ADVANCED MATERIALS & PROCESSES | JULY 2026 1 1 PROCESS TECHNOLOGY NEW PROCESS FOR LARGE METAL COMPONENTS Researchers at the DOE’s Oak Ridge National Laboratory, Tenn., developed a method that uses additive manufacturing (AM) to build custom canisters for powder metallurgical hot isostatic pressing (PM-HIP), streamlining production of large-scale metal components used in aerospace, energy, and medical applications. PM-HIP consolidates metal powder into fully dense parts such as turbine components, pressure vessels, and other large structural parts using high temperature and pressure inside a canister. Traditionally, non-equilibrium atomic diffusion and phase transformations to achieve micro- structural refinement and multiphase formation. As a result, the toughness of the material was improved by up to 30%. Unlike conventional heat treatments, the new process uniquely exploits the electron wind force in which electrons flowing through the material directly drive atomic motion. Through this mechanism, overall energy consumption was reduced by more than 50%. These findings are expected to enable an energy-efficient processing route for high-performance titanium materials used in applications such as aerospace structural components and artificial joints. The research focused on the impact force exerted by HDPEC on atomic arrangements in titanium alloys. This force induces athermal atomic diffusion, enabling formation of heterogeneous multiphase microstructures without prolonged heating. By controlling current density and pulse duration, the team investigated the microstructural evolution and mechanical properties of Ti-6Al-4V and Ti-6Al-7Nb alloys. Under various current densities, limited diffusion of ß-phase stabilizing elements (V and Nb) was consistently promoted by athermal effects, leading to the formation of refined multiphase microstructures. www.kumamoto-u.ac.jp. producing these canisters requires multiple steps including metal forming, machining, and welding, which can introduce defects and increase costs. After printing, the canister is filled with metal powder, vacuum-sealed, and processed in a hot isostatic press. Heat and pressure compress the powder into a solid metal component with minimal internal defects. The team used AM to fabricate canisters using several types of 3D printing, including laser and wire-based methods. The canister then undergoes the standard PMHIP process to produce a fully dense metal component. PM-HIP enables the use of alloys that can be engineered for enhanced corrosion resistance. Researchers can also control the material’s internal structure, tailoring properties such as radiation resistance and stability at high temperatures that are essential for nuclear applications. ornl.gov. MILLISECOND PULSE MAKES METALS STRONGER Scientists at Kumamoto University, Japan, developed a method that significantly enhances the strength and toughness of titanium alloys using an electric current applied for only a few milliseconds. In this research, a high- density pulsed electric current (HDPEC) treatment was applied to dual-phase titanium alloys, immediately inducing Researchers at Missouri S&T, Rolla, developed a physicsbased computational model that predicts conditions inside a wind tunnel and accounts for heat transfer, pressure losses, and how air behaves under extreme conditions. mst.edu. BRIEF This metal component was formed with a PM-HIP process inside an additively manufactured canister. Courtesy of Fred List III/ORNL, U.S. Dept. of Energy. Schematic illustration showing how the EWF (an athermal effect) induced by HDPEC drives atomic motion and triggers phase transformation much quicker than with conventional heat treatment. Courtesy of Kumamoto University.
RkJQdWJsaXNoZXIy MTYyMzk3NQ==