Given the high cost and limited repair options for these dies, improving their durability using advanced manufacturing techniques is of great interest. This research investigates the application of powder metallurgy and additive manufacturing to enhance the high-temperature deformation resistance, surface friction and hardness of H13 dies. Specifically, a reinforced coating made of an Inconel 625 and TiC metal matrix composite is applied through selective laser melting (SLM). The study concentrates on optimizing the powder reinforcement volume, SLM process parameters, and coating thickness to improve wear resistance and thermal stability, ultimately prolonging the service life of coated H13 forging dies.
903 - Effect of Peening Parameters on Surface Morphology of Laser Powder Bed Fusion-Manufactured Ti-6Al-4V
Sivasubramanian Chandramouli, Purdue University
Critical aerospace components, such as turbine blades and landing gears, are increasingly produced using additive manufacturing (AM), especially laser-powder-bed-fusion (LPBF) due to its design flexibility. However, the inherent high surface roughness and tensile residual stresses in LPBF parts compromise performance and dimensional stability. Shot peening, a surface work-hardening process, is an effective post-processing solution. The research objective is to understand the surface strengthening effect from grain refinement by inhomogeneous elastic-plastic deformation across surface orientations (0-90°) in AM parts. Peening parameters, specifically coverage and peening angle, are optimized to mitigate orientation-dependent surface properties in LPBF Ti-6Al-4V. Under optimized conditions, shot peening reduces AM deterministic features (i.e., large surface gradients and texture-induced area) by 90% and transforms tensile residual stress to significantly compressive (≈↓400%). Notably, peening angle, an easily controllable parameter, has a stronger effect than coverage. These findings highlight shot peening’s potential in improving AM components, supporting complex designs.
906 - Study and Characterization of 3D Printed 17-4PH Customized Porous Tube Supports
Noman Alias Ghulamullah, Kent State University
The introduction of metal supports in Solid Oxide Fuel Cells (SOFCs) has enabled reduced operating temperatures and lower costs, making them a promising advancement. Metal-supported SOFCs operate at intermediate temperatures, offering improved thermal cycling stability and facilitating the deposition of thin ceramic functional layers. Additive manufacturing provides a flexible and customizable approach to fabricating SOFC metal supports, enabling precise control over design parameters. In this study, tubular metal supports were fabricated using 17-4PH precipitation-hardened and 430L stainless steel, with tailored wall thickness, pore size, and structure. The tubes were subjected to operational temperatures of 800°C for 100 hours to investigate their weight gain and oxidation behavior, critical for evaluating their long-term stability in SOFC applications and suitability in the plasma based ceramic deposition of functional layers.
907 - Evaluating Material Capabilities Using Open-course Binder Inkjet Printer
Andrew Gillespie, Purdue University in Indianapolis
With the ever-growing and rapid development in powder-based additive manufacturing, the need for a cost-effective, modifiable, open-source 3D printer tailored to specific ceramic or metallurgical materials has become more pressing in research and industry. This project aims to explore the material processing possibilities and usage of an open-source Binder Inkjet 3D printer in the production of components. This research investigates the properties of specimens produced from open-source printing of several materials. It analyzes the properties of the specimens created by the printer and the influence of the open-source device on part quality, along with comparing the ease of printing on the printer. These findings will contribute to a foundation on appropriate materials for open-source powder printing to aid future studies on usage and development for research and component development.
909 - Effects of High Green Strength Lubricant in Silver Tungsten Powder
Julie Hedlund, Pennsylvania State University, DuBois
Conventional lubricants used as a binder in silver tungsten carbide powder CW0719 for the fabrication of silver tungsten contacts has, unfortunately, been linked/identified as a possible cause for visual defects in the product that include cracking and peeling. In turn, this led to an unsatisfactory fallout quantity. This study was performed to investigate the effects of substituting the current lubricant with high green strength lubricant to improve the quality of green parts during production. To achieve this, a comprehensive assessment and characterization of powder characteristics, flow property, green strength, and mechanical properties of sintered parts, as well as a visual defect inspection was performed on parts made with the high green strength lubricant and the results compared to previously collected data on conventionally made parts. This paper presents the results that include cost benefits in terms of labor and materials.
910 - Commercial Resins for Stereolithography of Silicon Carbide
Tien Herd, University of North Carolina, Charlotte
Stereolithography (SLA) is a promising additive manufacturing process for producing high-resolution, geometrically complex silicon carbide (SiC) components. Creating a SiC slurry with a high solids loading generally requires mixing monomers, photoinitiators and dispersants to achieve the necessary rheological and curing properties for printing. In this work, commercially available resins were used to formulate a printable SiC slurry with a solids loading of 50% by volume, using 10 um SiC powder. This was achieved by combining two resins in a 3:1 ratio by weight. The resulting slurry successfully cured using both a high-power SLA printer and a lower-power digital light projection (DLP) printer, demonstrating versatility across different systems.
912 - Sintering Behavior of Hydrogen-Reduced Iron Powder from Ore Concentrates
Zhaozhen Huang, University of Utah
The Hydrogen Reduction and Melt-less Steelmaking (HRMLES) process, currently being developed at the University of Utah, is a novel powder metallurgy pathway designed to achieve ultra-low life cycle emissions for steel production. The foundation of this innovation is direct reduction and alloying from concentrated iron ore to produce steel products without the need for melting, thereby avoiding traditional iron and steelmaking processes. This study investigates the sintering behavior of iron powder produced via direct hydrogen reduction of iron ore concentrate, with a primary focus on minimizing oxide inclusions and impurities in sintered parts. Microstructural evolution and phase transformations during sintering are examined using SEM, EDS, and in-situ XRD, supported by computational simulations. This research aims to develop a meltless, cost-effective steelmaking method, contributing to sustainable and energy-efficient metallurgical processes.
913 - Gravity-Based Hydro-Separation of Iron Ore for Meltless Steelmaking
Alex Hyatt, University of Utah
Traditional iron ore refinement relies on energy-intensive smelting to remove impurities. Magnetic separation concentrates magnetite into high-grade ore; however, it cannot minimize silica content without smelting. This study presents a novel hydro-separation technique to enable meltless steelmaking. By milling below liberation size, silica is freed from iron oxide particles and subsequently separated using gravity-based settling in a water column. Exploiting the density differences between iron oxide and silica, the process leverages buoyancy and drag effects on settling to separate particles, allowing lighter particles to flow out and reducing silica content in the concentrate. The resulting iron oxide is reduced with hydrogen to achieve metallurgical-grade iron powder, which is mixed with alloying elements, then pressed and sintered into steel parts. The hydrogen-reduced iron powder is characterized in this study. This process has the potential to significantly reduce energy consumption compared to conventional steelmaking, offering a scalable pathway to green steelmaking.
914 - Effect of Lunar Dust on Microstructural and Mechanical Properties of 3D Printed Stainless Steel
Aye Thiri Khaing, California State University, Los Angeles (Cal State LA)
Additive manufacturing is a promising technology used in many industries today. With its flexibility in parameter and material control, it is a unique tool for advanced production. Exploring lunar resources, particularly using lunar dust, has also become an area of growing interest in space engineering. This study investigates the effects of lunar dust on the microstructural and mechanical properties of 3D printed stainless steel using laser- wire directed energy deposition. Single-track line samples were created under controlled printing parameters, followed by a comparison between printed steel with and without the inclusion of regolith powder. Microstructural changes were analyzed through scanning electron microscopy (SEM) and optical microscopy, while mechanical properties such as tensile strength and hardness were evaluated using standardized testing methods. By studying the properties of 3D printed stainless steel, this research aims to offer an understanding of how lunar dust influences its performance, contributing to the development of functional materials for future lunar missions and space exploration.
915 - Production, Processing, and Characterization Gas-Atomized 800H Powder for Additive Manufacturing
Benjamin Labiner, North Carolina State University (NCSU)
Alloy 800H is a high-temperature, corrosion-resistant material typically produced through wrought processing, where it develops an austenitic microstructure with carbide precipitates that enhance strength. While well-characterized in conventional forms, its behavior in additive manufacturing (AM) remains largely unexplored. The rapid solidification in AM introduces characteristics across physical scales such as complex dislocation sub-grain structures, highly textured grains, voids, cracks, microstructural heterogeneity, residual stress, and non-equilibrium phases.
A major limitation to studying AM 800H is the lack of commercially available powder feedstock. To address this, 800H powder was produced in house via gas atomization. From these powders solid specimens were fabricated using electron beam and laser powder bed fusion AM processing. The microstructure and composition of the powder and solid components were characterized and compared to conventionally wrought 800H.
919 - 3D Printing of Ceramic Interference Screws for ACL Reconstruction
Monem Moktadir, University of Louisville
Anterior Cruciate Ligament (ACL) reconstruction relies on interference screws, but existing designs often require revision surgeries. This project presents a novel interference screw design, 3D printed using alumina and zirconia ceramics. We utilized Lithoz for zirconia ceramic 3D printing and developed an in-house binder system for printing with a liquid resin-based Digital Light Processing (DLP) printer. Our findings highlight the impact of printer type and UV intensity on fabrication, with alumina proving easier to print than zirconia while maintaining shape integrity. The screws, printed using both Lithoz and in-house DLP processes, were sintered at 1400°C–1600°C depending on ceramic type. We compared density, feature resolution, and material properties of screws produced by both methods, demonstrating a viable pathway for in-house DLP printing of zirconia-toughened alumina. This research advances ceramic 3D printing for biomedical applications, offering a promising alternative for ACL reconstruction implants.
920 - Hybrid Manufacturing of Base Metals for High Performance Applications
Krishna Sai Aparna Munjuluri, University of Louisville
Metal 3D printing technologies like Powder Bed Fusion (PBF) and Electron Beam Melting have demonstrated exceptional capability in producing complex geometries for thermal management, particularly in aerospace and electronics. However, these processes are energy-intensive and costly, with unit prices ranging from $500 to $20,000. To overcome these challenges, this study investigates a hybrid manufacturing approach combining Stereolithography (SLA)—a high-precision UV-light-based 3D printing technology—with Freeform Injection Molding (FIM). While SLA is constrained by its use of resin materials, it is employed to fabricate sacrificial mold inserts compatible with metal injection molding systems.
This work aims to demonstrate the feasibility of hybrid SLA-FIM manufacturing for producing heat sinks for high-performance applications. The study includes design and simulation of the FIM process using molding software, focusing on optimizing feedstock flow and defect mitigation. Validation of the simulation results will be carried out through experimental testing to assess the overall effectiveness of the process.
921 - Multiphysics Modeling of Thermocapillary Force Driven Pore Elimination from Liquid Metal Droplets For Manufacturing Pore-Free Powders for Additive Manufacturing
Ali Nabaa, University of Wisconsin - Madison
Gas atomization (GA) is a widely adopted method for metal powder production, involving the atomization of molten metal using pressurized gases. Despite its prevalence in additive manufacturing (AM), GA-produced powders often contain pores that can transfer to the as-built parts to deteriorate part quality. Here, we report an approach to achieve pore-free gas-atomized metal powders by inducing a reversed thermal gradient through rapid heating. The resultant thermocapillary force drives the pores out of the molten metal droplets. We demonstrate the feasibility of utilizing rapid heating to eliminate pores from droplets of different metal alloys, using high-fidelity simulation. Furthermore, we derive an analytical model to estimate the critical thermal gradient needed for pore-free powder production.
923 - Scalable Production of Spherical Ceramic and Metal Powders via Vibration-Jet Technology
Bianka Pajo, Purdue University
The demand for spherical powders with controlled composition and morphology is increasing in additive manufacturing (AM) and powder metallurgy (PM) due to their superior flowability, packing density, and uniform melting behavior. However, existing production methods often face challenges related to cost, oxidation, and particle size uniformity. This work introduces a novel vibration-assisted droplet generation method for producing spherical powders. Vibration-jet technology makes use of an external force in the form of vibration to break up a fluid jet coming from a nozzle into uniform droplets, which consolidate after drying into supraparticles. This method operates at lower temperatures compared to conventional melting processes, which allows for precise control over particle size distribution. This approach provides a scalable and flexible route for synthesizing powders from a range of materials, including metals and ceramics. The technique offers a scalable, low-cost solution for producing high-quality spherical powders with improved flowability suitable for AM and PM applications.
924 - Development of Powder-Cored Wire for Alloy Control with Wire Laser Directed Energy Deposition Additive Manufacturing
Raffi Shirinian, California State University, Los Angeles (Cal State LA)
Wire Laser Directed Energy Deposition (WL-DED) offers a flexible and clean additive manufacturing (AM) process unmatched by powder-based systems. While complex alloys are easier to produce with powder-based AM, these systems present challenges such as contamination and extensive post-processing. This study focuses on the development of a cost-effective powder-cored wire system to enhance alloy control in WL-DED. Precise powder composition within the wire enables tailored alloying and optimization of mechanical properties and microstructure. Additionally, this approach facilitates the study of unconventional materials such as metal matrix composites and contaminated materials in WL-DED processes. The findings validate powder-cored wire as a reliable feedstock for WL-DED, enhancing alloy customization and process stability. This innovation broadens AM capabilities, offering new opportunities for aerospace, energy, and space exploration applications.
925 - Effect of Deposition Parameters and Rescanning on the Microstructure, Texture, and Thermomechanical Behavior of Additively Manufactured NiTi
Naiyer Shokri, University of Louisville
Laser powder bed fusion (L-PBF) is a leading additive manufacturing process. Many researchers have utilized this method to create high-quality NiTi alloys with precise properties. This study systematically assesses the impact of laser powder bed fusion additive manufacturing (L-PBF-AM) parameters, specifically laser speed and energy density, and the effect of rescanning on the thermomechanical behavior and microstructure of Ni50.8Ti49.2 SMA. The samples were fabricated with hatch spacings and layer thickness of 80 and 40 µm respectively at a constant laser power of 180W and the laser speed differs from 500 mm/s to 800 mm/s resulting in parts with volumetric energy density levels from 70 to 110 J/mm3. Moreover, the rescanning strategy was applied to a set of samples to improve the density and reduce cracking of the AM parts. The energy density associated with rescanned parts is 25 J/mm3.
926 - Additive Manufacturing of 6061 Aluminum Alloy and Pure Aluminum by Paste Extrusion
Hassan Soltani, University of Louisvilley
This research studies Material Extrusion (MEX) 3D printing of 6061 aluminum alloy and pure aluminum. Paste feedstock was prepared by mixing 6061 aluminum alloy or pure aluminum powder with polymer binders at room temperature. The paste was pneumatically extruded into green parts that were involved in thermal debinding process to remove polymer binders, then sintered in protective atmosphere. Resulting grain structure, sintered density, and mechanical properties will be characterized and compared with corresponding metal parallels in annealed states. The main objective is to explore the feasibility of metal 3D printing by paste extrusion with low energy and space requirements, sponsored by NASA Marshall and Kennedy Centers. The overarching goal is to convert used aluminum food packaging into 3D printing feedstock for rapid, low cost and accurate production of metal parts with 3D features, thereby significantly increasing the efficiency and lowering the costs for future space expeditions.
927 - Wired Laser Directed Energy Deposition of Silicon Carbide Reinforced Stainless Steel Metal Matrix Composites
Cristian Soria Lopez, California State University, Los Angeles (Cal State LA)
Additive manufacturing processes have revolutionized fabricating materials for the aerospace, automotive, and biomedical industries. Additive manufacturing methods allow for the design of complex geometries, strengthen materials, and produce new material combinations. Wire laser directed energy deposition is one such process that enables high volume production of materials with fine microstructural control. The large thermal gradients inherent to the directed energy deposition process allow for the development of metal matrix composites with improved qualities. Metal matrix composites consist of a metal matrix reinforced by a ceramic, which when synthesized via directed energy deposition further enhances tensile strength and can improve ductility. In this work, the microstructure, tensile strength, and ductility of silicon carbide reinforced stainless steel 316L are examined. The findings show that low compositions of silicon carbide best catalyze grain refinement and improve tensile strength and ductility.
928 - A Novel Approach to Printing Soft Magnetic Composites
Hope Spuck, Pennsylvania State University, DuBois
As the global shift toward electrification accelerates, there is an increasing focus not only on the adoption of electric motors but also on improving the efficiency of their production methods. Soft Magnetic Composites (SMC’s) bring efficiencies in performance, size, and design flexibility to electric motors; however, the processing of these components can be challenging. The current method, with heated compaction, very high green densities, and long lubricant removal times, makes the processing very costly and challenging, especially for larger components.
In this project, we explore the use of additive manufacturing to produce SMC’s. In previous work, it was demonstrated that typical water-atomized, add mixed FC-0208 powder can be printed and sintered to 7.56 g/cc without the need for a lubricant. Using similar technology, we will investigate the 3D printing of SMC’s and consider a new processing approach to improve processing efficiencies, increase design flexibility, and enhance the properties of the SMC’s, while using commercially available powders.
929 - Predicting the Effects of a Lunar Environment on a Wire-Laser Directed Energy Deposition Process via Numerical Modeling
Nathan Stoetzel, California State University, Los Angeles (Cal State LA)
As humanity prepares for sustained lunar exploration, in-situ manufacturing using additive technologies offers transformative potential for reducing dependence on Earth-based supply chains. Recent advancements in wire-laser directed energy deposition (WL-DED) have sparked interest in the use of this technology on the Earth’s moon due to its reduced reliance on a strong gravitational force, as required for powder-based processes. Numerical modeling offers an effective way to simulate the solidification dynamics of DED processes, providing insights into how process parameters influence the melt pool geometry and thermal history of the part. This study investigates the simulation of WL-DED for manufacturing on the lunar surface, focusing on the challenges the lunar environment poses. Using advanced multiphysics computational models, we simulate the laser-material interaction under reduced gravity, near-vacuum conditions, and extreme thermal gradients, advancing the understanding of how process control under different environmental conditions can be used to improved material properties in additive manufacturing.
934 - Binder Infill Pattern Design Strategies for Increased Mechanical Properties in Binder Jet Additive Manufacturing Parts
Amanda Wei, Virginia Tech
Use of a liquid binding agent is critical for forming part shape and providing green part strength in binder jetting (BJT). Traditionally, binder is homogeneously deposited throughout the entire part volume during printing. However, research in shell printing suggests that reducing the quantity of binder increases sintered density and strength over that of the conventional solid binder infill, albeit at the cost of green strength. In the present work, shell-infill binder patterning strategies comprised of a shell with either an internal lattice structure or topology optimized (TO) infill are applied to 316L stainless steel parts to balance the tradeoff between green and sintered part properties. A comparison of the two infill strategies is conducted. In particular an octet infill and TO infill were found to have an 86% and 89% decrease respectively in green part strength from a traditional solid infill, but a 48% and 78% higher sintered flexural strength.
935 - Reclamation of 17-4 PH Green Parts in Metal Binder Jetting
Lucas Williams, Pennsylvania State University, DuBois
The Metal Additive Manufacturing method of 3D Binder Jet printing has been around since the last 90s but has evolved into a viable commercial method of printing precise metal parts in bulk quantities quickly for numerous industries. Regardless of the versatility of its application, the method of creating these parts remains the same: an efficient process using a binder to create objects layer by layer. Although this precise method allows for its known efficiency and reasonably low material waste, there is still room for more material recovery. This was the motivation for this study, and 17-4PH was used for investigation. Two methods were used for rejuvenation. Both methods involve the initial grinding of the green part to expose the binder. In the first method, the ground powder was heated to 240°C for 48-72 hours to remove the binder and then sieved before reprinting. In the second method, the ground powder was immersed in isopropyl alcohol for 24-48 hours before being dehydrated in a vacuum oven. This was in a small test volume and was found to need a specialized sieve to drain the binder-saturated isopropyl without losing the smallest particles of the powder metal (PM), leading to additional research available for this method. Initial results of the PM showed oxidation issues from baking the binder out at this temperature but were still promising. Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS) imaging and analysis were used for characterization. Green strength and sintered strength of the 17-4PH were tested using Transverse Rupture Strength (TRS) bars of the pure virgin and reclaimed powders as well as a mix of the two powders at ratios of 90:10, 80:20, and 70:30. The results are printed in this paper.
940 - Computational Modeling of Metal Fiber Sintering and Surface Diffusion Dynamics
Liwei Zhang, Purdue University in Indianapolis
This study examines the sintering process of metal fibers using computational modeling. The Lattice Boltzmann Method (LBM) is applied to analyze surface diffusion and its impact on sintering neck growth. The research focuses on the relationship between fiber geometry and diffusion-driven material behavior, providing a numerical approach to understanding sintering dynamics. By leveraging computational simulations, this work contributes to the study of powder metallurgy and additive manufacturing, offering insights into material processing and optimization.