22 31 43 P. 15 Hybrid Furnace Technology for Intelligent Energy Use Technical Roadmap Updates Spotlight on Materials Startups INVENTION AND EVOLUTION OF ENGINEERED GRAPHITE MATERIALS INNOVATIONS AND TRENDS NOVEMBER 2026 | VOL 184 | NO 6
22 31 43 P. 15 Hybrid Furnace Technology for Intelligent Energy Use Technical Roadmap Updates Spotlight on Materials Startups INVENTION AND EVOLUTION OF ENGINEERED GRAPHITE MATERIALS INNOVATIONS AND TRENDS NOVEMBER 2026 | VOL 184 | NO 6
Showcase your thought leadership and innovations at one of ASMʼs conferences and expositions, which offer unparalleled access to highly engaged audiences of industry leaders and decision-makers. Learn more about each event and related exhibit and sponsorship opportunities at asminternational.org/events 2027 EVENTS FAS Summit on Failure Analysis & Prevention | February 2 – 4, 2027 | Oceanside, California A gathering dedicated to advancing the science and practice of failure analysis. Dive into in-depth sessions on fatigue mechanisms, fracture modes, and failure prevention. Learn from leading experts and engage in meaningful discussion—all while contributing to the growth of this critical field. International Thermal Spray Conference and Exposition (ITSC) May 12 – 14, 2027 | Rotterdam, Netherlands ITSC is the world’s foremost international conference and exhibition for thermal spray technologists, researchers, manufacturers, and suppliers. This conference rotates between North America, Europe, and the Pacific Rim and is organized by the ASM Thermal Spray Society, the German Welding Society (DVS), and iiw. Shape Memory & Superelastic Technologies Conference and Exposition (SMST) May 19 – 20, 2027 | Belén, Heredia Province, Costa Rica The International Conference on Shape Memory and Superelastic Technologies (SMST) is the leading worldwide conference and exposition for the shape memory and superelastic technologies and is highly focused on the manufacturing and application of shape memory materials. AeroMat | May 25 – 27, 2027 | Palm Springs, California AeroMat focuses on innovative aerospace materials, fabrication, and manufacturing methods that improve performance, durability, and sustainability of aerospace structures and engines with reduced life-cycle costs. International Conference on Advances in Materials, Manufacturing, and Repair for Power Plants (EPRI) | June 7 – 11, 2027 | Tucson, Arizona As the global energy sector undergoes transformation, the demand for safe, reliable, efficient, and environmentally responsible power generation has never been greater. Join industry leaders and innovators for the 11th EPRI conference. International Materials, Applications, and Technologies (IMAT) October 4 – 7, 2027 | Columbus, Ohio IMAT, ASM’s annual event, is the only targeted event on advanced materials, applications, and technologies in key growth markets that will have a focus on economic trends and business forecasts. The event will include a diverse group of materials experts, including the ASM Programming Committees, AeroMat Committee, and all six of ASM’s Affiliate Societies, who are heavily involved in building the technical symposiums, which will have a strong focus on real-world technologies that can be put to use today. North American Cold Spray Conference (NACSC) | October 5 – 6, 2027 | Columbus, Ohio NACSC is the premier forum for researchers, engineers, manufacturers, and end users advancing cold spray technologies across aerospace, defense, energy, and industrial applications. The conference brings together the global cold spray community for several days of technical exchange, collaboration, and innovation. Heat Treat | October 5 – 7, 2027 | Columbus, Ohio The Heat Treat Conference and Exposition is the premier event for heat treating, thermal processing, and materials performance professionals worldwide. The conference brings together engineers, metallurgists, researchers, equipment manufacturers, suppliers, and end users for an unmatched combination of technical education, industry insight, and hands-on solutions. Residual Stress Technology Conference (RSTC) | October 6 – 7, 2027 | Columbus, Ohio Discover the forefront of residual stress research and its impact on material behavior at this enriching event. Engage with experts and practitioners across diverse fields through symposium topics, networking opportunities, and technical programming. International Symposium for Testing and Failure Analysis (ISTFA) October 31 – November 4, 2027 | Phoenix, Arizona ISTFA is the only North American event devoted to the semiconductor, electronic sample preparation, and imaging markets. ISTFA offers the best venue for failure analysts and the FA community for sharing challenges and acquiring the technical knowledge and resources needed to take them on. Navigating a Greener Sky: Symposium on Advances in Thermal Spray and PVD Coatings for the Aerospace Industries | November 16 – 18, 2027 | Limoges, France This symposium is a pivotal gathering that aims to shape the future of aerospace through innovative thermal spray and PVD coatings. Join us as we unite key players in the aerospace industry, including OEMs, suppliers, and distinguished researchers from academia and industry.
47 IMPACT OF ARTIFICIAL INTELLIGENCE ON MATERIALS RESEARCH AND JOURNAL PUBLICATIONS PANEL AT IMAT 2026 Editors from ASM’s suite of journals discuss the evolving landscape of AI in materials research, manuscript preparation, and peer review. 130 YEARS OF ENGINEERED GRAPHITE: INVENTION TO INDISPENSABLE Ryan M. Paul This historical review details the critical developments and evolving applications of graphite from the dawn of carbon materials to the space age and beyond. 15 ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 2 Microstructure of needle coke. Courtesy of GrafTech International. On the Cover: 50 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. Includes photo gallery from IMAT 2026. WHERE MATERIALS ENGINEERING IS HEADED: INSIGHTS FROM ASM’S NAE MEMBERS Observations from ASM members who also belong to the National Academy of Engineering shed light on the future of materials engineering and help shape ASM’s content strategy. 34
4 Editorial 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Process Technology 12 Emerging Technology 13 Sustainability 14 Stress Relief 63 Editorial Preview 63 Special Advertising Section 63 Advertisers Index 64 3D PrintShop TRENDS INDUSTRY NEWS DEPARTMENTS Check out the Digital Edition online at asminternational.org/asm-news/magazines/am-p ASM International serves materials professionals, nontechnical personnel, and managers worldwide by providing high-quality materials information, education and training, networking opportunities, and professional development resources in cost-effective and user-friendly formats. ASM is where materials users, producers, and manufacturers converge to do business. Advanced Materials & Processes (ISSN 0882-7958, USPS 762080) publishes six issues per year: January, March, May, July, September, and November, by ASM International, 9639 Kinsman Road, Materials Park, OH 44073-0002; tel: 440.338.5151; fax: 440.338.4634. Periodicals postage paid at Novelty, Ohio, and additional mailing offices. Vol. 184, No. 6, NOVEMBER 2026. Copyright © 2026 by ASM International®. All rights reserved. Distributed at no charge to ASM members in the United States, Canada, and Mexico. International members can pay a $30 per year surcharge to receive printed issues. Subscriptions: $499. Single copies: $54. POSTMASTER: Send 3579 forms to ASM International, Materials Park, OH 44073-0002. Change of address: Request for change should include old address of the subscriber. Missing numbers due to “change of address” cannot be replaced. Claims for nondelivery must be made within 60 days of issue. Printed by Kodi Collective, Lebanon Junction, Ky. FEATURES NOVEMBER 2026 | VOL 184 | NO 6 ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 3 22 22 HTPro HYBRID FURNACE TECHNOLOGY FOR INTELLIGENT ENERGY USE Bora Özkan and Martin Hellwig Hybrid heating systems, CO2 forecasting, and atmosphere control contribute to sustainable heat treating. 26 SMST NEWSWIRE ENHANCED TRANSFORMATION STRESS AND CRYOGENIC SUPERELASTICITY IN A NiTiNbY SHAPE MEMORY ALLOY S. Cai and J.E. Schaffer Thermomechanical processing of a shape memory alloy provides stable superelastic performance over extremes of temperature and stress. See also SMJ Highlights p 30. 31 FOLLOWING THE DATA: EARLY FINDINGS FROM ASM’S TECHNICAL CONTENT ROADMAP Scott Henry A data-driven review of how members and researchers use ASM Handbooks and journals is helping set ASM’s technical content priorities for the next decade. 38 MATERIALS PULSE: SNAPSHOT OF MEMBERS’ VIEWS 39 ASM HEAT TREATING SOCIETY ROADMAP HIGHLIGHTS GAPS FOR TECH IMPROVEMENT 41 INTERNATIONAL ROADMAP FOR FAILURE ANALYSIS 43 SPOTLIGHT ON MATERIALS INNOVATION STARTUPS Lun Chan A look at some unique materials-centric startups, how they are breaking new ground, and what could help to advance their technology. 26
4 ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 ASM International 9639 Kinsman Road, Materials Park, OH 44073 Tel: 440.338.5151 • Fax: 440.338.4634 Joanne Miller, Editor joanne.miller@asminternational.org Victoria Burt, Managing Editor vicki.burt@asminternational.org Frances Richards and Corinne Richards Contributing Editors Anne Vidmar, Layout and Design Allison Freeman, Production Manager allie.freeman@asminternational.org EDITORIAL COMMITTEE John Shingledecker, Chair, EPRI Beth Armstrong, Vice Chair, Oak Ridge National Lab Adam Farrow, Past Chair, Los Alamos National Lab Carl Boehlert, Michigan State University Punnathat Bordeenithikasem, Machina Labs Daniel Grice, Materials Evaluation & Engineering Benjamin Huebner, Stevens Institute of Technology Hideyuki Kanematsu, Suzuka National College of Technology Ibrahim Karaman, Texas A&M University Ricardo Komai, Tesla Krassimir Marchev, Northeastern University Bhargavi Mummareddy, Dimensional Energy Christian Paglia, SUPSI Institute of Materials and Construction Ryan Paul, GrafTech International Felice Rubino, University of Salerno Satyam Sahay, John Deere Technology Center India Abhijit Sengupta, Bechtel Corporation Vasisht Venkatesh, Howmet Aerospace ASM BOARD OF TRUSTEES Daniel P. Dennies, President and Chair Tirumalai Sudarshan, Senior Vice President Toni Marechaux, Vice President Elizabeth Ho man, Immediate Past President William Jarosinski, Treasurer Rahul Gupta Emily Kinser Victoria Miller Laura Moyer Erik Mueller Ramana G. Reddy JP Singh Véronique Vitry Fan Zhang Veronica Becker, Executive Director STUDENT BOARD MEMBERS Sofía González Espinosa, Andrew Gillespie, Wenchi Li Individual readers of Advanced Materials & Processes may, without charge, make single copies of pages therefrom for personal or archival use, or may freely make such copies in such numbers as are deemed useful for educational or research purposes and are not for sale or resale. Permission is granted to cite or quote from articles herein, provided customary acknowledgment of the authors and source is made. The acceptance and publication of manuscripts in Advanced Materials & Processes does not imply that the reviewers, editors, or publisher accept, approve, or endorse the data, opinions, and conclusions of the authors. ROADMAP TO SUCCESS In his “Moon to Mars” keynote at IMAT in Quebec City, Tyler Nester gave attendees a peek into his world at NASA as he reviewed the aims of the Artemis missions. He explained that every launch has different goals. Each is designed to move the needle forward, test new capabilities, and learn more about how various materials perform in space. Nester shared that the main lesson the NASA team learned from the Apollo program is to “take as big of a step as you can—but not too big.” This seems to be salient advice for any product development plan. That same spirit of bold ingenuity tempered with systematic progress is embodied in a variety of examples in this special “Materials Innovations and Trends” issue of AM&P. Our lead article explores how engineered graphite was first invented, and how it continued to be refined over subsequent decades. New formulations led to new applications. After 130 years, graphite materials are still evolving as their key properties—lightness and strength—continue to solve difficult challenges. Just as graphite has its origin story, we introduce you to nine entrepreneurial companies at the early stages of their inventions. In our “Spotlight on Materials Innovation Startups,” we share the new ground these founders are breaking and the type of support they may need to get their products to the next level. To move products or industries toward a more advanced stage of maturity, roadmaps are often created and consulted. In this issue of AM&P, we share several roadmaps created by ASM members and staff. The Heat Treating Society’s R&D Committee is working on their industry’s roadmap, which serves as a “voice of the customer” to guide heat treaters, equipment manufacturers, and others in their supply chain. Meanwhile, the Electronic Device Failure Analysis Society has already published their initial roadmap and are working on a revised edition. Their document identifies gaps and technological needs for failure analysis of electronic devices, along with possible solutions. Also included is a technical content roadmap that explores usage of ASM Handbooks and journals. This document identifies topics that are the most accessed by users of ASM’s current portfolio of products, as well as subject areas to be expanded in the future. In compiling the data, a survey was conducted of ASM members who are also National Academy of Engineering members. Some results are highlighted in this issue. That group was also asked to share their insights about current trends and where the materials industry is headed. One respondent acknowledged ASM’s role in “bridging the gap between academic research and industrial applications.” We aspire to do just that by bringing together the materials community, especially during our IMAT events and through committees that develop ASM Handbook and journal content. With support from the ASM community, researchers, entrepreneurs, and corporate engineers can all take the next step forward on their path to success. joanne.miller@asminternational.org Tyler Nester, NASA.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 5 RESEARCH TRACKS DESIGNING ORGANIC MATERIALS WITH DATA AND AI A new data-driven, artificial intelligence (AI)-enabled approach is being developed by Iowa State University’s Wenjie Xia and partner research teams from MIT, the University of Southern Mississippi, and the University of Windsor in Canada. Collaborative research grants from the U.S. National Science Foundation (NSF) and the Natural Sciences and Engineering Research Council of Canada are funding the project. A fouryear, $879,911 NSF grant is supporting Xia, an associate professor of aerospace engineering, and his group’s work to develop computational modeling and data-driven tools and techniques for the project. Key to the project’s success is understanding the relationship between the molecular structure of the materials and their physical properties and performance. The project focuses on organic, mixed ionic-electronic conducting polymers, which can conduct electronic charge while also transporting ions. Combining electronic conductivity and ion transport is particularly important for bioelectronic applications and can enable a broader range of device functions. By tuning molecular structure and processing conditions, these coupled electronic and ionic transport properties can be controlled to optimize device performance. Researchers say such materials could help create lightweight, flexible, and even stretchable low-cost devices for applications such as flexible electronics, wear- able sensors, and bio- electronics. Xia will lead the Iowa State team working on the computational and data-driven modeling of materials from the molecular scales to their resulting properties. The University of Windsor group will tackle design and synthesis of the most promising materials. The University of Southern Mississippi will lead the materials processing effort, and the MIT group will spearhead device fabrication and testing. iastate.edu. GRANT SUPPORTS PEROVSKITE SEMICONDUCTOR MANUFACTURING Researchers at Georgia Tech and Albany State University, both in Georgia, received a $1.3 million award through the National Science Foundation’s Historically Black Colleges and Universities Excellence in Research program. The project will advance manufacturing methods for perovskite semiconduc- tors, with potential applications in solar energy, photonics, electronics, and quantum technologies. The threeyear project, “CloseSpace Sublimation for Scalable Perovskite Optoelectronics Manufacturing,” is led by Liqiu Zheng, assistant professor of physics at Albany State, and Juan-Pablo Correa-Baena, associate professor in Georgia Tech’s School of Materials Science and Engineering. Albany State and Georgia Tech will jointly study thin-film growth, structure, and device performance. Georgia Tech researchers will support Albany State as the team acquires and begins using new equipment, sharing expertise in operation, data collection, and analysis. Students will receive hands-on training in thin-film deposition, x-ray characterization, solar cell fabrication, and data analysis. The project also includes exchanges between Georgia Tech and Albany State, giving students access to research facilities, expertise, and collaborative research opportunities at both institutions. The research focuses on a manu- facturing technique known as closespace sublimation. Researchers typically produce perovskite thin films using liquid inks. Close-space sublimation instead uses heat to transport material as vapor across a short distance. The team will investigate whether the approach can be adapted for perovskite materials, potentially enabling faster, more material-efficient, and more scalable manufacturing. gatech.edu. Researchers led by Iowa State’s Wenjie Xia are discovering new conducting materials. Courtesy of Christopher Gannon/Iowa State University. Illustration of metal halide perovskites. Courtesy of JuanPablo Correa-Baena/Georgia Tech.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 6 METALS | POLYMERS | CERAMICS The nanotechnology-based system employs engineered particles containing benzotriazole, a common corrosion inhibitor. When incorporated into waterbased polyurethane coatings, these particles respond to changes in acidity, releasing the inhibitor when conditions indicate corrosion may be occurring. Each particle functions as a nanoscale container designed to deliver the protective compound in response to changing environmental conditions. Electrochemical testing showed that the coating could restrict corrosion to 37 nm per year, a rate reported to be more than 600 times lower than that of many existing high-performance coatings, which can allow corrosion rates of approximately 0.025 mm per year. Unlike conventional coatings, which primarily provide a protective barrier, the new formulation is designed to respond to changing conditions and release corrosion-inhibiting compounds when needed. This targeted delivery mechanism could provide longer-lasting protection for bridges, buildings, vehicles, and other steel infrastructure while reducing the frequency and cost of recoating. “Coatings that contain our technology will have a greatly expanded lifetime, meaning far less maintenance, and a much longer time between applications,” says lead researcher Asep Nugraha. METALLIC RECIPES TUNE MATERIAL PROPERTIES Researchers at the University of Birmingham, U.K., created a metal-organic framework (MOF) whose properties can be adjusted by changing the proportions of metals within its structure, offering a new approach to designing customizable porous materials. The research team, which included scientists from the universities of Birmingham, Nottingham, and Limerick, developed UoB-116, a MOF capable of incorporating up to 16 different metals within a single crystal structure. This represents the highest number of metals yet achieved in a MOF and the first reported framework to combine metals from three different regions of the periodic table. To develop the material, researchers first created and characterized 15 versions of UoB-116, each incorporating a different rare earth metal. Next, they progressively combined multiple metals within the same framework before introducing indium to produce a structure containing 16 metals simultaneously. MOFs consist of metal atoms connected by organic molecules, forming ordered structures with microscopic pores. Researchers demonstrated that adjusting the relative amounts of dysprosium and lanthanum in UoB-116 can modify several material properties, including magnetism, light absorption, porosity, and carbon dioxide uptake. The CO2 uptake decreased from 5.72 mmol/g in the all-dysprosium material to 1.23 mmol/g in the all-lanthanum version under the conditions tested. Increasing dysprosium content also enhanced magnetic response and altered near-infrared light absorption, while increasing lanthanum reduced the material’s measured surface area. The findings show how modifying a material’s metallic composition can provide control over its functional properties without requiring an entirely new structure for each application. This approach could support development of tailored porous materials for gas storage, separation, and sensing. www.birmingham.ac.uk. NANOTECH COATING REPAIRS RUST DAMAGE Scientists at The University of Queensland, Australia, developed a self-healing coating that could significantly extend the service life of steel structures by slowing corrosion and reducing maintenance requirements. The Copper Development Association, McLean, Va., announces Copper Advocates, a free network for individuals, public officials, organizations, and companies that recognize copper’s importance to the U.S. economy. Advocates will receive updates on policy developments and industry news. copper.org. BRIEF New metal-organic frameworks o er a multitude of opportunities to alter behavior without developing new materials. Courtesy of the University of Birmingham. This self-healing rust-proof coating could potentially protect steel structures for hundreds of years. Courtesy of The University of Queensland.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 7 The team is preparing for pilot- scale testing, with the goal of developing a commercial product within five years. www.uq.edu.au. METAL ALLOYS RESIST COLD CRACKING A research team from the University of Oxford, University of California, Berkeley, and Lawrence Berkeley National Laboratory discovered a micro- scopic mechanism that allows two metal alloys to remain damage-tolerant even at temperatures as low as 20 K. The new study focused on two experimental niobium-titanium-base alloys, which remained significantly resistant to cracking with no measurable transition to brittle behavior at the lowest temperature tested. The scientists say this is due to the alloys effectively switching how they deform as they enter the deep freeze. Typically, bending and deformation of bcc metals relies on the movement of dislocations in their crystal structure. At low temperatures, these become increasingly difficult to move, restricting the material’s ability to deform around a crack and making a fracture more likely. However, in the alloys studied, a different process takes over. The team observed nanoscale twinning coupled with a local transformation of the crystal structure. When these newly formed structures reach the boundaries between neighboring crystals, they create points of stress that trigger new defects in the metal. These defects then allow the material to keep deforming rather than cracking. “Using these insights, we may be able to design underlying micro- structural conditions that allow a material to create its own routes to remain ductile at extreme temperatures,” says lead researcher David Cook. The discovery could give scientists a new strategy for designing metals capable of operating in exceptionally cold environments. www.ox.ac.uk. This image taken with electron microscopy shows new defects forming between neighboring crystals of the niobium-titanium-based alloys. Courtesy of Cook et al., 2026. with our ENHANCED PRODUCT SELECTOR (201) 343-8983 · main@masterbond.com · www.masterbond.com Filter by specific chemistry and specifications Verify compliance with industrial certifications Pinpoint the ideal material for your application Filters Product Applications Product Type Certifications Electrical Conductivity Thermal Conductivity Optical Clarity Cryogenically Serviceable Product Selector Certifications Applications EP4EN-80 One component flowable epoxy cures at 80°C · Bonding · Encapsulation · Potting UV17Med UV curable adhesive offers excellent adhesion to TPUs MasterSil 323 Two component addition cured silicone system · NASA Low Outgassing · RoHS Compliant · Bonding · Sealing · Coating · Gap Filling · ISO 10993-5 for Cytotoxicity · RoHS Compliant · Bonding · Sealing · Encapsulation · Coating · Gap Filling · Potting · RoHS Compliant Visit www.masterbond.com/product-selector
8 ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 pressure-sensitive paints also respond to temperature changes, which can distort measurements during highspeed tests. The new material incorporates a light-emitting, platinum-based compound into a specially engineered polymer, preventing the compound’s molecules from clustering. Testing showed temperature sensitivity of just 0.3% per degree Celsius, a 25% improvement over the current industry benchmark. Researchers tested the paint on a cone-shaped model in a supersonic wind tunnel, where airflow can exceed Mach 5. Measurements closely matched computer simulations despite significant temperature variations across the model. The paint also revealed complex, corkscrew-shaped airflow patterns known as Görtler vortices, which help engineers understand airflow near curved surfaces. Such measurements are particularly valuable because aerodynamic heating can vary TESTING | CHARACTERIZATION REAL-TIME HEAT SHIELD IMAGING Researchers at the U.S. DOE’s Lawrence Berkeley National Laboratory, California, developed a way to observe spacecraft heat shield materials as they break down under extreme heat, providing new data to improve thermal protection systems. During atmospheric reentry, spacecraft heat shields endure temperatures exceeding 3000°F. Their protective materials gradually decompose through ablation, sacrificing outer layers to protect the vehicle and crew. Previously, scientists largely relied on observations taken before and after heating to understand this process. Using x-ray microcomputed tomo- graphy at Berkeley Lab’s Advanced Light Source, a team from the University of Illinois Urbana-Champaign and NASA captured 3D images of two commercial materials, SLA-220 and SLA-561V, as they heated to 1652°F. Imaging enhanced by artificial intelligence (AI) revealed that SLA-561V’s cork filler decomposed, leaving iso- lated pockets, while SLA-220 formed interconnected channels. These contrasting structures affect how heat and gases move through each material, influencing its protective performance under reentry conditions. The technique combines rapid, large-volume imaging with AI-based super-resolution to capture structural changes in greater detail. The findings provide data to improve predictive models and help engineers better assess heat shield performance. The research builds on Berkeley Lab’s work examining materials used in NASA missions, including Artemis, following unexpected heat shield performance during the program’s first mission. lbl.gov. GLOWING PAINT MAPS AIR PRESSURE Scientists at The University of Manchester in England created a pressure-sensitive paint that reduces temperature-related measurement errors, potentially improving the design of more efficient aircraft and spacecraft. The paint glows in response to air pressure on a model’s surface, allowing engineers to map airflow during wind tunnel testing. However, conventional This heat shield from NASA’s Orion spacecraft was inspected following the Artemis I test flight. Courtesy of NASA. Solar Atmospheres of Western PA, Hermitage, installed a new Kasto saw at its metallurgical laboratory, specifically for preparation and analysis of difficult-to-machine materials including Inconel and titanium. solaratm.com. LECO Corp., St. Joseph, Michigan, announces its 812 Series of new multiphase elemental analyzers built for rapid, simultaneous determination of carbon and moisture across organic and inorganic materials. leco.com. BRIEFS Aerodynamic performance data on a truncated cone model at supersonic flow. Courtesy of The University of Manchester.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 9 across an aircraft’s surface, making it difficult to distinguish pressure effects from temperature effects. More accurate pressure measurements could help aerospace engineers improve aircraft performance, fuel efficiency, and safety. The research team plans to test the material under a wider range of conditions to further evaluate its reliability. www.manchester.ac.uk. PREHISTORIC IRON BARS REVEAL TRADE ROUTES A team of researchers from Austria’s University of Innsbruck and France’s Université de Technologie de Belfort-Montbéliard identified the largest known assemblage of prehistoric iron bars in Europe, offering new insight into Iron Age production and trade. Discovered during gravel extraction near Deinham, Austria, along the Danube River, the assemblage contains at least 500 iron semi-products weighing more than 1 metric ton. Analysis and radiocarbon dating indicate the bars date to the La Tène period, which spanned the mid-fifth through first centuries B.C. Scientists believe the iron may have been lost in a shipwreck while being transported along the Danube for trade. The bars were potentially produced in Bavaria, Germany, where archaeological evidence points to established ironmaking centers near fortified Iron Age settlements. The quantity of iron demonstrates the scale of production and transportation networks in prehistoric Central Europe. According to lead researcher Peter Trebsche of the University of Innsbruck, the material could have been used to forge approximately 500 swords, even accounting for losses during manufacturing. The cargo’s enormous volume suggests that large quantities of iron could be transported and exchanged in a single transaction during the Late Iron Age. The discovery provides rare evidence of large-scale iron commerce Iron bar from Deinham with adhering gravel (top) along with two bars cleaned by the gravel crusher. Courtesy of Peter Trebsche, Antiquity, 2026, doi. org/10.15184/aqy.2026.10404. during a period of expanding production and increasingly organized trade. Researchers say it offers a unique opportunity to investigate how iron resources moved across the region. www.uibk.ac.at/en, www.utbm.fr/en/. EXPAND YOUR EXPERTISE WITH ASM EDUCATION & TRAINING EARN CERTIFICATES IN ANY OF THE FOLLOWING TECHNICAL AREAS: As an IACET Accredited Provider, ASM International offers IACET Continuing Education Units (CEUs) for its learning events that comply with the ANSI/IACET Continuing Education and Training Standard. Education • Applied General Metallurgy • Corrosion: Chemical & Elevated Temperature • Failure Analysis • Ferrous Metallurgy • Heat Treating • Non-Ferrous Metallurgy • Testing & Inspection • Welding Metallurgy
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 10 MACHINE LEARNING | AI AI INSPECTION IMPROVES 3D PRINTING Scientists at the DOE’s Lawrence Livermore National Laboratory (LLNL) developed a camera-based inspection system that can monitor 3D-printed structures layer by layer, using artificial intelligence (AI) and machine learning (ML) to measure tiny variations and potentially identify problems before a part even leaves the printer. The approach could reduce the time and labor required to inspect components produced through direct ink writing, an additive manufacturing (AM) technique. It also presents a way to examine large parts that may be difficult to inspect using conventional x-ray computed tomography, according to the team. The system combines cameras mounted on a 3D printer with ML-based image segmentation and computer vision tools to convert thousands of images captured during printing into detailed measurements and spatial maps of the deposited material. “We now have kind of a brain behind the eyes,” says researcher Brian Weston. “Our system can now see as we’re printing, and we can make data-informed decisions going forward.” The team trained an ML image segmentation model using a cur- ated dataset of nearly 15,000 human-annotated images representing several lattice geometries. A computer vision algorithm then used the model’s results to trace printed strands and measure their dia- meter. In tests involving 55 parts, the automated measurements were typically within a few micrometers of human-derived analysis. Manually measuring a large image could take a person from about 20 minutes to an hour, according to the scientists, while the automated pipeline can perform the analysis in milliseconds. llnl.gov. USING AI FOR FASTER, CHEAPER 3D-PRINTED PARTS Researchers at Washington State University used AI to find a more efficient, less expensive way to 3D- print a high-performance metal alloy, eliminating the need to test more than 100 million options. The findings could one day allow this common aerospace alloy to be printed using widely avail- able commercial equipment, according to the team. The alloy, GRCop-42, com- prises three metals— copper, chromium, and niobium. Developed by NASA, it has high thermal An automated inspection pipeline analyzes images roughly 100,000 times faster than a human can. Courtesy of LLNL. conductivity and remains strong under extreme heat, so it is used in applications such as liquid rocket engine combustion chambers. However, it is expensive and energy-intensive to print, requiring a significant amount of laser power. Researchers have tried unsuccessfully to print the alloy at the lower wattages and laser powers that are used by more common commercial printers, but testing different configurations requires expensive materials, specialized equipment, and significant labor. A single print run can cost hundreds of dollars, while detailed post-print quality analysis can take days. The team used AI-selected process configurations to print GRCop-42 and evaluated the resulting samples. Over three months and within a budget of 40 experiments, the team identified six successful configurations over different laser power levels. The scientists then successfully printed the alloy at 500 watts for the first time, and they believe the same AI-guided framework could be adapted to discover processing conditions for other metal alloys and AM systems. wsu.edu. Researchers used AI to sort through millions of options to identify a more efficient way to print a metal alloy commonly used in the aerospace industry. Courtesy of Alones Creative/iStock.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 1 1 PROCESS TECHNOLOGY ADVANCING ATOMIC SCALE PROCESSING Collaborators from Penn State University, University Park, Pa., and Kurt J. Lesker Company (KJLC), Jefferson Hills, Pa., are advancing methods to create and modify ultrathin material layers essential to semiconductors, advanced packaging, quantum technologies, photonics, and other emerging applications. The partnership establishes the Kurt J. Lesker Company Atomic Scale Processing Center of Excellence at Penn State (ASPIRE), a research and workforce development hub combining KJLC’s vacuum technology and process expertise with Penn Laurel, Md., created a method that could cut manufacturing time for carbon-carbon composites from months to days, potentially easing supply constraints for these heat-resistant materials. The composites remain strong and structurally stable at temperatures exceeding 5000°F, making them valuable for rocket nozzles, hypersonic vehicles, and spacecraft heat shields. The new process, called fieldassisted sintering technique for carbon-carbon or FAST CAR , replaces conventional multicycle densification with a single-step process. It uses a carbon-bearing material and rapid, high-current pressing to consolidate carbon fibers into a dense composite. Using the technique, the team produced a 1-inch cylinder in just days, less than one-tenth the time required by conventional methods. Researchers later manufactured 6- and 8-inch samples, demonstrating potential for larger scale production. Microscopic analysis showed relatively uniform structures with smaller pores than those often found in commercially produced composites. Although the technology remains in early development, researchers are working with external partners to access larger presses and scale up production. If further validated, FAST CAR could accelerate the manufacture of advanced materials for aerospace, defense, and other high-temperature applications. jhuapl.edu. State’s nanofabrication, characterization, and materials research capabilities. ASPIRE’s ribbon-cutting ceremony took place Sept. 9 at the Millennium Science Complex. KJLC will loan three ultra-high purity atomic scale processing systems, valued at approximately $4.45 million, to Penn State’s Nanofabrication Laboratory. The equipment will support research into atomic layer deposition and atomic layer etching for applications ranging from quantum technologies and nanoscale sensors to biomedical coatings, advanced packaging, and flexible electronics. KJLC will retain ownership and maintenance responsibilities. Researchers from both organizations will develop and validate standardized processing protocols defining the materials, temperatures, timing, and other conditions needed to produce specific thin films and structures. The resulting library of processing methods could be shared with academic researchers and KJLC customers worldwide. Penn State researchers will also gain access to 38 existing KJLC processes and technical expertise. The partnership will provide hands-on training opportunities for undergraduate and graduate students and early career professionals, who will use the loaned equipment to develop and test new materials and processing methods for applications including micro- and nano-scale sensors and mechanical devices, biomedical coatings, flexible electronics, and more. psu.edu. SPEEDING UP COMPOSITE PRODUCTION Engineers at the Johns Hopkins Applied Physics Laboratory (APL) in Bodycote, U.K., agreed to a cash acquisition by Vulcan Alpha Bidco Ltd., part of Veritas Capital Fund Management. The offer values Bodycote’s share capital at approximately $2.18 billion. Bodycote provides heat treatment and thermal processing with 4000 employees worldwide. bodycote.com. BRIEF Andrew Read, Penn State senior vice president for research, right, and Kurt Lesker IV, president and CEO of Kurt J. Lesker Company, le , at a ceremonial ribbon cutting to launch their next-gen materials partnership. Courtesy of Jennifer M. McCann/Penn State. The team used FAST CAR2 to manufacture 6-inch (le ) and 8-inch (right) carboncarbon samples. Courtesy of William Fahy and Wes Chapkin/Johns Hopkins APL.
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 EMERGING TECHNOLOGY 12 3D-PRINTED TITANIUM LATTICE STAYS AFLOAT Engineers at Australia’s RMIT University developed a lightweight, 3D-printed titanium structure that remains buoyant even after significant damage, offering potential applications in marine infrastructure. The hybrid lattice comprises hollow, interconnected titanium struts filled with polyurethane foam. Unlike conventional metallic lattices, which can sink as water enters their open spaces, the design allows water to flow through the structure while maintaining flotation. Researchers demonstrated that the material remained buoyant in freshwater for more than two months. Testing also showed it was 70% stronger than stainless steel or high-density polyethylene used in marine applications when compared at the same overall density. To predict buoyancy in open structures, the team developed a measure called skeletal density, which accounts only for components that exclude water, including titanium walls and sealed, foamfilled channels. In seawater corrosion testing, the lattice lost just 0.15% of its mass after two weeks, while its strength declined by less than 1%. The structure also remained buoyant after cracking, connection failures, and the fracture of an entire lattice layer. It sank only after severe crushing and compaction. The researchers demonstrated the technology in a 3D-printed marine buoy that remained stable in a turbulent seawater tank tilted to 45 degrees, without a sealed casing, protective coating, or additional flotation. The team plans to scale up the components and investigate long-term performance in marine and deep-sea conditions. Potential applications beyond marine infrastructure include energy absorption, thermal management, and vibration control. www.rmit.edu.au. PRINTED MATERIAL ENABLES ADAPTIVE COOLING Researchers at the University of Illinois Urbana- Champaign created a printable textile that combines passive cooling with motion-powered energy harvesting to enable adaptive temperature control in wearable applications. The team de- signed a single nanocomposite material that reflects sunlight, releases heat to its surroundings, and generates electrical signals from human movement. The approach integrates cooling and energy harvesting without requiring multiple functional layers. Using direct ink writing, researchers say they can print the material into flexible, breathable textile structures suitable for applications such as athletic clothing. Testing showed the textile reflected 96% of incoming sunlight while efficiently releasing heat. During outdoor trials under direct sunlight, it maintained temperatures approximately 3° to 6°C cooler than the surrounding air. The new technology can also use energy generated by human motion to adjust its thermal response. Electrical signals produced during movement can trigger and regulate heating, allowing the textile to switch between passive cooling and active heating according to the wearer’s activity. The integrated approach could offer a pathway toward wearable materials that manage temperature while capturing energy from everyday movement. Its printable construction and breathable structure may also support development of clothing that responds dynamically to changing environmental conditions and physical exertion. mechse.illinois.edu. QuesTek Innovations, Evanston, Illinois, was named Innovator of the Year at the 2026 Illinois Manufacturing Excellence Awards for its ICMD materials simulation software. ICMD models likely outcomes before companies commit to testing, tooling, and manufacturing iterations. questek.com. BRIEF Cross sections of the titanium lattice cube are shown before and after being filled with polyurethane foam for buoyancy. Courtesy of Sara Tan/RMIT. Photographs show the textile’s mechanical flexibility (left) and permeable fiber-structured geometry (middle). Infrared thermal image of textile on shirt under light exposure (right).
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 13 SUSTAINABILITY EGGSHELLS OFFER GREENER ALLOY PRODUCTION Researchers at North Carolina State University in Raleigh developed a technique that uses powdered eggshells to produce stronger, harder magnesium alloys, offering a more sustainable alternative to conventional calcium materials. The alloys have potential applications in automotive manufacturing, aerospace equipment, and biomedical devices. Eggshells are approximately 95% calcium carbonate, a compound commonly used to manufacture metal alloys. Traditionally, calcium materials are extracted from mined ore through energy-intensive processing. The new technique bypasses these steps by incorporating eggshell powder directly into magnesium during manufacturing. Using a process called friction stir extrusion, researchers fill holes drilled into a magnesium block with finely ground eggshells, then press and rotate a steel mandrel against the material at 300 rpm. The resulting friction converts the eggshells’ calcium carbonate into calcium oxide and calcium, which react with the magnesium to form a highstrength alloy. The process produces an extruded rod of magnesium alloy while reducing manufacturing steps, energy consumption, and reliance on mined resources. Because eggshells are inexpensive and widely available as biological waste, the approach could also support more sustainable supply chains. The research demonstrates a potential new use for food waste in producing high-value materials. The team has also shown that friction stir extrusion can be used to create magnetic composites by combining magnetic samarium-cobalt powder with recycled aluminum, suggesting the technique could have applications beyond eggshells and magnesium alloys. ncsu.edu. RECYCLING TOUGH INDUSTRIAL PLASTICS A team of researchers from The University of Texas at Austin and Sandia National Laboratories created a lowwaste technique for recycling poly(dicyclopentadiene), or pDCPD, a durable plastic used in vehicle bumpers, construction equipment, and chemical storage tanks. Despite its strength and lightweight properties, pDCPD is extremely difficult to recycle and is often incinerated, consuming energy and producing harmful byproducts. The new method breaks down the plastic while preserving valuable reinforcing fibers for reuse. Researchers placed pDCPD in a solution containing an environmentally friendly solvent and a ruthenium-based catalyst. Stirring the solution for several hours to several days—dependent on the object’s size—dissolved the plastic into a powder that can be used to manufacture new materials. Reinforcing fibers, including glass and carbon, can also be recovered in reusable condition. The discovery emerged unexpectedly when researchers found that a chemical solution intended to strengthen the plastic instead dissolved it. The team’s findings could help establish a circular recycling process for a material previously considered impractical to recycle. Further work is needed to determine whether the ruthenium catalyst can be recovered and reused economically. The researchers have applied for a U.S. patent covering the technology. utexas.edu, sandia.gov. Matergenics Inc., Pittsburgh, deployed its hydrogen-in-steel monitoring sensor at a hydrogen-natural gas blending facility in Italy, marking the first operational use of the technology. The system uses continuous dilation measurements and HEILD-based analysis to assess hydrogen embrittlement risks in steel piping. matergenics.com. Eggshells are a low-cost, sustainable alternative to conventional calcium materials. Courtesy of Bharat Gwalani. This 3D-printed pu erfish, made of pDCPD, begins deconstruction via solution. Courtesy of the University of Texas at Austin. U.S. Critical Materials Corp., Salt Lake City, and Columbia University signed a two-year research agreement to help enable U.S. production of gallium, scandium, titanium, and rare earth elements from red mud, a byproduct of aluminum refining. uscriticalmaterials.com. BRIEFS
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 14 STRESS RELIEF POLYMER NANOPARTICLE INK MAKES TATTOOS DISAPPEAR A team of engineers from the University of Colorado Boulder designed a new line of multicolored tattoo inks that switch on and off with different kinds of light. Their technology could help business people hide their tattoos before an important meeting. Artistically inclined users could even doodle on their own skin using a simple laser pointer. “Tattooing is a very ancient technology that remains mostly untapped as a platform for today’s technologies,” says lead author Carson Bruns. The new inks, known as PhotoTat, are made from dyes and a plexiglasslike material common in many medical technologies on the market today, including dermal fillers. The dyes are normally invisible to the human eye. But shining an ultraviolet light on them activates their color change—turning them vibrant blue, magenta, and yellow. “PhotoTat is like a switch. You turn it on with UV light, but you can turn it off again when you go to grandma’s house,” says Bruns. The technology is not yet available at your local tattoo parlor. But Bruns and his team are perfecting the inks to make that a possibility in the coming years. colorado.edu Tattoo ink disappears a er light activation. Courtesy of University of Colorado, doi.org/10.1016/j.matlit. 2026.100119. FAS SUMMIT 2027 The Failure Analysis Society (FAS) has organized the Failure Analysis & Prevention Summit, which will take place in beautiful Oceanside, California, on February 2-4, 2027. Back again after a successful inaugural event last year, the Summit brings together engineers, researchers, and industry professionals to explore real-world failures, case studies, and next-generation prevention techniques. This year’s theme is “When Materials Meet Their Environment: Understanding Environmentally-Assisted Failures.” The Technical Program features invited talks by Thomas Akerson, David Ahearn, ASM President Daniel P. Dennies, Satish Dixit, Larry Hanke, Nikkhil Kar, Chris Misorski, David C. Riegner, Craig Schroeder, Han Tsan, Amy M. Wells, Eric Welshapt, and March Zupan. Multiple networking opportunities will allow attendees to connect with peers, industry leaders, and innovators across the field often with picturesque sunsets in view. Applied Technical Services is sponsoring the welcome reception and the two-day event. FAS President Dustin Turnquist serves as the Summit chair. Registration is now open and the early bird deadline is December 29. For more information and to register, visit asminternational.org/fas-summit-event. asminternational.axomo.com Show Your ASM Pride! Shop ASM apparel and essentials, affiliate society t-shirts, and more in our gear store!
130 YEARS OF ENGINEERED GRAPHITE: INVENTION TO INDISPENSABLE GRAPHITE DEVELOPMENT 15 Ryan M. Paul* GrafTech International Holdings Inc., Cleveland This historical review details the critical developments and evolving applications of graphite from the dawn of carbon materials to the space age and beyond. *Member of ASM International
ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 16 Carbon is an extraordinary element, often called the “king of elements.” It is no surprise then, that engineered materials made of carbon are extraordinary—materials that are light, strong, tough, and stable at high temperature. The unique physical and chemical properties of graphite materials have made them absolutely essential for energy storage, energy generation, electronics, and extreme applications. What is also extra- ordinary is the story of how engineered graphite went from invention to indispensable in the last 130 years. Today, graphite in application touches many materials, enabling broad technological success, but its vital role has not been as publicly visible as other materials. Furthermore, graphite remains misunderstood as an engineered material. In fact, there is not just one graphite. Strictly speaking, graphite is a crystal structure of elemental carbon, but practically speaking, graphite materials are a large category of complex composite materials that vary in form factor, bulk density, bulk isotropy, extent of graphitization, purity, and other properties. For form factor, bulk articles and powders are common, but graphite materials are also made into fibers, foils, and films, among others. Graphite materials are not just a composition of polycrystalline grains, but their structure is polygranular, multiscale, and heterogenous. On one side, natural graphite is mined from the Earth, and its most common form is as flakes that can be processed into powders and foils or used in refractories, friction materials, and energy storage. On the other side, synthetic or engineered graphite materials are formed sequentially and irreversibly from controlled heat treatment of carbonaceous precursors and have a different structure from natural graphite (Figs. 1 and 2). Synthetic graphite requires high-quality carbonaceous materials like petroleum coke and coal tar and petroleum pitch (Figs. 3-5). A review of the literature shows no clear classification of graphite materials, ambiguous and inconsistent terminology, poor interchangeability, and no established structure-property relationships. It is easy to see why there is wide confusion. It is from this vantage point that the motivation for this article is set. Fig. 1 — Example routes for bulk article processing of synthetic graphite, and primary powders from synthetic and natural routes. Fig. 2 — Examples of lithium-ion battery grade natural graphite (left) and synthetic graphite (right) active anode materials. Fig. 3 — Petroleum needle coke, a precursor for synthetic graphite (left). Microstructure of needle coke showing oriented and aligned structure (right).
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