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AMP 06 September 2025

11 27 53 P. 17 DOE Demonstration Facility Empowers Manufacturing ASM Reference Publications & Digital Databases Catalog HTPro Newsletter Included in This Issue SHEET METAL FORMING WITH ROBOTICS AND AI ADVANCED MANUFACTURING SEPTEMBER 2025 | VOL 183 | NO 6

11 27 53 P. 17 DOE Demonstration Facility Empowers Manufacturing ASM Reference Publications & Digital Databases Catalog HTPro Newsletter Included in This Issue SHEET METAL FORMING WITH ROBOTICS AND AI ADVANCED MANUFACTURING SEPTEMBER 2025 | VOL 183 | NO 6

140.116 Cerium 58 2 8 18 19 9 2 Ce 140.90765 Praseodymium 59 2 8 18 21 8 2 Pr 144.242 Neodymium 60 2 8 18 22 8 2 Nd (145) Promethium 61 2 8 18 23 8 2 Pm 150.36 Samarium 62 2 8 18 24 8 2 Sm 151.964 Europium 63 2 8 18 25 8 2 Eu 157.25 Gadolinium 64 2 8 18 25 9 2 Gd 158.92535 Terbium 65 2 8 18 27 8 2 Tb 162.5 Dysprosium 66 2 8 18 28 8 2 Dy 164.93032 Holmium 67 2 8 18 29 8 2 Ho 167.259 Erbium 68 2 8 18 30 8 2 Er 168.93421 Thulium 69 2 8 18 31 8 2 Tm 173.054 Ytterbium 70 2 8 18 32 8 2 Yb 174.9668 Lutetium 71 2 8 18 32 9 2 Lu 232.03806 Thorium 90 2 8 18 32 18 10 2 Th 231.03588 Protactinium 91 2 8 18 32 20 9 2 Pa 238.02891 Uranium 92 2 8 18 32 21 9 2 U (237) Neptunium 93 2 8 18 32 22 9 2 Np (244) Plutonium 94 2 8 18 32 24 8 2 Pu (243) Americium 95 2 8 18 32 25 8 2 Am (247) Curium 96 2 8 18 32 25 9 2 Cm (247) Berkelium 97 2 8 18 32 27 8 2 Bk (251) Californium 98 2 8 18 32 28 8 2 Cf (252) Einsteinium 99 2 8 18 32 29 8 2 Es (257) Fermium 100 2 8 18 32 30 8 2 Fm (258) Mendelevium 101 2 8 18 32 31 8 2 Md (259) Nobelium 102 2 8 18 32 32 8 2 No (262) Lawrencium 103 2 8 18 32 32 8 3 Lr 1.00794 Hydrogen 1 1 H 6.941 Lithium 3 2 1 Li 9.012182 Beryllium 4 2 2 Be 22.98976928 Sodium 11 2 8 1 Na 24.305 Magnesium 12 2 8 2 Mg 39.0983 Potassium 19 2 8 8 1 K 40.078 Calcium 20 2 8 8 2 Ca 85.4678 Rubidium 37 2 8 18 8 1 Rb 87.62 Strontium 38 2 8 18 8 2 Sr 132.9054 Cesium 55 2 8 18 18 8 1 Cs 137.327 Barium 56 2 8 18 18 8 2 Ba (223) Francium 87 2 8 18 32 18 8 1 Fr (226) Radium 88 2 8 18 32 18 8 2 Ra 44.955912 Scandium 21 2 8 9 2 Sc 47.867 Titanium 22 2 8 10 2 Ti 50.9415 Vanadium 23 2 8 11 2 V 51.9961 Chromium 24 2 8 13 1 Cr 54.938045 Manganese 25 2 8 13 2 Mn 55.845 Iron 26 2 8 14 2 Fe 58.933195 Cobalt 27 2 8 15 2 Co 58.6934 Nickel 28 2 8 16 2 Ni 63.546 Copper 29 2 8 18 1 Cu 65.38 Zinc 30 2 8 18 2 Zn 88.90585 Yttrium 39 2 8 18 9 2 Y 91.224 Zirconium 40 2 8 18 10 2 Zr 92.90638 Niobium 41 2 8 18 12 1 Nb 95.96 Molybdenum 42 2 8 18 13 1 Mo (98.0) Technetium 43 2 8 18 13 2 Tc 101.07 Ruthenium 44 2 8 18 15 1 Ru 102.9055 Rhodium 45 2 8 18 16 1 Rh 106.42 Palladium 46 2 8 18 18 Pd 107.8682 Silver 47 2 8 18 18 1 Ag 112.411 Cadmium 48 2 8 18 18 2 Cd 138.90547 Lanthanum 57 2 8 18 18 9 2 La 178.48 Hafnium 72 2 8 18 32 10 2 Hf 180.9488 Tantalum 73 2 8 18 32 11 2 Ta 183.84 Tungsten 74 2 8 18 32 12 2 W 186.207 Rhenium 75 2 8 18 32 13 2 Re 190.23 Osmium 76 2 8 18 32 14 2 Os 192.217 Iridium 77 2 8 18 32 15 2 Ir 195.084 Platinum 78 2 8 18 32 17 1 Pt 196.966569 Gold 79 2 8 18 32 18 1 Au 200.59 Mercury 80 2 8 18 32 18 2 Hg (227) Actinium 89 2 8 18 32 18 9 2 Ac (267) Rutherfordium 104 2 8 18 32 32 10 2 Rf (268) Dubnium 105 2 8 18 32 32 11 2 Db (271) Seaborgium 106 2 8 18 32 32 12 2 Sg (272) Bohrium 107 2 8 18 32 32 13 2 Bh (270) Hassium 108 2 8 18 32 32 14 2 Hs (276) Meitnerium 109 2 8 18 32 32 15 2 Mt (281) Darmstadtium 110 2 8 18 32 32 17 1 Ds (280) Roentgenium 111 2 8 18 32 32 18 1 Rg (285) Copernicium 112 2 8 18 32 32 18 2 Cn 4.002602 Helium 2 2 He 10.811 Boron 5 2 3 B 12.0107 Carbon 6 2 4 C 14.0067 Nitrogen 7 2 5 N 15.9994 Oxygen 8 2 6 O 18.9984032 Fluorine 9 2 7 F 20.1797 Neon 10 2 8 Ne 26.9815386 Aluminum 13 2 8 3 Al 28.0855 Silicon 14 2 8 4 Si 30.973762 Phosphorus 15 2 8 5 P 32.065 Sulfur 16 2 8 6 S 35.453 Chlorine 17 2 8 7 Cl 39.948 Argon 18 2 8 8 Ar 69.723 Gallium 31 2 8 18 3 Ga 72.64 Germanium 32 2 8 18 4 Ge 74.9216 Arsenic 33 2 8 18 5 As 78.96 Selenium 34 2 8 18 6 Se 79.904 Bromine 35 2 8 18 7 Br 83.798 Krypton 36 2 8 18 8 Kr 114.818 Indium 49 2 8 18 18 3 In 118.71 Tin 50 2 8 18 18 4 Sn 121.76 Antimony 51 2 8 18 18 5 Sb 127.6 Tellurium 52 2 8 18 18 6 Te 126.90447 Iodine 53 2 8 18 18 7 I 131.293 Xenon 54 2 8 18 18 8 Xe 204.3833 Thallium 81 2 8 18 32 18 3 Tl 207.2 Lead 82 2 8 18 32 18 4 Pb 208.9804 Bismuth 83 2 8 18 32 18 5 Bi (209) Polonium 84 2 8 18 32 18 6 Po (210) Astatine 85 2 8 18 32 18 7 At (222) Radon 86 2 8 18 32 18 8 Rn (284) Nihonium 113 2 8 18 32 32 18 3 (289) Flerovium 114 2 8 18 32 32 18 4 Fl (288) Moscovium 115 2 8 18 32 32 18 5 (293) Livermorium 116 2 8 18 32 32 18 6 Lv (294) Tennessine 117 2 8 18 32 32 18 7 (294) Oganesson 118 2 8 18 32 32 18 8 Nh Mc Ts Og © 1997-2025. American Elements is a U.S. Registered Trademark www.americanelements.com American Elements Opens a World of Possibilities...Now Invent! TM Now Invent. THE NEXT GENERATION OF MATERIALS SCIENCE MANUFACTURERS Bulk & lab scale manufacturers of over 35,000 certified high purity compounds, chemicals, metals, and nanoparticles, including a wide range of materials with applications in industries such as aerospace, automotive, military, pharmaceutical, and electronics, all engineered to meet the most rigorous quality standards.

44 IMAT 2025 SHOW PREVIEW This year’s International Materials, Applications, and Technologies (IMAT) Conference and Exhibition, held in Detroit on Oct. 20-23, features an Executive Leadership Forum. THE MANUFACTURING DEMONSTRATION FACILITY: EMPOWERING INNOVATION AT THE SPEED OF INDUSTRY Craig Blue, Leo Christodoulou, Alan Liby, William Peter, Ryan Dehoff, Yarom Polsky, Vincent Paquit, Vlastimil Kunc, and Brian Post The U.S. Department of Energy’s Manufacturing Demonstration Facility engages industry in a unique way to accelerate adoption of new advanced manufacturing technologies and strengthen entire supply chains. 11 ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 2 Close up of a RoboCraftsman sheet metal forming cell. Courtesy of Machina Labs Inc. On the Cover: 75 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. ASM REFERENCE PUBLICATIONS & DIGITAL DATABASES CATALOG Our vast, authoritative reference library offers the most comprehensive and upto-date materials information. 27

4 Editorial 5 Machine Learning 9 Feedback 6 Metals/Polymers/Ceramics 8 Testing/Characterization 10 Emerging Technology 83 Editorial Preview 83 Special Advertising Section 83 Advertisers Index 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-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 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. 6, SEPTEMBER 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. Canada Post Publications Mail Agreement No. 40732105. Return undeliverable Canadian addresses to: 13487 S Preston Hwy, Lebanon Junction, KY 40150. Printed by Kodi Collective, Lebanon Junction, Ky. 17 SHAPING THE FUTURE: INCREMENTAL SHEET METAL FORMING WITH ROBOTICS AND AI Punnathat Bordeenithikasem and Babak Raeisinia New capabilities in sensors and artificial intelligence combine to create a factory of the future that integrates multiple operations in one robotic cell. 22 HIGH-TEMPERATURE PERFORMANCE MEETS PRINTABILITY: A BREAKTHROUGH IN AM SUPERALLOYS Alex Bridges, John Shingledecker, Zara Hussain, and David Crudden ABD-900AM is a newly developed nickel-base superalloy tailored for powder bed fusion additive manufacturing and optimized for high-temperature structural applications. 49 ASM MATERIALS EDUCATION FOUNDATION IMPACT REPORT 51 INTERNATIONAL CONFERENCE ON RESIDUAL STRESS (ICRS 12) SHOW PREVIEW 84 ASM INTERNATIONAL STRATEGIC PLAN 2026-2030 FEATURES SEPTEMBER 2025 | VOL 183 | NO 6 ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 3 17 49 53 22 53 HTPro The official newsletter of the ASM Heat Treating Society. This supplement focuses on heat treating technology, processes, materials, and equipment, and features a preview of the 33rd Heat Treating Society Conference and Exhibition, held in Detroit from Oct. 21-23.

4 ADVANCED MATERIALS & PROCESSES | SEPTEMBER 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 Carl Boehlert, Michigan State University Punnathat Bordeenithikasem, Machina Labs Daniel Grice, Materials Evaluation & Engineering Surojit Gupta, University of North Dakota 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 Ryan Paul, GrafTech International Satyam Sahay, John Deere Technology Center India Abhijit Sengupta, USA Federal Government Kumar Sridharan, University of Wisconsin Vasisht Venkatesh, Howmet Aerospace 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 Victoria Anson, Emily Ghosh, Wyeth Haddock 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. INTELLIGENT MANUFACTURING The factory of the future is here. Smart factories are popping up everywhere and changing the materials and manufacturing landscape. The advent of Industry 4.0, artificial intelligence (AI), and robotics has created fertile ground for the growth of numerous advanced manufacturing technologies. And it is poised for more expansion. The smart factory market, which boasted a value of $103.33 billion in 2024, is projected to generate $211.04 billion by 2031, globally—a CAGR of 10.30%—according to Verified Market Research. A large portion of that gain will be generated by the materials sectors in industries from automotive and aerospace to medical devices and semiconductors. In this issue, we put a spotlight on several early adopters of these cutting-edge, intelligence-based technologies. A premier example comes from Oak Ridge National Laboratory. Its Manufacturing Demonstration Facility (MDF) in Tennessee works directly with industry to develop solutions to manufacturing challenges, especially those with energy and defense applications. Founded in 2012 by the U.S. Department of Energy, MDF shares resources and technical expertise with industrial partners to help introduce advanced manufacturing options. In their article, authors from MDF present several case studies highlighting 3D printing of large parts, some used in extreme conditions, as well as the development of AI software for real-time monitoring and quality control during printing. A recent webinar hosted by SME on “Preparing Manufacturing for the AI Revolution” highlighted the critical role that such AI software tools play in smart factories. The speakers pointed out that most companies have a treasure trove of unstructured data in the form of legacy 2D drawings, sensor readings, meeting notes, machine logs, customer feedback, and “tribal knowledge” from tenured employees. AI data platforms like CADDi, which was featured in the webinar, can digitize that information allowing companies to make better data-driven decisions. Our cover story in this issue provides an example of a data-driven production system at a company that invented their own version of digital manufacturing. Machina Labs in California developed the software-based RoboCraftsman, which captures all the intelligence generated during their sheet metal forming process including digital records, data, and quality assessments. Their factory of the future utilizes two robots in one cell to complete multiple manufacturing steps from sheet metal forming and trimming through the heat treating process. The robot also creates a laser scan of the part, which is compared to the original CAD model. The system then can inform the robot if a stress relieving step is recommended. That’s a smart setup. Yes, the future is here. But more high-tech manufacturing developments that will impact the materials industries are yet to come. MDF, CADDi, and Machina Labs offer just a few exciting glimpses into the wide possibilities that lie ahead. Intelligence-based technologies will continue their growth path. And smart companies will embrace them. joanne.miller@asminternational.org RoboCra sman. Courtesy of Machina Labs.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 5 MACHINE LEARNING | AI Arizona State University, Tempe, received a grant from the National Science Foundation for a project that will use AI to make metal 3D printing faster and more reliable by predicting how the material will form during manufacturing. The team will first 3D print a five-axis, metal naval propeller using 316L stainless steel. asu.edu. BRIEF AI HELPS REMOVE RADIOACTIVE IODINE Researchers at the Korea Advanced Institute of Science and Technology (KAIST) used artificial intelligence to discover a new material that can remove radioactive iodine for nuclear environmental remediation. This form of iodine primarily exists in aqueous environments in the form of iodate, yet existing silver-based adsorbents have weak chemical adsorption strength for removing it. To find a better alternative, the scientists used a machine learning- based experimental strategy to identify optimal iodate adsorbents among layered double hydroxides (LDHs), which contain various metal elements. The multi-metal LDH developed in this study—Cu₃(CrFeAl)— showed exceptional adsorption perfor- mance, eliminating over 90% of the iodate. This outcome was achieved by exploring a vast compositional space using AI-driven active learning to help narrow down the most promising options. The team focused on the fact that LDHs can incorporate a wide range of metal compositions and possess structures favorable for anion adsorption. However, due to the overwhelming number of possible metal combinations in multi-metal LDHs, identifying the optimal composition through traditional experimental methods has been nearly impossible. Starting with data from 24 binary and 96 ternary LDH compositions, the researchers expanded their search to include quaternary and quinary candidates. As a result, they were able to discover the best material for iodate removal by testing only 16% of the total candidate materials. The team will now pursue commercialization through industry-academia collaborations for applications such as iodine-adsorbing powders and contaminated water treatment filters. www.kaist.ac.kr. AI-BUILT MATERIALS BEAT THE HEAT An international team of scientists from The University of Texas at Austin, Shanghai Jiao Tong University, National University of Middle building is wrapped with meta-emitter materials, achieving lower temperatures than those using conventional paint. Courtesy of UT Austin. Singapore, and Umea University in Sweden developed a machine learning- based approach to create complex 3D thermal meta-emitters. Using this system, researchers came up with more than 1500 different materials that can selectively emit heat at various levels and in different manners, making them well suited for achieving precise cooling and heating. To test their platform, the team fabricated four materials to verify the designs. Next, they applied one of the materials to a model house and compared it to commercial paints regarding the cooling effect. After a four-hour midday exposure to direct sunlight, the meta-emitter- coated building roof came in between 5° and 20°C cooler on average than the ones with white and gray paints, respectively. The researchers estimated that this level of cooling could save the equivalent of 15,800 kW per year in an apartment building in a hot climate. Beyond energy efficiency in homes and offices, thermal meta-emitters could be used to manage a spacecraft’s temperature by reflecting solar radiation and emitting heat efficiently. Other potential cooling applications include textiles, fabrics, and car wraps. utexas.edu. AI helps explore materials for radioactive iodine removal. Courtesy of J. Hazard. Mater, 2025, doi.org/10.1016/j.jhazmat.2025.138735.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 6 METALS | POLYMERS | CERAMICS EXPLORING PLUTONIUM’S DELTA PHASE Scientists at Lawrence Livermore National Laboratory (LLNL) set a goal to predict the behavior of plutonium in all its phases. Solving the mystery behind the delta-plutonium phase and its abnormal behavior at high temperatures—shrinking instead of expanding—is an important step. In a new study, the researchers demonstrated a model that can reproduce and explain delta-plutonium’s thermal behavior and unusual properties. The model calculates the material’s free energy. “Free energy fundamentally dictates the state of a material, so it is foundational for understanding it,” says scientist Per Söderlind. “An immense amount of effort at LLNL is dedicated to predicting the behavior of plutonium. The confidence in these STUDYING TWINNING IN MAGNESIUM Researchers at the University of Michigan used x-rays to capture the first 3D views of the formation of microscopic structures that can help absorb stress without breaking in a magnesium alloy. The results will improve understanding of the alloy’s complex reaction to mechanical stress. Because magnesium alloys weigh 30% less than aluminum, some car manufacturers have started using them for non-load-bearing parts. If their behavior under stress could be optimized, this could lead to wider use. Deformation twinning in magnesium allows it to stretch in more directions without breaking, creating ductility, but at a certain point too much twinning can create a concentration of defects that causes cracks to form. “We were surprised to find all three twins formed in triple junctions, where three crystals touch, and defects always formed where the twin touches another crystal. This consistency can help us understand twin microstructures to optimize the material lifetime,” says researcher Ashley Bucsek. Before the experiment, the team used a CT scanner to map how crystal grains were oriented within a magnesium alloy sample. Then they selected a specific grain of interest with a good orientation for following the twinning process. Next, they used the European Synchrotron Radiation Facility in France to image the grain of interest at an ultra-high resolution. They then applied three typical car part loads that would stretch the alloy—0.6, 30, and 45 MPa—imaging the sample after each load. “Real-space x-ray images gave us a front-row seat to observe twinning as stress was applied. We literally watched the twin appear and evolve with our own eyes for the first time,” says doctoral student Sangwon Lee. The next step is to capture changes in real time. umich.edu. Sangwon Lee prepares a magnesium alloy sample for darkfield x-ray microscopy to understand deformation twinning. Courtesy of Ashley Bucsek/Michigan Engineering. Delta-plutonium has been found to have unusual thermal properties. Courtesy of Pixabay/CC0 Public Domain. Boston Metal raised $51 million in new capital from existing investors. Funds will support deployment of the company’s critical metals plant in Brazil, slated to come online in mid-2026, and also finance continued development of its green steel approach. bostonmetal.com. BRIEF

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 7 predictions depends on a deep theoretical understanding of its electronic structure and free energy.” Plutonium’s electronic structure is among the most complex of all elemental metals because its electrons are easily influenced by relativity, magnetism, and crystal structure. The new free-energy model accounts for magnetic fluctuation effects for the first time. “Our model is unique and novel because it includes magnetic states that are allowed to fluctuate and depend on temperature,” says Söderlind. Acknowledging those magnetic states in the theory allows it to match the odd experimental observations of contraction at high temperatures. As a next step, the team plans to address the impact of microstructures, defects, and imperfections present in the physical material. They believe this methodology could be extended to other materials where dynamic magnetism plays a role, such as iron and its alloys, which are important in geophysics. llnl.gov. BALL MILL TURNS ALGAE INTO PLASTIC A team of chemists at Virigina Tech is working on a new approach to creating plastics made of whole-cell algae and common chemicals. They say the biohybrid plastics are strong, highly adaptable, and fully recyclable. Josh Worch, assistant professor, and his team invented a strategy to enhance the recyclability of plastic materials without compromising performance. They combined unprocessed algae with common chemical components in a ball mill to make the tough bio- hybrid plastics. The key to creating the material is the team’s mechanochemical synthesis strategy, which came from a moment of “serendipitous science,” according to Worch. When the team put the algae and chemical components into the mill, they found that the ball mill technique shortened plastic synthesis from two days to one-and-a-half hours and allowed the biomass to integrate with the synthetic parts of the material, making it a hybrid plastic. Researchers used spirulina as the biomass because it is inexpensive and widely available. They also considered other types of biomass such as agricultural waste from crop processing. “This is one of the most exciting parts of our ball milling approach, since we believe the technique is generalizable to many different materials,” says Worch. He added that the new hybrid plastic is robust, adaptable, and can easily be remolded into new shapes or completely broken down into its component parts for reuse. vt.edu. WORLD-LEADING ELECTRON BEAM TECHNOLOGY pro-beam.com PRECISE. QUICK. HIGH QUALITY. Welding with the electron beam offers these and many other advantages - find out more about it here: From left: Associate Professor Josh Worch watches graduate student Meng Jiang and former undergraduate student Emily Bird prepare the ball mill for use. Courtesy of Spencer Coppage/Virginia Tech.

8 ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 team discovered that liquid carbon exhibits far more complex crystallization behavior than previously thought. Most surprisingly, they found that graphite can form spontaneously even when diamond should be the stable phase, possibly derailing diamond formation. In the study, the team prepared models at various pressures from 5 to 30 GPa as the molten carbon cooled from 5000 to 3500K. While the team expected to get glassy carbon from the rapid quench of the liquid, they noticed spontaneous crystallization. At high pressures, the liquid carbon crystallized into diamond, and at lower pressures, it crystallized into graphite. Researchers found that graphite acts as a steppingstone in diamond formation because its structure more closely resembles liquid carbon’s density and bonding patterns. Through the simulations, the team also revealed the molecular structures TESTING | CHARACTERIZATION ULTRASOUND SPOTS ALUMINUM INCLUSIONS Researchers at Fraunhofer IZFP, Germany, developed a new measuring system for aluminum foundry cus- tomers to detect contamination in molten metal. “The purity of the molten metal, whose temperature ranges from 600-800°C, is hugely important to the final product. For example, any ceramic particles that may be present in the melt don’t liquefy until they get to a temperature of 2000° or more, and they remain in the finished component as inclusions if they aren’t deliberately removed. This can lead to cracks and holes, and thus in the worst case to component failure,” says scientist Thomas Waschkies. The team decided to develop a mobile, ultrasound-based measure- ment system for molten aluminum to address these challenges. The AloX project was launched, with the name derived from aluminum melt and oxide inclusions. “It’s a lot like a car parking sensor in that the system, immersed in the molten metal, transmits signals that then bounce off a reflector. If any particles—meaning contaminants—float by, there is a disruptive signal,” says researcher Andrea Mross. Those signals make it possible to react on the production floor to assure quality. Working closely with industry, the team developed an initial prototype. The measuring trolley features a special unit equipped with ultrasonic waveguides and built-in cooling, along with a dedicated software program featuring a patented analysis algorithm for de- tecting inclusions. www.fraunhofer.de. MOLECULAR SIMULATIONS EXPLORE CARBON FORMATION Scientists at the University of California, Davis and George Washington University are investigating how molten carbon crystallizes into either graphite or diamond at temperatures and pressures similar to the Earth’s interior. Using machine learning- powered molecular simulations, the Testbed 80. Courtesy of Rolls-Royce. Simulations show the nucleation pathways of graphite (top row) and diamond (bottom row) from direct molecular dynamics simulations at pressures of 15 and 15.5 GPa and a temperature of 3650K. Courtesy of Davide Donadio/UC Davis. Thomas Waschkies and Andrea Mross received the Joseph von Fraunhofer Prize for 2025 for developing the AloX mobile ultrasoundbased measuring system. Courtesy of Piotr Banczerowski/Fraunhofer. Lawrence Livermore National Laboratory researchers and colleagues measured the structure of liquid carbon for the first time. Experiments were conducted with the DiPOLE 100-X high-energy laser at the European X-ray Free-Electron Laser (XFEL) facility. DiPOLE was used to shock compress and liquify a glassy carbon sample while XFEL measured its structure. llnl.gov. Wabtec Corp., Pittsburgh, acquired Evident’s inspection technologies division, Waltham, Mass., formerly part of the scientific solutions division of Olympus Corp. The purchase expands Wabtec’s digital intelligence business with products for the rail, mining, and industrial sectors. wabteccorp.com. BRIEFS

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 9 of liquid carbon as it crystallized into graphite and then, separately, as liquid carbon crystallized into diamond. Graphite crystallized in column-like patterns that eventually elongated outwards. Diamond crystallized through compact crystallites. In materials manufacturing, understanding these pathways could improve industrial diamond synthesis, especially for applications like quantum computing where precise control over crystal structure is essential. ucdavis.edu. CHARACTERIZING TIN CATALYSTS Researchers at Tohoku University, Japan, are using machine learning to characterize tin (Sn) catalyst activity. The highly accurate simulations could help scientists quickly and simply design high-performance complex catalysts. While Sn’s utility as a catalyst is well known, its underlying structureperformance relationship is poorly understood, limiting the ability to maximize its potential. “The reason these catalysts are so important is that they can convert harmful carbon dioxide into carbon-based fuels using renewable electricity, offering a sustainable solution to energy shortages and climate change,” says scientist Hao Li. To closely examine Sn catalysts, the team used machine learning to run large-scale molecular dynamics simulations, capturing the reconstructed configurations of SnO2/SnS2. This approach used data from over 1000 experimental literature sources to identify various Sn-based catalysts. The catalysts identified by the model were run in simulations that monitored their activity at different pH levels at the reversible hydrogen electrode scale. The researchers then examined the CO2 reduction reaction to see how each catalyst performed under different conditions. The new results provide unique insight into the behavior of these catalysts. www.tohoku.ac.jp. Molecular dynamics simulations at the nanosecond scale and mesoscopic size for (a) SnO2-x and (b) SnS2-x. Insets show the possible structures with the lowest energy surface screened out by large-scale sampling. Light gray, red, and yellow spheres represent Sn, O, and S, respectively. Courtesy of Y. Wang, et al. (a) (b) AM&P WINS TECHNICAL ARTICLE AWARD Advanced Materials & Processes (AM&P) magazine received some exciting feedback from the organizers of the 2025 Tabbie Awards conducted by Trade Association Business Publications International (TABPI). AM&P won an Honorable Mention for Technical Articles! The winning article, “Cymbal Making: The Art of Bronze Metalworking, Part I,” appeared in AM&P May/June 2024. Kudos to the author, Joseph Paul Mitchell, and our editorial team. FEEDBACK We welcome all comments and suggestions. Send letters to joanne.miller@asminternational.org. Revisit the winning article here: https://static.asminternational.org/ amp/202405/33/. This is the fourth Tabbie recognition AM&P magazine has received since 2019.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 10 EMERGING TECHNOLOGY BUILDING LIVING MATERIAL FROM FUNGI Researchers at Empa’s Cellulose and Wood Materials laboratory, Switzer- land, developed a bio-based material that is biodegradable, tear-resistant, and has versatile functional properties. The new material requires minimal processing and does not use chemicals. For its base, the team used the mycelium of the split-gill mushroom. Typically, mycelial fibers (hyphae) are cleaned and chemically processed if needed. The Empa scientists chose a different approach, using whole mycelium. As it grows, the fungus not only forms hyphae, but also an extracellular matrix of fiber-like macromolecules, proteins, and other biological sub- stances. The team chose a strain of split-gill mushroom that produces high levels of two macromolecules, the long-chain polysaccharide schizophyllan and the soap-like protein hydrophobin. Hydrophobins collect at interfaces between polar and apolar liquids, for example water and oil. Schizophyllan is a nanofiber, less than a nanometer thick but more than a thousand times as long. Together, these biomolecules give the living mycelium properties that make it suitable for a wide range of applications. The researchers demonstrated two possible applications for the living material, an emulsion and a plastic-like film. One challenge with emulsions is to stabilize the mixtures so they do not separate. A benefit of the schizophyllan fibers and the hydrophobins is that they act as emulsifiers, and the fungus keeps releasing more of these molecules. Further, the fungal filaments and their extracellular molecules are nontoxic, biologically compatible, and edible. The living fungal network is also suitable for classic materials applications. In a second experiment, the team manufactured the mycelium into thin films. Other promising applications include biodegradable moisture sensors, fungal batteries, and paper batteries. www.empa.ch. ORIGAMI SUPPORTS NEW CLASS OF MATERIALS Georgia Tech scientists are part of an international team using origami as the foundation for next-generation materials that can both act as a solid and predictably deform. They say their research could lead to innovations in everything from heart stents to airplane wings. The team includes colleagues from Princeton University, University of Michigan, and University of Trento. The challenge is using physics to find a way to predictably model which creases to use and when, in order to achieve the best results. When considering origami-inspired materials, physicists start with a flat sheet that is carefully creased to create a specific 3D shape, with the folds determining how the material behaves. The method is limited because only parallelogram-based origami folding, which uses shapes like squares and rectangles, had previously been modeled and only allowed limited types of deformation. “From our models and physical tests, we found that trapezoid faces have an entirely different class of responses,” says researcher James McInerney. The new designs exhibit the ability to change their shape in two distinct ways—“breathing” by expanding and contracting evenly, and “shearing” by deforming in a twisting motion. “We learned that we can use trapezoid faces in origami to constrain the system from bending in certain directions, which provides different functionality than parallelogram faces,” adds McInerney. gatech.edu. University of Tokyo scientists developed a digital laboratory to autonomously synthesize thin film samples and measure their material properties. The system demonstrates advanced automatic and autonomous materials synthesis for data and robotdriven materials science. www.u-tokyo.ac.jp. BRIEF This thin mycelial film is almost transparent, has good tensile strength, and could be used as a living bioplastic. Courtesy of Empa. Researchers model how various origami structures made from trapezoidal subunits (i) respond to stresses like compression (ii) and stretching (iii). Courtesy of J.P. McInerney et al., Nat. Commun., 2025, doi.org/10.1038/ s41467-025-57089-x.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 1 1 The U.S. Department of Energy’s Manufacturing Demonstration Facility engages industry in a unique way to accelerate adoption of new advanced manufacturing technologies and strengthen entire supply chains. THE MANUFACTURING DEMONSTRATION FACILITY: EMPOWERING INNOVATION AT THE SPEED OF INDUSTRY Craig Blue, FASM,* Leo Christodoulou, Alan Liby, William Peter,* Ryan Deho , Yarom Polsky, Vincent Paquit, Vlastimil Kunc, and Brian Post Oak Ridge National Laboratory, Tennessee *Member of ASM International ADVANCED MANUFACTURING 1 1

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 12 Industry’s technical and economic needs are constantly evolving. At the same time, implementing innovative ideas can be challenging for industry, amid months- and years-long lead times inherent in global supply chains. The Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory helps U.S. industry rapidly develop and deploy advanced manu- facturing technologies and materials that meet today’s needs and shape what comes next. Through close collab- oration, MDF and industry partners work to bolster domestic supply chains and forge a more efficient, innovative future for American manufacturing. This article introduces MDF and provides an inside look at how it engages with industry to solve pressing manufacturing challenges, particularly those that stifle advancement in energy and defense applications. ADVANCING SCIENTIFIC AND ECONOMIC OPPORTUNITIES The Department of Energy (DOE) established MDF in 2012 to provide industry with direct access to shared resources and diverse technical expertise to speed the adoption of advanced manufacturing. MDF is an “idea factory” and an example of place-based innovation. Similar to Lockheed Martin’s Skunk Works or Boeing’s Phantom Works divisions, MDF brings together a cross-section of scientists, engineers, and industry representatives, along with advanced manufacturing tools to creatively solve industry’s biggest manufacturing challenges. MDF is tasked with developing advanced manufacturing solutions that strengthen U.S. supply chains, increase American manu- facturing competitiveness, and develop the workforce to meet industry needs and national goals. With support from the DOE Office of Energy Efficiency and Renewable Energy’s Advanced Materials and Manufacturing Technologies Office, MDF pursues its mission through six key actions: • Engaging industry on a continuous basis • Leveraging national laboratory capabilities • Facilitating collaboration and co-location • Providing a clear path for technology transfer • Publicly demonstrating new technologies • Cultivating a network around advanced manufacturing In collaboration with industry, academic, and government partners (including not only DOE but also Department of Defense offices), MDF has pioneered a range of next-generation manufacturing technologies including: • Large-scale polymer printing • Laser, electron beam, and binder jetting powder bed printing • Large-scale metal printing, such as wire arc additive manufacturing (WAAM) and laser-based wire deposition • Convergent manufacturing platforms utilizing both additive and subtractive capabilities • High-performance composites and alloys • Digital twins, robotic controls, and 3D printing software MDF’s 110,000 ft2 facility in Knoxville, Tennessee, currently houses more than 230 pieces of equipment and 250 staff. Researchers have used these systems to successfully fabricate parts of diverse shapes and sizes, from a 1.3-lb robotic hand to a 5000-lb compression molding tool. Staff at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory work to solve industry’s modern manufacturing challenges. Courtesy of ORNL, U.S. Dept. of Energy. MDF at ORNL develops platform technologies for a range of research and application areas to increase U.S. competitiveness. Courtesy of ORNL, U.S. Dept. of Energy. Over 40,000 people have visited and engaged with the MDF at ORNL, resulting in more than $5.5 billion in economic impact. Courtesy of Carlos Jones/ORNL, U.S. Dept. of Energy.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 13 UNDERSTANDING THE MDF PARTNERSHIP MODEL MDF uses a public-private partnership model and works at the pace of industry to accelerate the journey from concept to commercialization. In this model, MDF acts as a two-way portal: continuously taking in industry feedback on trends and challenges, while strategically channeling national laboratory expertise and resources toward solutions for real-world needs. MDF’s core program focuses on early-stage research and development, pushing concepts from low to medium technology readiness levels. This approach might involve designing early iterations of a new manufacturing process or pursuing fundamental discoveries about material properties. MDF researchers tap ORNL expertise across a range of disciplines, including material synthesis, metrology and characterization, process technology, modeling, automation, and machine learning. They also leverage DOE Office of Science user facilities at ORNL, such as the Spallation Neutron Source and the Oak Ridge Leadership Com- puting Facility. MDF engages industry partners to further improve, scale, and deploy promising technologies. Through the Technical Collaboration Program, researchers from MDF and a partner company work as a team on a shortterm, fast-paced project. Each project is designed to benefit both the partner company and American industry more broadly. The research team leverages both partners’ core expertise as well as shared project costs. Some partner companies send employees to work at MDF for the duration of a project. Since 2012, MDF has executed more than 280 collaborative projects with industry. Partners represent the entire manufacturing supply chain, from materials and parts suppliers to original equipment manufacturers to end users. They range from Fortune 100 companies to entrepreneurs. In fact, more than 20 start-ups have launched their companies based on manufac- turing technologies developed at ORNL. To incentivize innovation, industry partners retain rights to intellectual property they develop during these projects. They can also exclusively license intellectual property that ORNL develops during the collaboration. More than 400 of ORNL’s granted patents and applications as well as 78 licensed technologies and counting have originated at MDF. CREATING A VIBRANT NETWORK AND ECONOMY MDF’s influence extends beyond individual collaborations to a nation- wide advanced manufacturing consortium. MDF cultivates its network to bring together industry, academia, and government to address large-scale challenges, like bolstering existing supply chains and building new ones around novel technologies. Within this network, companies have access to more—and more convenient—pathways through which to network, collaborate, and help train the next-generation workforce. MDF leaders are particularly focused on bringing small and medium enterprises into the network to help them succeed more rapidly, in terms of both technical progress and economic growth. MDF is a physical hub for the consortium. The Knoxville facility is a day’s drive from 65% of the U.S. population and roughly two-thirds of its manufacturing base. Each year, the facility receives more than 5000 visitors representing more than 1000 unique entities. At this time, about half the equipment at MDF is supplied and owned by industry partners, which provides them with machine and application development, as well as exposure to potential suppliers and customers that visit the facility. Across the network, MDF partners have generated more than $5.5 billion of economic impact in the form of private industry investment. MDF is working with universities and other national laboratories to replicate this impactful engagement model to catalyze further economic and industry growth around the country. The following case studies demonstrate how MDF is empowering innovation and impact inside American manufacturing. DEMONSTRATING IMPACT: ORNL LAUNCHES BIG AREA ADDITIVE MANUFACTURING INDUSTRY A little over a decade ago, additive manufacturing processes were widely limited by relatively slow printing rates, a narrow range of source materials, and the small size of products that could be printed. From MDF’s beginning, researchers sought to change that paradigm and unlock the ability to produce significantly larger parts, quickly and efficiently. In 2014, MDF partnered with machine tool manufacturer Cincinnati Inc. to develop the first big area additive manufacturing (BAAM) system, which produced ready-for-use parts 15 times larger than the leading commercial system at the time. The research team designed BAAM to use pelletized extrusion techniques rather than polymer wire, which increased print speed 1000-fold and reduced production costs by 99%. Cincinnati Inc. quickly transitioned BAAM technology to the commercial market and sold four BAAM machines within a year. During subsequent research, MDF leveraged its network to collaborate with more than 30 materials, equipment, and contract manufacturers to enable multi-material printing, develop more than 100 polymer and composite formulations, and scale up to printing structures the size of a small house. BAAM’s success enabled the creation of a new large-scale polymer additive manufacturing (LSAM) industry— which led to more than $600 million in investments from MDF partners alone—and continues to fuel U.S. leader- ship in the global LSAM market. The overall effect is incalculable: entrepreneurs have launched new businesses around BAAM, and the technology has been adopted, adapted, or otherwise benefited companies in numerous sectors.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 14 DEMONSTRATING IMPACT: ANDURIL EXPANDS COMMERCIAL OPPORTUNITIES MDF researchers and industry partners pioneer new additive manufacturing processes and continuously adapt them for new applications and conditions—including underwater vehicles and the extreme conditions of the deep oceans. The Department of Defense has further leveraged DOE investments in BAAM by investigating how to use the technology within defense supply chains. For example, with sponsorship from the Office of Naval Research, MDF printed the submersible hull of a 30-ft Optionally Manned Technology Demonstrator (OMTD). The OMTD, which was unveiled in 2017, caught the attention of Dive Technologies, an MDF industry partner interested in similar capabilities. Dive Technologies was purchased by Anduril, a U.S.-based company specializing in autonomous systems, who then collaborated with MDF to design and produce a large displacement unmanned underwater vehicle (LDUUV). Underwater vehicles play key roles in defense and energy infrastructure maintenance. However, LDUUVs typically require costly customized designs and fabrication. Anduril and MDF aimed to apply large-format additive manu- facturing to decrease manufacturing costs while improving vehicle durability and performance. The project involved significant laboratory and field testing for materials, coatings, and interior reinforcement methods. Researchers started by defining and selecting a polymer for the vehicle panels. The partners chose to manufacture the hull in a series of panels made from CF-ABS, a carbon-fiber-reinforced thermoplastic developed at ORNL that provides structural support under intense pressure. Researchers printed the panels in such a way as to reduce the size and quantity of air pockets inside the material and so further bolstered structural integrity. Potential coatings were selected for hydrodynamic performance and the ability to deter build-up of barnacles or algae; these coating candidates were tested for mechanical properties and for performance underwater at pressures up to 9000 psi. Additional research tested ways to reinforce the vessel against physical impacts and water pressure; these methods included applying DuPont Kevlar and fiberglass cloth to the backs of the panels. The project team also experimented with a new design approach that added pockets filled with resin or fiberglass rods onto the backs of the panels. MDF researchers leveraged their existing expertise in large-format 3D printing to optimize the panel design and determine the printing parameters. After the panels were made at MDF, Anduril assembled the full vehicle and tested it in open water. Anduril emphasizes the speed at which it delivers results for its customers; this collaborative project enabled Different coatings were tested during the collaboration with Anduril. Courtesy of ORNL, U.S. Dept. of Energy. 3D-printed unmanned underwater vehicle parts fabricated with Kevlar fiber during the collaboration with Anduril. Courtesy of ORNL, U.S. Dept. of Energy. A team from MDF and Anduril developed a process to adapt large-format additive manufacturing to produce underwater unmanned vehicles like this one. Courtesy of Anduril Industries. A test panel with pockets designed on the back side, or inside of the vehicle, to inject epoxy or fiberglass rod. Courtesy of ORNL, U.S. Dept. of Energy.

ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 15 Anduril to rapidly progress from concept to complete vehicle to commercialization. Anduril has since partnered with Additive Engineering Solutions— an Ohio-based company founded to leverage BAAM technology—to design, manufacture, and sell hundreds of lowcost, high-quality 3D-printed LDUUVs for use in civilian and military sectors. DEMONSTRATING IMPACT: PEREGRINE BRINGS MANUFACTURING INTO THE FUTURE Researchers at MDF are developing digital manufacturing technologies to help companies of all sizes improve production and quality inspection processes. Such technologies are especially relevant for parts produced for harsh environments and high-risk applications like aerospace or nuclear power generation. Through conversations with multiple companies, MDF researchers realized that part qualification posed a particular challenge for manufacturers using powder bed printers to produce complex components. Due to the nature of the additive manufacturing processes, flaws could occur at any point during printing, forcing most manufacturers to rely on x-ray computed tomography (CT) scans after printing to qualify the parts. To solve this problem, MDF initiated a research and development project leveraging core ORNL expertise in additive manufacturing, materials science, machine learning, and data science to develop a more efficient and cost- effective alternative: an artificial intelligence (AI) software tool called Peregrine that enables real-time process monitoring, visualization, and quality control during printing. This tool offers a cost-effective alternative to expensive characterization equipment using an off-the-shelf camera, a high-powered desktop computer, a custom neural network architecture, and supporting processing algorithms. Peregrine uses AI to search camera images for anomalies identifiable by distinguishing features such as lines, color variations, and texture differences. It analyzes data in situ, continuously checking for uneven distribution of the powder or binding agent, porosity, and other anomalies. In some cases, Peregrine can be used for real-time adjustments to the printing process. Throughout the manufacturing process, Peregrine collects a suite of data that can be used in various ways by manu- facturers to inform ongoing process improvements. Since 2020, this tool has been licensed by more than 40 corporate, academic, and government entities. MDF and partners have demonstrated the software on more than 20 types of powder bed printers using electron beam melting, laser powder bed, and binder jet technologies. Comprehensive Peregrine datasets for representative additive systems are publicly available through the DOE Office of Scientific and Technical Information website. Peregrine is moving manufacturers closer to the “factory of the future,” characterized by energy, time, cost, and material efficiencies gained from self-correcting, automated manu- facturing systems. Ultimately, MDF researchers envision that tools like Peregrine will enable manufacturers to produce born-qualified components suitable even for critical energy and defense applications. To that end, MDF seeks to keep improving Peregrine by correlating detected anomalies with critical material flaws and quantitatively estimating component quality. ENGAGING WITH MDF In summary, a unique public- private partnership model, the Manufacturing Demonstration Facility, has been established to help U.S. industry develop efficient, cost-saving advanced manufacturing technologies, build domestic capacity, and ultimately drive economic growth and supply chain resilience. Over 40,000 people have visited and engaged with the MDF, resulting in more than 280 CRADAs, new industries, and more than $5.5 billion in economic impact, a true innovation ecosystem. Companies of all sizes that manufacture equipment, process materials, produce manufacturing-related software, or integrate energy systems in the U.S. can leverage ORNL’s expertise and MDF’s capabilities. Visit ornl.gov/ content/collaboration or contact Bob Slattery at slatteryrs@ornl.gov to learn more about the MDF Technical Collaboration Program. ~AM&P For more information: Craig Blue, chief manufacturing officer, Oak Ridge National Laboratory, 1 Bethel Valley Rd., Oak Ridge, TN 37830, 865.574.4351, blueca@ornl.gov, ornl.gov. The Peregrine system in operation at MDF. Courtesy of ORNL, U.S. Dept. of Energy. Peregrine monitors and analyzes components made with powder bed printers to assess quality and detect defects without the need for expensive characterization equipment. Courtesy of Vincent Paquit/ ORNL, U.S. Dept. of Energy.

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