19 21 29 P. 14 ASM Welcomes New President Purity Analysis in Metals Recycling Materials Testing Methods for Rubber PAIRING EBSD WITH X-RAY DIFFRACTION EMERGING ANALYSIS METHODS JANUARY 2026 | VOL 184 | NO 1
Showcase your thought leadership and innovations at one of ASMʼs 2026 conferences and expositions, which offer unparalleled access to highly engaged audiences of industry leaders and decision-makers. Learn more about each event and related exhibit and sponsorship opportunities at asminternational.org/events 2026 EVENTS FAS SUMMIT ON FAILURE ANALYSIS & PREVENTION: FATIGUE AND FRACTURE JANUARY 28 – 29, 2026 | OCEANSIDE, CALIFORNIA A brand-new gathering dedicated to advancing the science and practice of failure analysis. This summit’s theme is Fatigue & Fracture. Dive into in-depth sessions on fatigue mechanisms, fracture modes, and failure prevention. Learn from leading experts and engage in meaningful discussion—all while contributing to the growth of this critical field. INTERNATIONAL THERMAL SPRAY CONFERENCE AND EXPOSITION (ITSC) 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 iiw. HEAT TREAT MEXICO CONFERENCE AND EXPOSITION APRIL 14 – 16, 2026 | MONTERREY, MEXICO Heat Treat Mexico is powered by the strength of the ASM Heat Treating Society, ASM Mexico Chapter, and the organizers of Heat Treat North America. This conference and expo will showcase heat treating resources, programming, and technology for the emerging markets in Mexico. SHAPE MEMORY & SUPERELASTIC TECHNOLOGIES CONFERENCE AND EXPOSITION MAY 4 – 8, 2026 | LA JOLLA, CALIFORNIA The International Conference on Shape Memory and Superelastic Technologies (SMST) is the leading worldwide conference and exposition for the shape memory and superelastic technologies and is highly focused on the manufacturing and application of shape memory materials. AEROMAT | JUNE 2 – 4, 2026 | WEST PALM BEACH, FLORIDA AeroMat focuses on innovative aerospace materials, fabrication, and manufacturing methods that improve performance, durability, and sustainability of aerospace structures and engines with reduced life-cycle costs. THERMAL SPRAY OF SUSPENSIONS & SOLUTIONS SYMPOSIUM + EBCS (TS4E) SEPTEMBER 16 – 18, 2026 | PRAGUE, CZECH REPUBLIC The ASM Thermal Spray Society will again offer a symposium focused on suspension and solution thermal spray technology. This symposium offers an opportunity for scientists and engineers interested in the emerging S&STS technologies to address both research challenges and development of industrial applications. INTERNATIONAL MATERIALS, APPLICATIONS, AND TECHNOLOGIES (IMAT) SEPTEMBER 28 – OCTOBER 1, 2026 | QUEBEC CITY, CANADA IMAT, ASM’s annual event, is the only targeted event on advanced materials, applications, and technologies in key growth markets that will have a focus on economic trends and business forecasts. The event will include a diverse group of materials experts, including the ASM Programming Committees, AeroMat Committee, and all six of ASM’s Affiliate Societies, who are heavily involved in building the technical symposiums, which will have a strong focus on real-world technologies that can be put to use today. INTERNATIONAL SYMPOSIUM FOR TESTING AND FAILURE ANALYSIS (ISTFA) OCTOBER 4 – 8, 2026 | SAN ANTONIO, TEXAS 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.
19 21 29 P. 14 ASM Welcomes New President Purity Analysis in Metals Recycling Materials Testing Methods for Rubber PAIRING EBSD WITH X-RAY DIFFRACTION EMERGING ANALYSIS METHODS JANUARY 2026 | VOL 184 | NO 1
ASM International connects materials professionals with the finest resources available — to solve problems, improve materials performance, and support professional development. The World’s Largest Materials Society ASM World Headquarters, Cleveland, Ohio, USA FOR MORE INFORMATION Shape Memory & Superelastic Technologies
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35 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. GOOD APART, GREAT TOGETHER: ELECTRON BACKSCATTER DIFFRACTION AND X-RAY DIFFRACTION Laura G. Wilson, Richard E. Martin, and Ayden T. McCartney Two case studies demonstrate that gathering data from a complementary pair of materials characterization techniques can provide more valuable insights than using a single method. 14 ADVANCED MATERIALS & PROCESSES | JANUARY 2026 2 An electron backscatter diffraction map of mineral samples showing multiple phases. Courtesy of NASA Glenn Research Center. On the Cover: 48 3D PRINTSHOP Materials created specifically for 3D printers enable unique ways to design shapes and structures. EXECUTIVE LEADERSHIP FORUM PANEL AT IMAT 2025 Key takeaways from industry and academia experts on how they work together to drive innovation and strengthen the global materials ecosystem. 32
4 Editorial 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Process Technology 12 Emerging Technology 13 Sustainability 47 Editorial Preview 47 Special Advertising Section 47 Advertisers Index 48 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-effective and user-friendly formats. ASM is where materials users, producers, and manufacturers converge to do business. Advanced Materials & Processes (ISSN 0882-7958, USPS 762080) publishes six issues per year: January, March, May, July, September, and November, by ASM International, 9639 Kinsman Road, Materials Park, OH 44073-0002; tel: 440.338.5151; fax: 440.338.4634. Periodicals postage paid at Novelty, Ohio, and additional mailing offices. Vol. 184, No. 1, JANUARY 2026. Copyright © 2026 by ASM International®. All rights reserved. Distributed at no charge to ASM members in the United States, Canada, and Mexico. International members can pay a $30 per year surcharge to receive printed issues. Subscriptions: $499. Single copies: $54. POSTMASTER: Send 3579 forms to ASM International, Materials Park, OH 44073-0002. Change of address: Request for change should include old address of the subscriber. Missing numbers due to “change of address” cannot be replaced. Claims for nondelivery must be made within 60 days of issue. FEATURES JANUARY 2026 | VOL 184 | NO 1 ADVANCED MATERIALS & PROCESSES | JANUARY 2026 3 19 24 29 21 29 TECHNICAL SPOTLIGHT RUBBER MATERIALS TESTING: A PRIMER Proper elongation and break testing of rubber materials ensures the most accurate assessment of a sample’s properties. 19 ELIZABETH HOFFMAN 2025-2026 PRESIDENT OF ASM INTERNATIONAL Meet Elizabeth Hoffman, the new president of ASM, and learn about her professional background, service, and contributions as a leader. 21 TECHNICAL SPOTLIGHT HOW RECYCLING TURNS E-WASTE INTO GOLD STANDARD RESOURCES Purity analysis in precious metals recycling is shown to aid the successful recovery of critical samples. 24 FAILURE INVESTIGATIONS: A SYSTEMATIC PROBLEM-SOLVING PROCESS, PART II Jeffrey L. Hess This second part in an article series provides an overview of various phases of a failure examination and clarifies terminology used in metallurgical failures.
4 ADVANCED MATERIALS & PROCESSES | JANUARY 2026 ASM International 9639 Kinsman Road, Materials Park, OH 44073 Tel: 440.338.5151 • Fax: 440.338.4634 Joanne Miller, Editor joanne.miller@asminternational.org Victoria Burt, Managing Editor vicki.burt@asminternational.org Frances Richards and Corinne Richards Contributing Editors Anne Vidmar, Layout and Design Allison Freeman, Production Manager allie.freeman@asminternational.org EDITORIAL COMMITTEE John Shingledecker, Chair, EPRI Beth Armstrong, Vice Chair, Oak Ridge National Lab Adam Farrow, Past Chair, Los Alamos National Lab 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 Elizabeth Ho man, President and Chair Daniel P. Dennies, Senior Vice President Tirumalai Sudarshan, Vice President Navin Manjooran, Immediate Past President William Jarosinski, Treasurer Rahul Gupta Hanchen Huang Victoria Miller Christopher J. Misorski Erik Mueller Ramana G. Reddy JP Singh 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. MODERN ALCHEMISTS Synonymous with each new calendar year is resolution setting and the urge to make improvements of all types. Individuals set personal goals. Managers define key performance objectives. Corporations establish quarterly targets. The whole world is focused on a period of reflection and planning for future advancements. In medieval times, there was a rigorous pursuit of attempting to turn lead into gold through various refinements. Though this traditional meaning of alchemy was proven non-productive, the broader desire to transform an existing state or process into something better remains a noble goal today. We have several examples of the successful pursuit of enhancements in this issue. Authors from Horiba, in a quest to recover precious metal resources from e-waste, developed a novel recycling method. Their successful purity analysis meets three critical requirements: speed in quality assurance, preservation of the sample, and accuracy along with automation. Their process eliminates human error and environmental contamination and results in high-volume, high-purity reusable precious material. Another lesson in process improvement is provided in our lead article. Laura Wilson from NASA Glenn Research Center shares a two-part method for achieving better materials characterization results. If one analytical method is good, two might be even better. Wilson combines electron backscatter diffraction and x-ray diffraction to give a fuller picture of a sample’s mineralogical phases. This pairing of analysis methods transforms the process and provides superior results. Another entity, the National Institute of Standards and Technology, is seeking to advance the metals processing industry. Their new report, which is referenced on our Sustainability news page, is based on input from experts, including several ASM members, who attended a July 2024 information gathering session. The “Materials Challenges in Developing a Sustainable Metal Processing Infrastructure—Workshop Report” highlights five strategies for improving the existing metals infrastructure: Advance measurement science for sustainable metals manufacturing; develop the technical basis to support standards development; enhance data and modeling tools; promote workforce development and education; and convene stakeholders to foster knowledge-sharing and innovation. A similar call for collaboration came during the Executive Leadership Forum at IMAT 2025 last October. The event brought together esteemed experts from academia and industry who served as moderators and panelists to discuss the future of the global materials ecosystem. A summary of key takeaways from their conversation is provided in this issue. Navin Manjooran, FASM, as chair, emphasized the critical role ASM International plays in connecting materials experts across various sectors. He suggested that our Society is uniquely poised to encourage collaborations that can lead to future materials advancements. As individuals, as a Society, as an industry, we all can be alchemists in the best sense of the word, working to transform our areas of influence for the better in the coming year and beyond. joanne.miller@asminternational.org Watercolor of 17th century alchemist workshop. Courtesy of Wikimedia Commons.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 5 RESEARCH TRACKS ULTRA-THIN SODIUM FILMS SEE THE LIGHT Scientists from three universities— Yale, Oakland, and Cornell—collaborated to develop more cost-effective plasmonic materials, which are traditionally made of expensive metals like gold or silver. These materials are often used to manipulate light with extreme precision for applications ranging from solar panels to medical devices. The team’s new work brings together expertise in nanofabrication, ultrafast optics, and materials science. By developing a technique for structuring sodium into ultra-thin, precisely patterned films, the researchers found a way to stabilize the metal and make it perform exceptionally well in light- based applications. The new approach involved combining a thermally assisted spin coating with phase-shift photolithography, skillfully using heat and light to create nanoscopic surface patterns that trap and guide light in powerful ways. Further, the team used ultrafast laser spectroscopy to observe what happens when these sodium surfaces interact with light on time scales measured in trillionths of a second. The results were surprising, say researchers. Sodium’s electrons responded in ways that differ from traditional metals, suggesting it could offer new advantages for light-based technologies such as photocatalysis, sensing, and energy conversion. yale.edu. GRAPHENE-BASED SOLAR CELLS POWER TEMPERATURE SENSORS Researchers at the University of Arkansas and the University of Michigan report the first application of ultra-low power temperature sensors using graphene-based solar cells. They say the test is the first hurdle in developing autonomous sensor systems that draw power from multiple sources in the environment including solar, thermal, acoustic, kinetic, nonlinear, and ambient radiation. The goal is to develop multimodal sensors using the energy-harvesting capability of graphene that can last decades and help realize the Internet of Things in daily life. Success depended on overcoming two challenges: reducing sensor power demand to nanowatts as opposed to the current standard, which is measured in microwatts, and powering the sensor using energy harvested from the local environment. The Arkansas team was mostly responsible for completing the second challenge while the University of Michigan team was largely responsible for the first. The new study confirms it is possible to create an ultra-low power temperature sensor using graphenebased solar energy. By making them multimodal, intermittent shortages in solar power can be augmented with additional thermal or nonlinear power. Researcher Paul Thibado foresees the sensors being used in areas and fields where sensors would be useful but the need to replace batteries would make them labor and cost prohibitive. This could include things like tracking livestock, wearable fitness monitoring, building alarm systems, and predictive maintenance, among other applications. The next step is to perfect a kinetic energy harvester that collects energy from the vibrational qualities of graphene. This capability will then be joined with a solar sensor, creating a true multimodal sensor. uark.edu. Researchers from The University of Osaka and Daikin Industries Ltd., Japan, identified a new indicator for designing advanced lithium-ion batteries. They found that the electrolyte lithium-ion chemical potential, a measure of how “uncomfortable” a lithium ion is within a battery’s electrolyte, quantitatively determines whether a battery can be charged and discharged reversibly. www.osaka-u.ac.jp. BRIEF Researcher Conrad Kocoj works with ultrafast laser spectro- scopy equipment used to observe how sodium interacts with light. Testing of a graphene-based sensor. Courtesy of University of Arkansas.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 6 METALS | POLYMERS | CERAMICS Technology (TU Delft), the Netherlands, are investigating bacterial spores as an important candidate in the field of engineered living materials (ELMs). By embedding Bacillus spores within ELMs, the researchers are creating living materials that not only endure harsh environments but can also be programmed to perform specific tasks. Certain bacterial species can switch into a dormant and metabolically inactive state, called a spore, which is extremely resistant to heat, dryness, and chemical stress. The autonomously grown ELMs have a wide range of potential applications, such as detecting disease biomarkers and catalyzing the breakdown of environmental pollutants. They could also function as self-healing composites. In the future, these new substances could even be used as a sustainable replacement for fossil-based materials, according to the team. To fabricate the material, the scientists combined two bacterial species: Komagataeibacter rhaeticus and Bacillus subtilis. K. rhaeticus produces strong bacterial cellulose fibers that act as a protective physical barrier while Bacillus contributes its spore-forming capacity. The mixture creates a robust NEW PROCESS MAKES NEODYMIUM MAGNETS Researchers at Lawrence Livermore National Laboratory (LLNL), Case Western Reserve University (CWRU), and Ames National Laboratory created a new method for neodymium magnet fabrication that generates high-purity material at high efficiency. Although the U.S. has neodymium deposits, refining the material has remained out of reach due to the energy-intensive process, permitting restrictions, and the lack of a qualified workforce. The new technique could address all three barriers, according to the team. It operates based on chloride molten salt electrolysis. Neodymium enters the system attached to chloride ions. Next, the electrolysis setup uses electricity to split the incoming molecules apart, pulling the neodymium to one end of the system (the cathode) and chloride to the other (the anode). “We hope this method becomes a cornerstone for domestic production of neodymium magnets,” says LLNL scientist Eunjeong Kim. “It can enable a truly U.S.-based ‘mine-to-magnet’ manufacturing chain from rare earth mining and separation to final magnet fabrication, reducing reliance on overseas processing.” Compared to traditional refining, the new process avoids two energyintensive steps and does not produce harmful gases as a byproduct. Because the anode design prevents degradation, the device can operate continuously. Chloride molten salt electrolysis could also be extended to other rare earth metals critical for energy technologies, say scientists. CWRU led the electrochemical design and process modeling. LLNL contributed materials characterization and anode fabrication, and Ames used the material produced to fabricate magnets that are comparable to industry standards. Now, CWRU is working to scale up the electrolysis setup design while LLNL is testing new deposition approaches to further stabilize the anode. llnl.gov. ENGINEERED LIVING MATERIALS LOOK PROMISING Scientists at Delft University of The new process flow for magnet fabrication requires much less energy than traditional methods. Courtesy of Dan Herchek. This wet film of cellulose is composed of cellulose-producing bacteria Komagataeibacter rhaeticus and Bacillus spores. Courtesy of Jeong-Joo Oh/Aubin-Tam Lab. The Composites Institute (IACMI) launched a “Make It In America” outreach campaign to raise awareness of manufacturing careers and help fill 3.8 million jobs by 2030. The effort will educate workers about job opportunities through two programs, America’s Cutting Edge and Metallurgical Engineering Trades Apprenticeship & Learning. iacmi.org. BRIEF
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 7 living material. By genetically modifying the bacterial spores’ surface, the team added the needed functionality. Also, the genetic engineering step enhanced the spores’ ability to bind to the cellulose. “At this stage, our work is at a proof-of-concept level in the laboratory,” says researcher Jeong-Joo Oh. “To use these materials in concrete, for instance, they should match the strength of existing building materials. But the results are already very promising.” www.tudelft.nl. NEW ALLOY DESIGN FOR SOLID-STATE BATTERIES Engineers at the University of California (UC) San Diego, along with colleagues at UC Irvine, UC Santa Barbara, and LG Energy Solution, developed a novel design strategy for metal alloy negative electrodes. They say the new approach could significantly improve the performance and durability of next-generation solid-state batteries. The work could also help advance progress toward practical, high-performance energy storage for electric vehicles. The team focused on negative electrodes made of lithium-aluminum alloy. They studied how lithium ions move through different phases of the material—a lithium-rich beta phase and lithium-poor alpha phase—and how these phases influence the battery’s performance. By adjusting the ratio of lithium to aluminum, the researchers were able to control distribution of the alloy’s beta phase. The team found that increasing the proportion of the beta phase greatly enhanced the movement of lithium within the metal alloy, as it provided pathways for lithium ions to diffuse up to 10 billion times faster than through the alpha phase. The beta phase also led to denser, more stable electrode structures and enhanced channels of lithium diffusion between the electrode and solid electrolyte. In tests, batteries with beta phase-enriched lithium-aluminum alloy electrodes demonstrated high charge-discharge rates and maintained capacity over 2000 cycles. This is the first study to establish a correlation between the distribution of the beta phase and lithium diffusion behavior in lithium- aluminum alloys, the scientists noted. The findings could guide the design of future alloy-based electrodes with higher energy density, faster charge times, and longer lifespans. ucsd.edu. Microscope images and illustrations of a lithiumaluminum alloy electrode with enhanced lithium diffusion pathways. Courtesy of Yuju Jeon. NASA low outgassing Per ASTM E595 standards Electrically insulative Volume resistivity, 75°F >1015 ohm-cm Very low CTE, 75°F 10-13 x 10-6 in/in/°C Two Part EP30LTE-2 for PRECISE ALIGNMENT LOW CTE EPOXY Hackensack, NJ 07601 USA • +1.201.343.8983 • main masterbond.com www.masterbond.com flowable system for bonding, potting & encapsulation
8 ADVANCED MATERIALS & PROCESSES | JANUARY 2026 with uneven composition exhibit ex- ceptionally low thermal conductivity. Scientist Siqi Liu said the findings challenged conventional models that overlook the role of microstructural features. “People used to think low thermal conductivity in uneven materials was just due to how the different parts were mixed,” says Liu. “But we found it’s actually caused by tiny defects called edge dislocations that scatter heat more when they’re randomly arranged.” The team looked at a commonly used thermoelectric alloy (Bi0.4Sb1.6Te₃) as a model system. Researchers used advanced electron microscopy and scanning thermal probe techniques to map the compound’s composition and thermal properties at the atomic level. TESTING | CHARACTERIZATION HOLLOW-CORE FIBERS WITHSTAND RADIATION Scientists at CERN in Switzerland are testing the use of hollow-core optical fibers to measure the profile and position of beams extracted from the Super Proton Synchrotron, CERN’s second-largest accelerator. Unlike con- ventional fibers, which guide light through solid glass, hollow-core optical fibers are mostly empty inside but have a microstructure design that guides light through resonance-antiresonance effects on the electromagnetic field. By filling these fibers with a scintillating gas, researchers can create a simple yet powerful radiation sensor that helps them adjust the beam profile and position and may even allow them to measure the delivered beam dose in real time. Unlike the multiwire proportional chambers and scintillator detectors now used, the new fibers can work in an extreme radiation environment and will be very useful for CERN’s future accelerators. Reliably measuring particle beams is crucial for both experimental and beam physicists. The operation of all of CERN’s accelerators relies on a vast amount of data sent by thousands of beam sensors distributed along the machines. However, their reliability may be compromised at high energies or high intensities. This is also a concern for scientists developing accelerators for medical applications such as FLASH radiotherapy. The FLASH technique delivers radiation at ultrahigh dose rates and shows great promise in cancer treatment, but its extreme beam conditions require new kinds of monitoring tools to be developed. A team focusing on beam diagnostics for CERN’s experiments along with researchers working on medical applications are exploring new tools that can withstand extreme radiation. By linking accelerator expertise with medical research, the technology being tested at CERN could one day support the safe delivery of FLASH therapy to patients. https://home.cern. MAKING MATERIALS WITH TAILORED THERMAL PROPERTIES Researchers at Queensland Univer- sity of Technology (QUT), Australia, identified why some materials can block heat more effectively than others— a key feature for energy conversion, insulation, and gas storage. The new study discovered a structural mechanism that explains why some materials A beam instrumentation team member prepares to test a hollow-core fiber. Courtesy of CERN. Researchers from the University of South Carolina, Virginia Tech, and Duracell developed a statistical method to optimize zinc particle size, shape, and crystallinity, potentially enhancing alkaline battery performance. The breakthrough could revolutionize zinc anode design. https://rdcu.be/eQ3YK. BRIEF Top: Backscattered electron (BSE) image showing the composition distribution of Bi0.4Sb1.6Te3 pellet. Bottom: Scanning thermal probe micro-image (STPM) depicting the thermal conductivity ( κ) distribution corresponding to the area in top image. Courtesy of QUT.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 9 Liu said the research found that materials with more randomly mixed zones of bismuth and antimony blocked heat more effectively than those with a more ordered structure. This was due to the edge dislocations being scattered in all directions, which disrupts heat flow. The discovery opens new avenues for designing materials with tailored thermal properties, say researchers. “Whether it’s improving the efficiency of thermoelectric generators or developing better thermal insulators, this work gives us a new tool to control heat flow at the atomic level,” says Liu. www.qut.edu.au. MICROSCOPE SEES MICRO AND NANOSCALE STRUCTURES Researchers at The University of Tokyo built a “Great Unified Microscope” that can detect a signal over an intensity range 14 times wider than conventional equipment. Further, the observations are made label-free and without the use of additional dyes. This means the method is gentle on cells and adequate for long-term observations, holding potential for testing and quality control applications in the pharmaceutical and biotechnology industries. Microscopes have played a vital role in science since the 16th century. Progress has required not only more sensitive and accurate equipment and analysis, but also more specialized machines. Modern techniques have had to straddle tradeoffs involving things like particle size detection and having a comprehensive overview of cell structures. “I would like to understand dynamic processes inside living cells using noninvasive methods,” says researcher Kohki Horie. The team set out to investigate whether measuring both directions of light simultaneously could overcome the tradeoff and reveal a wide range of sizes and motions from the same image. To test the idea and confirm their newly built microscope was working as hoped, the scientists decided to observe what happened Conceptual illustration of a bidirectional quantitative scattering microscope. Courtesy of University of Tokyo. during cell death. They recorded one image encoding information from both forward and backward-traveling light. As a result, they were able to quantify not only the motion of cell structures (micro) but also of tiny particles (nano). In addition, by comparing the forward and back-scattered light, they could estimate each particle’s size and refractive index. The team plans to study even smaller particles such as viruses and explore how living cells move toward death. www.s.u-tokyo.ac.jp/en. WHAT’S IN YOUR 2026 MARKETING MIX? ASM INTERNATIONAL’S 2026 MEDIA KIT is YOUR GATEWAY to reaching a targeted audience of materials science and engineering professionals. ASM generates measurable impact by offering unparalleled access to engaging with a unique and motivated audience through integrated, omnichannel marketing capabilities. Develop a comprehensive campaign through sponsored emails, webinars, web and mobile ad placements, in-person event sponsorships, and more to target sizable audiences of decision makers. KELLY “KJ” JOHANNS BUSINESS DEVELOPMENT MANAGER CONTACT KJ TODAY AT: KJ.JOHANNS@ASMINTERNATIONAL.ORG OR 440.671.3851 VIEW THE 2026 MEDIA KIT AT: WWW.ASMINTERNATIONAL.ORG/ADVERTISE-WITH-US-RESULTS/
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 10 MACHINE LEARNING | AI AI POWERS CRITICAL MATERIALS SEARCH Scientists at the U.S. Geological Survey (USGS), along with the Defense Advanced Research Projects Agency (DARPA) and the Advanced Research Projects Agency–Energy (ARPA-E), launched a bold initiative called Critical Mineral Assessments with AI Support, or CriticalMAAS. The project helps strengthen collaborative research from the University of Minnesota and the Viterbi Information Sciences Institute (ISI) at the University of Southern California. The goal is to develop AI tools that can accelerate how the U.S. identifies and discovers mineral resources using a workflow known as critical mineral assessments. The project’s first challenge was extracting data from 100,000 historical maps, most of which exist only as scanned raster images. The raster format makes them difficult to analyze using AI, and manual digitization is slow and labor-intensive. Meanwhile, prior automated approaches struggle with the complex visual context and limited training data available for geological maps. So, the team developed Digmapper, a scalable system that automates the map digitization pipeline. When tested on more than 100 annotated maps from a DARPA- USGS dataset, Digmapper completed the process in under 25 minutes. Digitizing the historical maps speeds the process of assessing where critical minerals can be sourced, say scientists. The second major ISI-led effort, MinMod, addresses the need to unify mineral data from around the world into a searchable, AI-ready knowledge graph. “The goal of MinMod is to bring together everything we know about global mining sites,” says ISI researcher Craig Knoblock. So far, MinMod has processed tens of thousands of docu- ments on more than 679,000 sites and 190 different commodities. The team uses large language models and semantic technologies to extract, structure, and unify data into a machine-readable knowledge graph. This shared framework ensures different systems can access, analyze, and build on the same data with precision. As part of the broader CriticalMAAS initiative, the historical maps and MinMod knowledge graph serve as Example of extracting polygon features from geologic maps. Courtesy of W. Duan et al., 2025, doi.org/10.48550/ arxiv.2506.16006. the foundation for the program’s goal of using machine learning to predict undiscovered mineral deposits. isi.edu. MAGNETIC MATERIALS DATABASE VIA AI Researchers at the Uni- versity of New Hampshire are using artificial intelli- gence (AI) to accelerate discovery of new functional magnetic materials. They cre- ated the Northeast Materials Database of 67,573 mag- netic materials entries, including 25 previously unrecognized compounds that remain magnetic even at high temperatures. “By accelerating the discovery of sustainable magnetic materials, we can reduce dependence on rare-earth elements, lower the cost of electric vehicles and renewable- energy systems, and strengthen the U.S. manufacturing base,” says Ph.D. student Suman Itani. Scientists know that many undiscovered magnetic compounds exist, but testing millions of element combinations in the lab is prohibitively time-consuming and expensive. Itani and his team built an AI system that can read scientific papers and extract those key experimental details. This data is then fed into computer models that identify whether a material is magnetic and how high a temperature it can withstand before losing its mag- netism. Going forward, the scientists believe the large language model behind this project could have widespread use beyond this database, particularly in higher education. For example, converting images to modern rich text format could be used to modernize library holdings. nemad.org.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 1 1 PROCESS TECHNOLOGY MECHANOCHEMICAL METHOD SPEEDS UP RECYCLING Researchers at Georgia Tech, Atlanta, developed a process to break down polyethylene terephthalate (PET) using mechanical force instead of heat or harsh chemicals. The team used a mechanochemical method to quickly convert PET back into its building blocks, creating a path toward cleaner recycling. The scientists hit solid pieces of PET with metal balls with the same force they would experience in a ball mill. This can make the PET react with other solid chemicals such as sodium hydroxide, generating enough energy to break the plastic’s chemical bonds at room temperature. Guided by thermodynamic calculations, the researchers exposed α-spodumene, a naturally occurring hard-rock lithium mineral, to FJH and chlorine gas. The single-step process eliminates the need for the traditional multistep acid roasting method, allowing lithium to be extracted directly as lithium chloride. With a flash of electrical current, the mineral shifted from its stable α-phase to the high temperature- accessed ß-phase, making lithium available for reaction with chlorine gas. The lithium then vaporized as lithium chloride, while aluminum and silicon compounds were left behind. This was complete within seconds. The team achieved nearly instant lithium extraction from spodumene, producing lithium chloride with 97% purity and 94% recovery. A startup from Prof. Tour’s lab, Flash Metals USA, is now scaling the technology for metals extraction from waste. rice.edu. The team used single-impact experiments along with computer simulations to map how energy from collisions distributes across the plastic and triggers chemical and structural transformations. These experiments showed changes in tiny zones that experience different pressures and heat. By mapping these changes, researchers gained insight into how mechanical energy can trigger efficient chemical reactions. Each collision created a tiny crater, with the center absorbing the most energy. In this zone, the plastic stretched, cracked, and even softened slightly, creating ideal conditions for chemical reactions with sodium hydroxide. High-resolution imaging and spectroscopy revealed that the normally ordered polymer chains became disordered in the crater center, while some chains broke into smaller fragments, increasing the surface area exposed to the reactant. The team plans to test real-world waste streams and explore if similar methods can work for other difficult-to-recycle plastics. gatech.edu. ONE-STEP PROCESS EXTRACTS USABLE LITHIUM Scientists at Rice University, Houston, developed a single-step process for extracting high-purity lithium from spodumene ore by using flash Joule heating (FJH). The technique rapidly heats materials to thousands of degrees within milliseconds and works in conjunction with chlorine gas, quickly converting the ore into usable lithium. Franklin Precision Castings (FPC) is celebrating 40 years of manufacturing precision investment castings. Since 1985, FPC has grown from a supplier of glass mold components to serving industries such as steel, oil and gas, and defense. FPC is the oldest continuously operating casting foundry in Pennsylvania. franklincastings.com. ABB, Zurich, launched a new version of its Millmate Thickness Gauge (MTG) technology. MTG Box Gauge measures aluminum strip thickness below 8 mm at the tail end of hot rolling, where accurate data is crucial for quality control. abb.com. BRIEFS Image shows the moment a polymer surface liquefies due to the high impact of a metal ball in a ball mill reactor. Justin Sharp demonstrates the team’s lithium extraction method in James Tour’s lab. Courtesy of Jeff Fitlow/Rice University.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 12 EMERGING TECHNOLOGY TECH INCUBATOR SUPPORTS QUANTUM APPLICATIONS The University of Connecticut’s (UConn) Technology Incubation Program (TIP) is a prime example of the technological diversity stemming from quantum computing applications—and a new home to six quantum-related startups. For example, Access Quantum uses quantum principles to develop alloys and materials with more desirable properties, particularly for the aerospace industry where extreme environments require new and better fatigue-resistant materials. Other TIP start-ups include Plasmonic Reactor Systems, a company entering the nuclear power industry with a pioneering technology for small and micro nuclear reactors capable of delivering nuclear power without the nuclear risk. Another, called We-Sensing, focuses on development of next-generation AI and quantum-powered monitoring sensors. According to the researchers, these advanced sensors provide real-time insights that improve resource efficiency, reduce operational costs, and support sustainable management of water, soil, and industrial systems. Another startup is QuaSIM, a company developing classical and quantum algorithms that significantly accelerate the simulation of granular and molecular-scale materials offering dramatically improved insight into complex biological and pharmaceutical systems. QueHOT is a startup developing a hybrid quantum processor that uses pulses of light and advanced photonic architectures to achieve scalable, high-speed quantum information processing. AlgorithmicPro AI is developing low-cost, high-speed data- linking solutions to assist AI-driven computational techniques to solve large-scale information integration challenges for businesses and govern- ment. The promise of TIP is that it brings UConn quantum researchers from a multitude of disciplines together under one roof in a way that helps them commoditize their work and take it to market, according to the UConn team. uconn.edu. LIFT SUPPORTS THREE NEW PROGRAMS LIFT, the national advanced materials manufacturing innovation institute located in Detroit, announced three new initiatives as part of the Advanced Materials Challenge. First is “Enabling Robust Cross-Platform Printing of Structural High-Strength Aluminums and Aluminum Matrix Composites” with Elementum 3D. The project will develop a new approach to produce Elementum 3D’s Reactive Additive Manufacturing (RAM) aluminum AM feedstocks to enhance print quality and uniformity across machine makes. Next is “Development of Ti-Cu-X Alloy with Refined Microstructure and Enhanced Mechanical Properties Using Wire-Based Additive Manufacturing Processes” with Raytheon Technologies Research Center. The project aims to develop a unique Ti-Cu-X alloy tailored for wire-based AM processes, with a focus on achieving a refined micro- structure. The third initiative is “Virtual Qualification and Certification of an Advanced Structural Material Leveraging Advanced Data-Driven Approaches” with EOS North America. The project aims to revolutionize qualification and certification of advanced materials of interest to the Department of War by leveraging AI and machine learning. https://lift.technology. A new Aerospace Engineering Complex at Georgia Tech, Atlanta, will house the Daniel Guggenheim School of Aerospace Engineering, a state-of-the-art aircraft prototyping lab, and the newly launched Space Research Institute. Now in the design phase, the 225,000-sq-ft facility will include advanced laboratories to support work in aerodynamics, robotics, artificial intelligence, autonomous systems, propulsion, and space exploration. gatech.edu. BRIEF UConn’s TIP brings the teams from six startup technologies together in one space. LIFT’s Detroit headquarters. Courtesy of LIFT.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 13 SUSTAINABILITY BRIEF BIOBASED FILM MEETS PACKAGING NEEDS Researchers at Georgia Institute of Technology developed a biologically based film made of natural ingredients found in plants, mushrooms, and food waste that can block moisture and oxygen as effectively as conventional plastics. The team worked for more than a decade to create environmentally friendly oxygen and water barriers for packaging. However, while the earlier research using biopolymers seemed promising, high humidity continued to weaken the barrier properties. The scientists achieved success by using a blend of cellulose, chitosan (derived from crustacean-based food waste or mushrooms), and citric acid from certain fruits. The barrier technology developed by the researchers consists of three main components: a carbohydrate polymer for structure, a plasticizer to maintain flexibility, and a water-repelling additive to resist moisture. When cast into thin films, the ingredients self-organize at the molecular level to form a dense, ordered structure that resists swelling or softening under high humidity. Even at 80% relative humidity, the films show extremely low oxygen permeability and water vapor transmission, matching or outperforming common plastics such as poly(ethylene terephthalate) and poly(ethylene vinyl alcohol). gatech.edu. NEW TEFLON RECYCLING METHOD Scientists from Newcastle University and the University of Birmingham, both in the U.K., developed a clean and energy-efficient way to recycle Teflon, a material well known for its use in nonstick coatings and other applications that require high chemical and thermal stability. The researchers found that waste Teflon can be broken down and repurposed using only sodium metal and mechanical energy—at room temperature and without toxic solvents. The new low-energy, waste-free method offers an alternative to conventional fluorine recycling. Polytetrafluoroethylene (PTFE), best known by the brand name Teflon, is prized for its resistance to heat and chemicals, making it ideal for cookware, electronics, and laboratory equipment. Yet those same properties make it almost impossible to recycle. When burned or incinerated, PTFE releases pollutants known as “forever chemicals” (PFAS), which remain in the environment for decades. Traditional disposal methods raise major environmental and health concerns. The researchers addressed this challenge using mechanochemistry, a green approach that drives chemical reactions by applying mechanical energy instead of heat. Inside a ball mill, sodium metal fragments are ground with Teflon, which causes them to react at room temperature. The process breaks the strong carbon-fluorine bonds, converting them into harmless carbon and sodium fluoride, a stable inorganic salt widely used in fluoride toothpastes. The researchers then showed that the sodium fluoride recovered in this way can be used directly, without purification, to create other valuable fluorine-containing molecules. These include compounds used in pharmaceuticals, diagnostics, and other fine chemicals. www.ncl.ac.uk. In September 2025, the National Institute of Standards and Technology released a report outlining strategies to build a more efficient, sustainable, and resilient U.S. metals processing infrastructure, emphasizing the need for improved standards for recycled content and stronger supply chains for critical materials. Carelyn Campbell, FASM, and Mark Stoudt, FASM, are key authors. doi.org/10.6028/NIST.SP.1500-32. A new biologically based film was engineered from natural ingredients found in plants, mushrooms, and food waste. Courtesy of Georgia Institute of Technology. This team developed a low-energy, wastefree alternative to conventional fluorine recycling. Courtesy of Newcastle University.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 14 CHARACTERIZATION TECHNIQUES *Member of ASM International GOOD APART, GREAT TOGETHER: ELECTRON BACKSCATTER DIFFRACTION AND X-RAY DIFFRACTION Two case studies demonstrate that gathering data from a complementary pair of materials characterization techniques can provide more valuable insights than using a single method. Laura G. Wilson,* NASA Glenn Research Center, Cleveland Richard E. Martin, HX5 LLC, Brook Park, Ohio Ayden T. McCartney,* Ohio Aerospace Institute, Cleveland Optical image of mineral samples from within the Nevada National Security Site, USA. Courtesy of NASA Glenn Research Center.
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 15 One of the advantages of materials characterization is the variety of techniques available to solve problems, and an under- utilized secret weapon in materials characterization is combining various techniques. One characterization method may provide illuminating answers, but in tandem, multiple methods can be truly enlightening. Electron backscatter diffraction (EBSD) and x-ray diffraction (XRD) are two methods that are extremely useful when used together. Electron backscatter diffraction data is collected within a scanning electron microscope (SEM), exploiting the interaction of source electrons with sample electrons, providing information about the crystal structure of the sample. The typical area investigated can range from the micron to the millimeter scale and the results describe grain size, shape, and orientation of the material[1]. X-ray diffraction is collected with a diffractometer and produces a spectrum of intensity of x-ray signal over an angular range, based on Braggs Law. The data is often collected from approximately a centimeter-sized area and provides information about the phases present in the material[2]. Both methods can be used to understand textures within the material attributed to the dominating orientation of crystals in the material, presented with pole figures. The crystallographic information from both methods can also be used to identify phases within the material in question. While valuable on their own, EBSD and XRD can be invaluable in tangent. This article presents two case studies, both conducted at NASA Glenn Research Center, that demonstrate the power of combining EBSD and XRD[3,4]. CASE STUDY 1: TEXTURE AND PHASE IDENTIFICATION WITH XRD AND EBSD Introduction. Oxide dispersion strengthening (ODS) has been shown to be an effective method for improving high-temperature creep resistance in materials like superalloys. Additive manufacturing (AM) has provided a successful method to produce oxide dispersion strengthened metal superalloys. These AM ODS superalloys have superior mechanical strength at high temperatures when compared to nonODS materials[5-7]. However, metal AM processes like laser-powder bed fusion can induce significant texture in the build material due to high thermal gradients along the build direction[8]. The grain textures of these AM materials can have a significant impact on their mechanical strength, and therefore understanding texture in the material is critical[8-10]. As part of a study evaluating the creep and tensile rupture failure modes in AM, ODS and non-ODS, Ni-based superalloy samples, the grain microstructure and textures were evaluated using EBSD and XRD. Methods. Samples of a NiCrAl model superalloy were produced by laser powder bed fusion both with and without additions of Y2O3 oxide powder. These ODS and non-ODS samples underwent hot isostatic pressing and solution heat treatments prior to being sectioned and metallographically prepared. XRD texture measurements were performed on a PANalytical Empyrean Series 2 diffractometer using Cu Kα radiation. The area scanned was approximately 15 mm by 17 mm. Phase identification measurements were also collected using a Bruker D8 Advanced diffractometer using Cu Kα radiation. EBSD was performed on a Tescan MAIA3 field emission SEM at 20 kV accelerating voltage and with an Oxford HKLNordlys System and Aztec software. Approximately a 0.9 mm by 0.7 mm area was scanned. Results and Discussion. The non-ODS materials showed equiaxed grains and random texture. The ODS materials had elongated grains in the build direction and stronger texture in Fig. 1 — (a) Non-ODS grain texture measured transverse to the build direction (indicated by arrow) by EBSD and XRD, plus inverse pole figure from EBSD. (b) ODS grain texture measured with EBSD and XRD, also transverse to the build direction (indicated by arrow), plus inverse pole figure from EBSD. (a) (b)
ADVANCED MATERIALS & PROCESSES | JANUARY 2026 16 the [001] crystallographic direction. The pole figures generated from EBSD and XRD for both materials are shown in Fig. 1. While there is strong corre- spondence between the two sets of pole figures, slight differences are most likely due to the area sampled. Not only was the collection area different (~1.5 cm2 for XRD and ~1 mm2 for EBSD), but this also meant that the number of grains sampled was greatly different between the two methods. The XRD data area is more representative of the whole sample texture, in contrast to extremely localized texture gathered from EBSD. This finding is supported by the stronger texture hot-spots in the XRD-derived pole figures for the ODS sample in Fig. 1b as compared to the EBSD-derived pole figures, owing to the higher sampling statistics for the XRD data. The phase identification results of these samples revealed that the non-ODS samples consisted of only a single gamma phase while the ODS material had the gamma phase along with the dispersed oxide phase and a chromium carbide phase. The low volume percent of these additional components meant that these phases’ orientations did not appear distinctly in the XRD texture pole figures. These phases would, however, likely have impacted the EBSD pole figures due to their relative concentration in the smaller sample size of the EBSD scan. This accentuates a strength in EBSD data in highlighting minor phases that would not stand out in the bulk acquisitions that contribute to XRD data. The agreement between EBSD and XRD data support that the EBSD data is representative of the bulk and that the XRD data did not miss significant factors either. Conclusion. For this study, XRD was used to identify phases and investigate texture in the ODS and non-ODS AM superalloy samples. EBSD, as well as energy dispersive spectroscopy, was employed to investigate crystal orientation and to identify phases in these samples. Both methods showed random orientation in non-ODS samples, and some significant texture in the ODS samples. This strong agreement serves as self-validation for the two methods. The EBSD data were collected from a much smaller area than the XRD data, but the similar pole figures indicate that the EBSD was representative of the bulk sample and the XRD did not omit any significant phases. Another compelling insight from the comparison of these two methods’ data is that small carbide phases found within the SEM were significant but were in small quantity such that they were not a major factor in the XRD results. If the EBSD had been from an area within the sample exhibiting disproportionate amounts of the carbide phase, it would have had a higher influence on the EBSD pole figures. Having the XRD data from a much larger sample spot helps indicate the trace amount of the carbide phase within the bulk of the material. CASE STUDY 2: PHASE IDENTIFICATION FOR MINERAL SAMPLES Introduction. Understanding the radio frequency (RF) properties of a material is of concern to multiple projects at NASA Glenn Research Center, especially regarding signal propagation across non-Earth landscapes. Rather than spend energy developing a lunar simulant material with suitable mineralogical properties, candidate substitute materials to investigate RF properties of lunar soils were found in Nevada, USA. The Nevada National Security Site (NNSS) is a secure government area northwest of Las Vegas where nuclear arms were tested, thus making it a suspected good geologic analogue to lunar soils, however specific properties of the soil are not publicly available. Two soil samples were gathered from within this locality, one from within the crater of a 1960s nuclear test, and another from a nearby planned but never detonated test site. The task was to determine mineralogy of the soils selected to represent the RF properties of lunar soils. Methods. The samples, as-received, contained rocks and sand-sized particles. To prepare samples for XRD, the sand-sized material was separated by particle size using sieves. Screening resulted in three samples for each of the two sample localities, with particle sizes of < 180 µm, 180-595 µm, and > 595 µm. These samples were then milled with yttria-stabilized zirconium media, suspended in ethanol for five minutes each, and dispersed onto a zero-background silicon holder. The samples were then analyzed in a Bruker D8 Advanced diffractometer, from 5° to 120° 2θ with a step size of 0.02°, and 1 second per step. The instrument’s divergence slit was set to 0.3, used a Cu Kα filament, Bragg-Brentano focusing, and a linear position-sensitive Lynxeye detector. The data were analyzed using MDI Jade and PDF 2024. For EBSD, samples of the sandsized particles along with a few rocks were mounted in epoxy and then metallographically prepared and finished with a vibratory polish using 0.05 µm colloidal silica. The EBSD was collected on an Oxford Symmetry detector on a JEOL IT710 HR SEM using 20 kV and a probe current of 60-75; the maps were collected with a 70.6 ms frame time, with 5 frame averaging, gain of 2, image size of 1244 x 1024 pixels, and at 150× magni- fication. The Phase Identification tool in the Oxford AzTec software was used in conjunction with the American Mineralogist EBSD database. Results and Discussion. The EBSD maps were collected from multiple locations on the samples. The results showed that samples consisted of the following minerals: feldspars like anorthoclase, albite, and anorthite; quartz; muscovite and biotite micas; natrolite; and titanomagnetite. These phases were identified in at least one EBSD map taken throughout the samples. A representative EBSD map is shown in Fig. 2. This map shows multiple phases, with good confidence. Much of the matrix area around the grains showed zero solutions, which can be largely attributed to the data collection step size being larger than the grains within the matrix. There was some mis-indexing when it came to the feldspar grains. These grains had areas identified as anorthite and others as
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