21 26 33 P. 15 Lower-carbon Aluminum Alloys for Highway Signage Zeolite Monoliths Aid CO2 Absorption iTSSe Newsletter Included in This Issue NEXT-GEN FUSION FIRST-WALL MATERIALS GREEN MATERIALS ENGINEERING JULY/AUGUST 2025 | VOL 183 | NO 5
Showcase your thought leadership and innovations at one of ASMʼs 2025-26 conferences and expositions, which offer unparalleled access to highly engaged audiences of industry leaders and decision-makers. INTERNATIONAL CONFERENCE ON RESIDUAL STRESSES (ICRS) OCTOBER 20 – 23, 2025 | DETROIT, MICHIGAN 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 our symposium topics, networking opportunities, and technical programming. INTERNATIONAL MATERIALS, APPLICATIONS & TECHNOLOGIES (IMAT) OCTOBER 20 – 23, 2025 | DETROIT, MICHIGAN IMAT, ASM’s annual event, is the only targeted conference 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 and all six of ASM’s Affiliate Societies, who are heavily involved in building the technical symposiums, which will have a strong focus on realworld technologies that can be put to use today. HEAT TREAT 2025 OCTOBER 21 – 23, 2025 | DETROIT, MICHIGAN Discover the unrivaled opportunities awaiting you at Heat Treat Conference/Expo! As the LARGEST gathering for heat treating professionals, materials experts, and industry leaders in North America, Heat Treat is a MUST-ATTEND event! INTERNATIONAL SYMPOSIUM FOR TESTING AND FAILURE ANALYSIS (ISTFA) NOVEMBER 16 – 20, 2025 | PASADENA, CALIFORNIA 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. SYMPOSIUM ON EMERGING MATERIALS AND INNOVATIONS IN THERMAL SPRAY (SEMI) DECEMBER 1 – 3, 2025 | MELBOURNE, AUSTRALIA SEMI is a new symposium offered by the ASM Thermal Spray Society (TSS), in coordination with Swinburne University of Technology. This event will explore the latest advancements in thermal spray and cold spray technologies, with a focus on surface engineering, repair applications, and innovative materials for the mining and industrial sectors. INTERNATIONAL THERMAL SPRAY CONFERENCE & EXPOSITION (ITSC) MARCH 18 – 20, 2026 | BANGKOK, THAILAND 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 the International Institute of Welding (iiw). HEAT TREAT MEXICO APRIL 14 – 16, 2026 | MONTERREY, MEXICO Mark your calendars for Heat Treat Mexico 2026, the PREMIER event powered by the strength of the ASM Heat Treating Society, ASM Mexico Chapter, and Heat Treat North America Organizers. Discover cutting-edge heat treating resources, education, and technology tailored for Mexico’s flourishing markets. Secure your spot now! SHAPE MEMORY AND SUPERELASTIC TECHNOLOGIES CONFERENCE AND EXPOSITION (SMST) MAY 4 – 8, 2026 | LA JOLLA, CALIFORNIA Join us at SMST — the premier global event dedicated to the latest advances in shape memory and superelastic materials. Held in the stunning coastal setting of La Jolla Torrey Pines, this conference is a must-attend for professionals working with Nitinol and related technologies. AEROMAT JUNE 2 – 4, 2026 | WEST PALM BEACH, FLORIDA AeroMat will feature a wide range of technical topics, offering insights into the latest on innovative aerospace materials, fabrication, and manufacturing methods that improve performance, durability, and sustainability of aerospace structures and engines with reduced life-cycle costs. Learn more about each event and related exhibit and sponsorship opportunities at asminternational.org/events 2025-26 EVENTS
21 26 33 P. 15 Lower-carbon Aluminum Alloys for Highway Signage Zeolite Monoliths Aid CO2 Absorption iTSSe Newsletter Included in This Issue NEXT-GEN FUSION FIRST-WALL MATERIALS GREEN MATERIALS ENGINEERING JULY/AUGUST 2025 | VOL 183 | NO 5
3 EVENTS • 1 LOCATION DETROIT, MICHIGAN, USA | HUNTINGTON PLACE ICRSevent.org IMATevent.org HeatTreatevent.org ORGANIZED BY: OCTOBER 21-23, 2025 OCTOBER 20-23, 2025 OCTOBER 20-23, 2025
NOVEMBER 16–20, 2025 PASADENA CONVENTION CENTER | PASADENA, CA SCALING BEYOND MOORE’S LAW: HETEROGENEOUS COMPUTING AND ADVANCED PACKAGING SAVE THE DATE! High-performance compute solutions are simultaneously driving innovations in advanced packaging, high bandwidth I/O, heterogeneous compute architectures, device architectures, silicon scaling, and more. Each of these advances pose a unique challenge to failure analysis, but together present a disruption that the failure analysis community has yet to experience. Now is the time to act! New analysis methods and instrumentation must be developed to address these challenges and deliver the stellar analysis capability our failure analysis community is known for. Industry collaboration is the key to success. Together, we will spearhead the breakthrough approaches necessary to overcome the complex disruptions our society is facing as high-performance compute solutions scale beyond Moore’s law. STUDENT POSTER SESSION The 51st International Symposium for Testing and Failure Analysis (ISTFA) invites community college, undergraduate, and graduate students to participate in this year’s student poster contest. This program is designed to: • Foster exchanges between academia and the failure analysis engineering community. • Provide students with an opportunity to gain exposure to failure analysis within the microelectronics sector and to network with professionals and peers in the field. ISTFA is the premier microelectronics/semiconductor failure analysis conference in North America. It will be held at the Pasadena Convention Center from November 16–20, 2025. Learn more at ISTFAevent.org. •Access to tutorials •Four days of technical programming •Keynotes & Panel Discussion •Entrance to the Exhibit Hall Complete Full Conference Ticket Includes: Student Registration Available •Welcome Reception with the Exhibitors •Refreshment Breaks each day •Lunch vouchers •One ticket to the Social Event REGISTRATION OPENS IN JULY!
51 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. CHADWICK: ACCELERATING THE DISCOVERY OF NEXT-GENERATION FUSION FIRST-WALL MATERIALS Cheng Xu, Pankaj Trivedi, and Ahmed Diallo ARPA-E’s CHADWICK program (Creating Hardened And Durable Fusion First Wall Incorporating Centralized Knowledge) aims to discover novel materials that meet the demanding operating conditions of fusion energy systems through a comprehensive approach, thereby contributing to an abundant energy future. 15 ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 2 Depiction of plasma facing component tiles in a fusion grade plasma enduring high heat and neutron fluxes in a fusion energy system. Courtesy of ARPA-E. On the Cover: 68 3D PRINTSHOP A look at practical applications for additive manufacturing that also have an artistic slant. IMAT 2025 PROGRAM HIGHLIGHTS IMAT—the International Materials, Applications & Technologies Conference and Exhibition—and ASM’s annual meeting will be held in Detroit, Oct. 20 to 23. 31
4 Editorial 5 Research Tracks 6 Feedback 12 Machine Learning 8 Metals/Polymers/Ceramics 10 Testing/Characterization 13 Process Technology 14 Sustainability 67 Editorial Preview 67 Special Advertising Section 67 Advertisers Index 68 3D PrintShop TRENDS INDUSTRY NEWS DEPARTMENTS Check out the Digital Edition online at asminternational.org/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-e ective 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 eight issues per year: January/February, March, April, May/June, July/August, September, October, and November/December, 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. 183, No. 5, JULY/AUGUST 2025. Copyright © 2025 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. 21 LOWER-CARBON ALUMINUM ALLOYS FOR TRANSPORTATION INFRASTRUCTURE R.E. Sanders and B.V. Costello Alternatives to alloy 5052, including existing 3xxx or 5xxx alloys, can improve carbon footprint with no functional di erence in performance. 26 TECHNICAL SPOTLIGHT CARBON CAPTURE REINVENTED: ENSURING QUALITY THROUGH TESTING A carbon capture system is being revolutionized by a testing process that ensures the mechanical properties of zeolite monoliths. 28 TECHNICAL SPOTLIGHT A CENTURY OF TESTING EXPERTISE AT SMITHERS With origins as an independent tire testing company, Smithers celebrates 100 years of growth and evolution across various materials industries. FEATURES JULY/AUGUST 2025 | VOL 183 | NO 5 ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 3 21 28 33 26 33 iTSSe The official newsletter of the ASM Thermal Spray Society (TSS). This timely supplement focuses on thermal spray and related surface engineering technologies along with TSS news and initiatives, and a preview of the Symposium on Emerging Materials and Innovations in Thermal Spray (SEMI).
4 ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 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 Yun Bai, Ford Rajan Bhambroo, Tenneco Inc. Punnathat Bordeenithikasem, Machina Labs Daniel Grice, Materials Evaluation & Engineering Surojit Gupta, University of North Dakota Michael Hoerner, KnightHawk Engineering Hideyuki Kanematsu, Suzuka National College of Technology Ibrahim Karaman, Texas A&M University Ricardo Komai, Tesla Krassimir Marchev, Northeastern University Bhargavi Mummareddy, Dimensional Energy Scott Olig, U.S. Naval Research Lab Christian Paglia, SUPSI Institute of Materials and Construction Satyam Sahay, John Deere Technology Center India Abhijit Sengupta, USA Federal Government Kumar Sridharan, University of Wisconsin Vasisht Venkatesh, Pratt & Whitney ASM BOARD OF TRUSTEES Navin Manjooran, President and Chair Elizabeth Ho man, Senior Vice President Daniel P. Dennies, Vice President Pradeep Goyal, Immediate Past President Lawrence Somrack, Treasurer Amber Black Pierpaolo Carlone Rahul Gupta Hanchen Huang André McDonald Victoria Miller Christopher J. Misorski Dehua Yang Fan Zhang Veronica Becker, Executive Director STUDENT BOARD MEMBERS Gladys Duran Duran, Amanda Smith, Nathaniel Tomas 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. FISSION AND FUSION GUARDRAILS In the high mountain desert region of New Mexico, the Los Alamos area was selected by J. Robert Oppenheimer and General Leslie Groves as an ideal location for nuclear materials research in the early 1940s. As part of the Manhattan Project, some ready-made buildings at what came to be known as the Pajarito Site were easily converted into labs and offices to accommodate foundational uranium and plutonium research. In 1944 and 1945, battleship bunkers were added to meet the unique needs of implosion testing. The bunkers provided essential protection to the researchers and surrounding area during these dangerous tests. To honor the pivotal role it played in atomic research, the Pajarito Site was named an ASM Historical Landmark this year. Read more about it in our ASM News section honoring all the 2025 ASM awardees. A plaque bearing the new landmark designation will be installed at the entrance to the New Mexico site, further cementing its significance to the development of nuclear research. Still today, advancements are being made to nuclear energy safeguards. Savannah River National Laboratory (SRNL) recently received a U.S. patent for its radially oriented honeycomb structures. This exceptionally strong container design was created by forming a cylindrical structure with multiple radially aligned layers of strips of honeycomb cells. The new technology allows for greater wall thickness than previously possible. It will be used in radioactive material packaging applications where it will absorb impact energy should an accident occur. This high-strength barrier will prevent any release of hazardous materials in packaging and transportation operations. Switching gears from fission to fusion, next we explore today’s emerging energy focus. Excitement around the initial successful fusion shot at the National Ignition Facility at Lawrence Livermore National Laboratory (LLNL) in December 2022 was further buoyed by a second achievement of ignition in July 2023. Fusion energy proved possible. As with nuclear research, the next phase requires more materials testing to ensure the fusion’s safe containment. In AM&P September 2023, we featured an article by SRNL and LLNL discussing some of the next steps required in moving to successful commercial fusion energy. The authors presented the materials challenges of a fusion pilot plant. They proposed some polymer options for use as sealants, adhesives, and in mechanical assemblies within a power plant, as these materials would allow for long-term performance under extreme conditions. Another phase of research on similar protections is discussed in the lead article of this issue. Scientists from the Advanced Research Projects AgencyEnergy are working to accelerate the discovery of new materials that can withstand the harsh conditions found in commercial fusion reactors. One option is a first wall barrier made of liquid metal. Lessons learned from nuclear energy development are applicable to today’s fusion research. The design and strength of containers and first walls are critical. Materials solutions will provide those powerful safeguards. joanne.miller@asminternational.org SRNL’s cylindrical structure in a container.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 5 RESEARCH TRACKS 3D X-RAY MICROSCOPY FOR SMALLER LABS According to research led by the University of Michigan, it is now possible to study the microstructures of metals, ceramics, and rocks with x-rays in a standard laboratory rather than using a particle accelerator. The new technique makes 3D x-ray diffraction (3DXRD) more accessible, enabling faster sample analysis in both academia and industry. While synchrotron x-ray beams pro- duce state-of-the-art detail, only about 70 facilities exist worldwide. Projects often must wait between six months and two years to run experiments, which are limited to a six-day maximum. To make the new technique more available, the team worked with Proto Manufacturing to build the first lab-scale 3DXRD. Previously, smallscale devices could not produce enough x-rays for 3DXRD because at a certain point, the electron beam pumps so much power into the anode that it would melt. Lab-3DXRD leverages a liquid-metal-jet anode that is already liquid at room temperature, allowing it to take in more power and produce more x-rays than once possible at this scale. The team tested their design by scanning the same titanium alloy sample using three methods: lab-3DXRD, synchrotron-3DXRD, and laboratory dif- fraction contrast tomography. Lab-3DXRD was highly accurate, with 96% of the crystals it picked up overlapping with the other two methods. “Lab-3DXRD is like a nice backyard telescope while synchrotron-3DXRD is the Hubble Telescope. There are still certain situations where you need the Hubble, but we are now well prepared for those big experiments because we can try everything out beforehand,” says Ashley Bucsek, assistant professor. umich.edu. NANOSCALE VIEW OF SHARK SKELETON Sharks develop skeletons from a tough, mineralized form of cartilage. Their spines act like natural springs, allowing them to move through the water with powerful grace. Now, scientists at Florida Atlantic University (FAU) are studying shark skeletons at the nanoscale, revealing a microscopic “sharkitecture” that helps these predators withstand the extreme physical demands of constant motion. Using synchrotron x-ray nanotomo- graphy with detailed 3D imaging and in situ mechanical testing, the team, in collaboration with the German Electron Synchrotron (DESY) and NOAA Fisheries, mapped the internal structure of blacktip sharks in new detail. Results of the study reveal two distinct regions within the blacktip shark’s mineralized cartilage: the corpus calcareum and the intermediale. In both regions, mineralized plates are arranged in porous structures, reinforced by thick struts that help the skeleton withstand strain from multiple directions. At the nanoscale, researchers observed tiny needle-like bioapatite crystals aligned with strands of collagen. “After hundreds of millions of years of evolution, we can now finally see how shark cartilage works at the nanoscale—and learn from them,” says researcher Marianne Porter. fau.edu. The DOE’s Idaho National Laboratory and Missouri University of Science and Technology signed a new agreement aimed at advancing research and education. The goal is to collaborate on R&D projects of mutual interest, including integrated energy systems, advanced nuclear reactors, electric power and grid systems, and advanced materials for extreme environments. inl.gov, mst.edu. BRIEF Ashley Bucsek (left) and her team are using 3D x-ray diffraction to study polycrystalline materials on campus. Intermediale cartilage of a blacktip shark. Arrows highlight the internal mineralized network that reinforces the structure.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 6 SYMPHONY OF ELEMENTS EXHIBITION AT SLOSS FURNACES OFFERS METALLOGRAPHY EDUCATION AND ENGAGEMENT Against the backdrop of towering smokestacks and steel-laden history, the Sloss Furnaces National Historic Landmark in Birmingham, Alabama, became a portal into the inner workings of modern metallurgy with the opening of the Symphony of Elements: Art and Science of Metals exhibition. This innovative showcase, running through August 2025, offers a rare and compelling fusion of technical achievements, advanced materials science, and visual art. The centerpiece of the exhibition is a collection of 25 striking micrographs revealing the internal structure of metal components taken from the Honda J35 V6 engine. Each micrograph is paired with the physical engine part it represents, from crankshafts to connecting rods, allowing visitors to trace the direct link between microstructure and mechanical function. A full J35 engine with precision cutaways brings the system to life. In motion, viewers can observe how pistons rise and fall, valves open and close, and the crankshaft turns— all while signage breaks down the underlying metallurgy that makes this performance possible. The exhibit shows how the grain structures, phase transformations, and heat treatments define strength, wear resistance, and durability in each critical component. The grand opening on May 23 drew a crowd of 90 attendees including educators, engineers, artists, and community leaders. Representing ASM International, Vice President Daniel P. Dennies, FASM, addressed the crowd, emphasizing the importance of public engagement with materials science. “Metallurgy is at the heart of every technological leap—from steam engines to spacecraft. This exhibition of microstructures makes that truth visible, tangible, and inspiring,” he said. As the event’s curator and director of the exhibition, it’s important to me to highlight its broader mission. Our goal isn’t just to show what metal looks like under a microscope. It’s to connect people— especially students—with the idea that materials science is not just useful, it’s beautiful. And it’s essential to the future. Beyond the technical depth, Symphony of Elements stands as a bold STEM outreach effort. By arranging advanced concepts in a hands-on, visually arresting context, the exhibition speaks to audiences ranging from Families discuss the displays. From left: ASM Vice President Dan Dennies, FASM, with exhibit director Raymond Thompson, FASM. Symphony of Elements exhibit on its grand opening day. FEEDBACK
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 7 K-12 students to professional engineers. It makes the case that metallurgy is not some forgotten industrial relic, but a living, evolving science central to solving the problems of tomorrow with solutions such as lighter cars, functional dwellings, and more energyefficient processes. The setting of Sloss Furnaces adds yet another layer of resonance. Once a hub of pig iron production that helped fuel the South’s industrial growth, the site now bridges past and An educational poster makes for a teachable moment. present, industry and innovation. That juxtaposition is no accident. As the summer unfolds, the Symphony of Elements promises to become a regional touchstone for educational field trips, family visits, and materials professionals alike. The Symphony of Elements Foundation encourages members, educators, and students to attend, experience the beauty of metals from the inside out, and witness how a microscope can reveal not just grains and phases, but the foundations of technology itself. The exhibit also includes images from the ASM Micrograph Database. For more information, visit the Symphony of Elements exhibit website at symphonyofelements.org or plan a visit to Sloss Furnaces through August 31 of this year. Individuals or organizations interested in hosting this unique exhibit in their area can contact me at info@symphonyofelements.org. Raymond Thompson, FASM Examples of some of the intriguing micrographs on display. We welcome all comments and suggestions. Send letters to joanne.miller@asminternational.org. To appear in the listings, visit AMPdirectory.com/addyourcompany Simplify Your Search for Vendors Find the right solutions for your business. Search for products, research companies, connect with suppliers, and make confident purchasing decisions all in one place. AMPdirectory.com
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 8 METALS | POLYMERS | CERAMICS large-scale, 3D-printed polymer parts. Large-format additive manufacturing (LFAM) enables direct printing of meter-scale structures for aerospace, automotive, and defense tooling applications. However, widespread adoption has been limited by voids that weaken printed parts. Reducing porosity is key to improving strength, durability, and overall performance. ORNL researchers addressed this challenge with a unique approach: The team integrated a vacuum hopper during the extrusion process to remove trapped gases and minimize void formation in fiber-reinforced materials. These materials are widely used in LFAM for their stiffness and low thermal expansion but often suffer from intrabead porosity that limits part quality. The new system reduced porosity to less than 2%, even with varying fiber content. “Using this innovative technique, we are not only addressing the critical issue of porosity in large-scale polymer prints but also paving the way for stronger composites,” says researcher Vipin Kumar. “This is a significant leap forward for the LFAM industry.” Although the current method is designed for batch processing, ORNL developed a patent-pending concept for continuous deposition systems, which will be the focus of future research. ornl.gov. NEW ALLOY DESIGN ENHANCES ALUMINUM Researchers from the Max Planck Institute for Sustainable Materials in Germany, along with partners in Japan and China, developed a new alloy design technique that overcomes the challenge of embrittlement, which leads to cracking and failure when aluminum alloys are exposed to hydrogen. Key to this breakthrough is a size-sieved precipitation strategy in scandium-added aluminum-magnesium alloys. By using a two-step heat treatment, the researchers engineered fine Al3Sc nanoprecipitates on which a shell of a highly structurally complex Al3(Mg,Sc)2 forms in situ. These dual nanoprecipitates are distributed throughout the alloy to serve two key purposes. The Al3(Mg,Sc)2 phase traps hydrogen and increases resistance against hydrogen embrittlement, while the fine Al3Sc particles boost strength. “Our new design strategy solves this typical trade-off. We no longer have to choose between high strength and hydrogen resistance—this alloy delivers both,” says researcher Baptiste Gault. The results show a 40% increase in strength and a five-fold improvement in hydrogen embrittlement resistance compared to scandium-free alloys. The material also achieves a record uniform tensile elongation in hydrogen-charged aluminum alloys at relatively high hydrogen loading. Atom probe tomography measurements carried out at the Max Planck Institute were essential in verifying the role of the Al3(Mg,Sc)2 phase in hydrogen trapping at the atomic level, offering insights into how the alloy design works on a fundamental scale. The researchers tested their approach across various Al alloy systems and demonstrated scalability by using water-cooled copper mold casting and thermomechanical processing methods. www.mpg.de. VACUUM-ASSISTED EXTRUSION FOR POLYMER PRINTS Researchers at the DOE’s Oak Ridge National Laboratory (ORNL), Tenn., developed a vacuum-assisted extrusion method that reduces internal porosity by up to 75% in Emirates Global Aluminum chose Oklahoma as the site for the first new primary aluminum production plant to be built in the U.S. in 45 years. The $4 billion project will create 1000 direct jobs and 1800 indirect jobs. The facility will produce billets, sheet ingots, high-purity aluminum, and foundry alloys. www.ega.ae. BRIEF Complex nanoprecipitates can trap hydrogen inside aluminum alloys while maintaining their strength. Courtesy of Nature, 2025, doi.org/10.1038/S41586025-08879-2. A vacuum-assisted extrusion is used in large-scale additive manufacturing to reduce porosity in printed parts. Courtesy of Vipin Kumar/ORNL, U.S. Dept. of Energy.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 9 BIODEGRADABLE POLYMER SUPPORTS OCEAN HEALTH Researchers from Korea developed a new material that can be produced using existing methods and addresses the problem of nylon-based products such as fishing nets that are slow to degrade, especially in marine environments. The team includes scientists from the Korea Research Institute of Chemical Technology (KRICT), Inha University, and Sogang University. They made a high-performance polyester-amide (PEA) polymer that decomposes by over 92% in one year under real marine conditions, while maintaining strength and flexibility comparable to nylon. The new material is not only scalable and recyclable, but also applicable to a wide range of uses such as textiles, fishing nets, and food packaging. Unlike conventional biodegradable plastics that suffer from low durability and heat resistance, the PEA polymer combines ester (for biodegradability) and amide (for toughness) linkages in an optimized ratio. Researchers say the design offers both high degradability and mechanical durability. Marine biodegradability tests show that the new PEA achieves up to 92.1% degradation From left: Researchers Hyeonyeol Jeon, Sung-Bae Park, and Hyo Jeong Kim with their PEA yarns. Courtesy of KRICT. within one year, significantly outperforming other biodegradable plastics such as PLA (0.1%), PBS (35.9%), and PBAT (21.1%). The tensile strength of the PEA yarn reaches up to 110 MPa, surpassing that of both nylon 6 and PET. During experiments, a single PEA fiber strand was able to lift a 10 kg object without breaking. When woven into fabrics, it withstood ironing at 150°C, demonstrating its high thermal resistance. The team is now evaluating the material for commercialization, with a goal of industrial adoption within two years. “The key achievement is that this material overcomes the limitations of conventional biodegradable plastics while offering nylon-level performance,” says researcher Sung-Bae Park of KRICT. www.nst.re.kr. • Extraordinarily high shear and peel strength •Room temperature curing • Superior electrical insulation properties • Optically clear Adhesive for High Performance Structural Bonding www.masterbond.com Hackensack, NJ 07601 USA +1.201.343.8983 • main@masterbond.com Epoxy EP31 1016LK_3.25x4.875_EP31.indd 1 12/7/11 10:06 PM
10 ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 NEW ROD-SHAPED CRYSTAL IDENTIFIED Researchers at New York University (NYU) documented how crystals evolve from shapeless blobs to orderly structures in a new study. During their work, the team came across a rod-shaped crystal that had not been previously identified, naming it “Zangenite” after Shihao Zang, the team member who discovered it. To study their formation, some researchers use crystals made up of colloidal particles, which are small yet much larger than the atoms that make up other crystals. To learn how colloidal crystals form, the team ran experiments to observe how charged colloidal particles behave in different growth conditions as they transition from saltwater suspensions to fully formed crystals. By running numerous computer simulations, the scientists found that colloidal crystals form through a twostep process—amorphous blobs of TESTING | CHARACTERIZATION EXTENDED SLIP BANDS DISCOVERED Scientists at the University of California, Irvine recently added new information to the accepted model that governs the mechanics of slip banding, which produces strain marks in metals under compression. Their discovery offers a deeper understanding of the behavior of advanced materials important to energy, space, and nuclear applications. The researchers report the discovery of extended slip bands, a finding that challenges the classic model developed by physicists Charles Frank and Thornton Read in the 1950s. While the Frank-Read theory attributes slip band formation to continuous dislocation multiplication at active sources, the Irvine team found that extended slip bands emerge from source deactivation followed by the dynamic activation of new dislocation sources. The process that results in extended slip bands was observed at the atomic scale as researchers performed mechanical compression on micropillars of an alloy of chromium, cobalt, and nickel. Using scanning transmission electron microscopy and large-scale atomistic modeling, the team was able to view the confined slip band as a thin glide zone with minimal defects and the extended slip band with a high density of planar defects. “Our ability to capture these processes at atomic and nano- meter scales provides new insight into collective dislocation motion and microscopic deformation instability in advanced structural materials,” says associate professor Penghui Cao. “With the advent of new, advanced ‘supermaterials’ such as the CrCoNi alloy, a deep understanding of their behaviors is more critical than ever.” uci.edu. Testbed 80. Courtesy of Rolls-Royce. Zangenite is a hollow crystal structure named after the NYU graduate student who made its discovery. Courtesy of Shihao Zang. Top row: Formation of a confined slip band (C-SB) with localized glide on slip plane ABC. Bottom row: Generation of extended slip band (E-SB), which triggers partial slip and formation of twin boundaries (TB), stacking faults (SF), and hexagonal close-packed (hcp) regions, resulting in band thickening along the ABD plane. Courtesy of Penghui Cao and Hangman Chen/UC Irvine. Researchers at the University of Glasgow, U.K., built the NextSpace TestRig as the first dedicated facility for testing the structural integrity of polymers, ceramics, and metals to be 3D printed in space. The rig features a vacuum chamber for generating temperatures from -150° to 250°C and the facility is open to both academic and commercial clients worldwide. www.gla.ac.uk. Tescan Group, Czech Republic, an electron microscope manufacturer, announces a new collaboration with The University of British Columbia. Tescan USA will provide researchers with Mira, Tensor, and Amber electron microscopes. tescan.com. BRIEFS
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 1 1 particles first condense before transforming into ordered crystal structures. During the experiments, Zang came across a rod-shaped crystal he could not identify. He compared the unknown structure with more than a thousand crystals found in the natural world and could not find a match. The discovery of Zangenite creates an opportunity to explore applications for hollow, low-density crystals. A deeper understanding of how crystals form holds promise for developing new materials, including photonic bandgap materials useful for lasers, fiberoptic cables, solar panels, and other technologies that transmit or harvest light. nyu.edu. LEARNING WHY LITHIUM-ION BATTERIES FAIL Using a new computational model, a University of Wisconsin-Madison mechanical engineering professor achieved a new understanding of why lithium-ion batteries fail. Developed by Weiyu Li, the model explains lithium plating, in which fast charging triggers metallic lithium to build up on the surface of a battery’s anode, causing the battery to degrade faster or catch fire. This knowledge could lead to fast-charging lithium-ion batteries that are safer and longer-lasting. Until now, the mechanisms that trigger lithium plating were not well understood. With her model, Li studied lithium plating on a graphite anode in a lithium-ion battery. The model revealed how the complex interplay between ion transport and electrochemical reactions drives lithium plating. “Using this model, I was able to establish relationships between key factors, such as operating conditions and material properties, and the onset of lithium plating,” says Li. “From these results, I created a diagram that provides physics-based guidance on strategies to mitigate plating. The diagram makes A model of lithium plating on a graphite particle coated with a solid electrolyte interphase (SEI) layer. Courtesy of Weiyu Li/ACS. these findings very accessible, and researchers can harness the results without needing to perform any additional simulations.” Li adds that her model offers a way to investigate the onset of lithium plating over a wide range of conditions, enabling a more comprehensive picture of the phenomenon. wisc.edu. Fibercraft™ Heating Elements Offer Superior Performance in High-Temperature Applications. • Temp Range up to 1200°C (2200°F) • Exceptional Durability • Versatile Application • Customizable Design TC 8.375X5.5625_031025.indd 1 3/11/25 2:10 PM
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 12 MACHINE LEARNING | AI AI HELPS OPTIMIZE SOLID-STATE BATTERIES Researchers at Tohoku University, Japan, developed a data-driven AI framework that suggests promising solid-state electrolyte (SSE) candidates for sustainable energy applications including solid-state batteries. The model not only selects optimal candidates but also predicts how the reaction will occur and why the candidate is a good choice, helping scientists make signifi- cant headway before running any physical experiments. “The model essentially does all of the trial-and-error busywork for us,” says Professor Hao Li. “It draws from a large database from previous studies to search through all the potential options and find the best SSE candidate.” The new AI framework integrates large language models, MetaD, multiple linear regression, genetic algorithm, and theory-experiment benchmarking analysis. The predictive models draw from both experimental and computational data. A goal of this study was to understand the structure-performance relationships of SSEs. The model predicts activation energy, identifies stable crystal structures, and improves overall workflow. The findings demonstrate that MetaD is an optimal computational technique that shows high levels of agreement with experimental data for complex hydride SSEs. Further, by combining feature analysis with multiple linear regression, they constructed precise predictive models for the rapid evaluation of hydride SSE performance. The researchers believe their work will help enable more efficient design of next-generation solid-state batteries. www.tohoku.ac.jp. MACHINE LEARNING PREDICTS MATERIAL FAILURE Two scientists at Lehigh University, Bethlehem, Pa., predicted abnormal grain growth in simulated polycrystalline materials for the first time. They say the development could lead to better materials for high-stress environments such as combustion engines. So far, predicting abnormal grain growth has been extremely challenging due to the numerous combinations that can go into making any given alloy. The new computational simulation helps narrow down possibilities by eliminating Cross-sections shown every 10M MCS (Monte Carlo steps). The highlighted (red) grain becomes abnormally large just after 67M MCS. The Lehigh team predicted this grain would become abnormal using only the data from 11 to 15M MCS, long before abnormality occurs. materials that are likely to develop abnormal grain growth. The challenge is that abnormal grain growth is a rare event and early on, grains that will become abnormal look just like the others. To address this, the team developed a deep learning model that combines two techniques to analyze how grains evolve over time and interact with each other: A long short-term memory network models how the material properties would be evaluated while a graph-based convolutional network establishes relationships between the data that could then be used for prediction. Critical to early detection was using the models to examine a grain’s characteristics over time before the abnormality occurred. The team aligned each simulation at the point in time where the grain became abnormal and then worked backward examining its evolving properties. By identifying consistent trends in these properties, they were able to predict which grains would become abnormal. The goal, says researcher Brian Chen, is to identify materials that are highly stable and can maintain their physical properties under a wide range of high-temperature, high-stress conditions. lehigh.edu. A new AI framework suggests promising solid-state electrolyte candidates to build better batteries.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 13 PROCESS TECHNOLOGY NEW PROCESS REFINES METALS FROM WASTE ALLOYS Researchers from the University of Melbourne, Australia, and King Fahd University of Petroleum and Minerals, Saudi Arabia, report a discovery that could transform how metals are extracted and purified from crude metals and waste alloys. The technique is based on electrocapillary principles and enables selective separation of metals from liquid alloys using differences in their surface energy, a new concept in metallurgy. In molten alloys, certain invention of the Ames Process, which was originally developed to produce high-purity uranium for the Manhattan Project. The process remains an effective method for producing high-purity rare earth metals to this day. Now, a team of researchers at the lab’s Critical Materials Innovation Hub developed a safer and scalable method for pro- ducing rare earth metals that employs the Ames Process. The new method, Rare Earth Metals from Alternative Fluoride Salt (REMAFS), uses an alternative fluoride salt in the production of rare earth metals instead of tradi- tional rare earth salts made with hydrofluoric acid (HF). In addition, the method can be integrated earlier in the rare earth supply chain to reduce the number of steps required to convert mined materials to rare earth metals. Research scientist Ikenna Nlebedim explained that by eliminating both the use and generation of HF, the REMAFS method significantly improves safety, environmental impacts, and scalability. “This process uses rare earth fluoride, but instead of traditional rare earth fluoride, it uses sodium rare earth fluoride. The difference is that sodium rare earth fluoride can be prepared without hydrofluoric acid,” says Nlebedim. “It can be prepared at room temperature, and it is very easy to scale, so you can produce large quantities of it.” ameslab.gov. metals migrate to the surface, enriching the interface based on their surface energy levels. In the new process, crude metals and alloys can be dissolved into low- melting-point post- transition metals such as gallium to form liquid alloys that remain fluid at or near room temperature. When liquid alloys are placed in a special solution, they create a boundary layer. By applying a small electric charge to this layer, the surface tension of the alloy is reduced. This causes certain metals, specifically those with lower surface energy such as bismuth, tin, and lead, to move to the surface and separate from the mixture in a defined sequence. The process achieves high-purity metal separation without the need for high temperatures or harmful chemicals. Unlike conventional smelting or chemical extraction, the new method minimizes energy consumption and reduces environmental impact. “The commercial application of our metal expulsion technology is expected to utilize proven renewable energy sources for achieving a net- zero process. This discovery opens the door to sustainable metallurgy,” says lead researcher Mohannad Mayyas. www.kfupm.edu.sa. NONTOXIC METHOD FOR PROCESSING RARE EARTHS Scientists at the DOE’s Ames National Laboratory, Iowa, have been producing rare earth metals for over 75 years. An important aspect of this history is based on Harley Wilhelm’s Researchers at Cornell University, Ithaca, N.Y., developed an inexpensive and potentially scalable approach that uses a commercially available peroxide to bind polyethylene and polypropylene together, creating a more useful, highquality plastic recycling additive. cornell.edu. BRIEF The process of creating a liquid alloy surface slab model. Courtesy of Advanced Functional Materials, 2025, doi.org/10.1002/ adfm.202505583. The REFMAS process uses sodium neodymium fluoride salts and can result in the bonded magnet shown. Courtesy of Ames Lab.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 14 SUSTAINABILITY POLYMER MEMBRANE SEPARATES LITHIUM Researchers at Imperial College London developed a technology to extract lithium from saltwater sources such as salt-lake brines or geothermal brine solutions as an alternative to mining. Conventional lithium extraction from brines takes months and uses significant amounts of water and chemicals, while the new method uses a membrane to separate lithium from salt water by filtering it through tiny pores. A typical problem with this approach is that the pores also let through magnesium and other contaminants, but the team developed a class of special polymers that are highly selective for lithium. This new generation of synthetic polymer membranes is based on materials known as polymers of intrinsic microporosity (PIMs), which contain tiny, hourglass-shaped micropores that provide ordered channels through which small molecules and ions can travel. In the latest study, researchers fine-tuned the micropores to become highly selective for lithium. Used in an electrodialysis device, the lithium ions are pulled through the membrane micropores by an electrical current, while larger magnesium ions are left behind. Tested on simulated salt-lake brines, the PIM membranes are highly selective for lithium and produce highpurity, battery-grade lithium carbonate. Regarding production, the polymers are soluble in common solvents and can be turned into membranes using established industrial techniques. Imperial has filed patent applications for the membranes and a range of different uses, including lithium extraction. www.imperial.ac.uk. CORAL REEFS INSPIRE GREEN BUILDING MATERIALS A research team at the University of Southern California is taking inspiration from coral reefs and their natural ability to create rigid structures by sequestering carbon dioxide. The new mineralpolymer composites demonstrate impressive mechanical strength, fracture toughness, and fireresistant properties. “Unlike traditional carbon capture technologies that focus on storing carbon dioxide or converting it into liquid substances, we found this new electrochemical manufacturing process converts the chemical compound into calcium carbonate minerals in 3D-printed polymer scaffolds,” explains Professor Qiming Wang. The method was directly inspired by how coral creates its aragonite skeletal structures, known as corallites. In nature, coral builds corallites through biomineralization, in which coral sequesters CO2 from the atmosphere during photosynthesis. It then combines the chemical compound with calcium ions from seawater to precipitate calcium minerals around organic templates. The team replicated this process by creating 3D-printed polymer scaffolds that mimic coral’s organic templates. Next, they coated them with a thin conductive layer. These coated structures were then connected to electrochemical circuits as cathodes and immersed in a calcium chloride solution. When CO2 was added to the solution, it underwent hydrolysis to be broken down into bicarbonate ions. These ions reacted with calcium in the solution to form calcium carbonate, which gradually filled the 3D-printed pores. This resulted in a dense mineralpolymer composite. After a rigorous life cycle assessment, researchers found that the manufactured structures have a negative carbon footprint. usc.edu. This salt brine at Lake Magadi, Kenya, could be a future site for lithium extraction. Courtesy of Wikimedia Commons. Researchers mimic the formation of coral reef structures as they develop new construction materials. Courtesy of Wikimedia Commons. Hydnum Steel is building a flat steel plant in Spain to become one of the leading clean steel producers in Europe. Hydnum will supply thyssenkrupp Materials Processing Europe with up to 100,000 tons of decarbonized flat steel per year for an initial seven-year period once the plant opens. hydnumsteel.com. BRIEF
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 15 15 FUSION MATERIALS ARPA-E’s CHADWICK program (Creating Hardened And Durable Fusion First Wall Incorporating Centralized Knowledge) aims to discover novel materials that meet the demanding operating conditions of fusion energy systems through a comprehensive approach, thereby contributing to an abundant energy future. CHADWICK: ACCELERATING THE DISCOVERY OF NEXT-GENERATION FUSION FIRST-WALL MATERIALS Cheng Xu, MITRE Corp., McLean, Virginia Pankaj Trivedi, Booz Allen Hamilton, McLean, Virginia Ahmed Diallo, Advanced Research Projects Agency-Energy Washington, D.C.
ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 16 Fusion power will serve as a primary abundant energy source, emitting no greenhouse gases and providing global energy security. The high energy density released from nuclear fusion reactions suggests megawatts of power can theoretically be generated from just a few grams of deuterium and tritium fuel. For the last six decades, steady progress has been made in pursuit of unlocking that potential, with the aim of achieving scientific gain (Q_sci—the ratio of power output to power input in fusion reactions) greater than 1. Here, Q_sci > 1 is defined as releasing more power from the fusion reaction than the power input needed to initiate the reaction within the plasma[1]. BACKGROUND On December 5, 2022, the National Ignition Facility (NIF) achieved a scientific energy gain (Q_sci) of approximately 1.5, producing 3.15 MJ of fusion energy from 2.05 MJ of laser energy delivered to the target. Subsequently, in 2023, NIF conducted additional experiments that also achieved Q_sci > 1. Notably, on July 30, 2023, an experiment yielded 3.88 MJ of fusion energy, surpassing the December 2022 result. Recent results (April 6, 2025) yielded 8.6 MJ from a 2.05 MJ laser energy on target, translating in Q_sci of 4.2. These repeated successes demonstrate NIF’s consistent ability to achieve net energy gain in fusion reactions. As nuclear and plasma physics continue advancing toward higher scientific gains from fusion reactions, the major challenges shift to engineering solutions that can sustain these highly energetic reactions for commercial viability. One such engineering challenge is the survivability of the plasma-facing and structural materials in a commercial fusion power plant[2]. Traditional materials qualified for use in nuclear environments by ASME BPVC Section II are not expected to last more than a few years in a commercial fusion environment. A new class of materials is needed to meet the specific performance demands of fusion power plants. Commercial fusion power plants will require continuous operation at power densities of 1-2 MW/m2, with firstwall components surviving neutron fluxes of ~1014 n/cm2/s. Current pro- jections suggest demonstration plants may be operational by 2035-2040, requiring qualified materials within the next 5-10 years. This timeline demands accelerated materials development approaches, including soft materials[3], beyond traditional trial- and-error methods. FUSION FIRST-WALL PERFORMANCE CRITERIA The following sub-sections highlight major challenges facing fusion first-wall components including criteria needed to ensure successful operations. Low-Temperature Irradiation Hardening. Most materials, when exposed to neutron irradiation, experience increased hardness, accompanied by a reduction in ductility and toughness. This phenomenon is well understood and experimentally observed in a variety of steels and nickel alloys but is expected to be a problem in any new alloy systems developed for fusion energy. The hardening and embrittlement are the result of surviving vacancies and interstitials created from neutron irradiation migrating to various biased sinks that grow to become obstacles to dislocation motion. Irradiation embrittlement happens quickly and could present itself at very low doses[4]. For steels, the hardening has been observed to saturate at high doses (>20 dpa)[5]. Irradiation hardening and embrittlement of fusion first-wall materials must be well characterized to ensure the structure does not crack or fail during temperature transients. Irradiation Segregation and Phase Stability. In addition to creating point defects, irradiation damage will break existing crystalline bonds in the material and provide a driving force for the material to transform into phases not found under normal conditions. This segregation can lead to microscopic changes in precipitate composition, size, density, and grain size, which will result in macroscopic changes in the mechanical and chemical performance of the material[6]. The fusion first wall will experience large temperature gradients. Plasma-facing surfaces could experience temperatures above 750°C and drop to as low as 350°C at the interface for the breeder blanket[7]. Materials that experience significant phase change or segregation in those temperature ranges under irradiation may introduce uncertainty in material performance that is unaccounted for in the design. Therefore, any new material for the fusion first wall should characterize any phase instabilities across the relevant temperature and irradiation ranges. At a minimum, accelerated testing is needed to validate the material’s performance at the end of life. Irradiation Swelling and Creep. For high-temperature reactors exposed to a high neutron dose, irradiation swelling, and creep will be the life- limiting factors for the components. Ideally, the first-wall material should not experience steady-state swelling that puts additional stress on structural components. Swelling is the volumetric change induced by irradiation, driven by void and bubble formation in the material. It is independent of the stress state and typically shows a linear dose dependence after an incubation period[8,9]. The incubation period is highly dependent on the microstructure and temperature. New materials can be designed with high neutral sink density to enhance point defect recombination, mitigate void growth, and bubble coalescence. In contrast, creep is the high-temperature plastic deformation below the yield stress driven by dislocation loops and networks (and not void or bubble formation). Under irradiation, the accelerated formation of defects will make materials experience creep at much lower temperatures than in the unirradiated condition[10]. At tempera- tures relevant to fusion systems, combined thermal and irradiation creep can cause excessive plasticity in the first wall, becoming a lifetime-limiting failure mechanism for the component. High-Temperature Helium Embrittlement. One major difference between fusion and fission environments is the far higher helium concentration
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