Metal Powder Technology Spring 2025 by Inovar Communications

POWDER METAL

Starmix® Nova

Improves compaction productivity up to 30%

Starmix Nova from Höganäs is designed to meet the demanding requirements of cost-efficient manufacturing for high-performance components. Perfect for producing taller and more complex-shaped parts, it excels in compacting components with narrow sections. Starmix Nova has proven its superiority through rigorous trials by numerous satisfied customers, delivering outstanding results every time.

Main product benefits

Excellent fillability: Achieve optimal material distribution in every mold.

Excellent lubrication: Ensure smooth operations and extend the life of your machinery.

Efficient compaction: Benefit from higher apparent density and faster compaction, leading to more consistent, higher-quality products.

Experience excellence. Experience Starmix Nova.

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Introducing Metal Powder Technology magazine: the new name for PM Review

PM Review’s metamorphosis into Metal Powder Technology serves to reflect the rapidly evolving landscape of metal powder applications. While our name has changed, our commitment remains the same: to be the leading business-to-business magazine covering metal powder production, the expanding range of Powder Metallurgy products, and the broader industrial use of metal powders.

The name Metal Powder Technology, therefore, better represents the shifting global markets for metal powders and aligns with their expanding role in advanced manufacturing across a wide range of applications.

Metal Powder Technology’s broadened coverage now includes non-structural applications of metal powders, such as batteries and energy storage. Our coverage of metal powders used in magnetic and electrical/ electronic applications will also increase as these markets open up to PM component producers.

As we enter a new era shaped by digital manufacturing, Artificial Intelligence, changing global political and industrial landscapes, and an ongoing drive towards sustainability and better resource utilisation, Metal Powder Technology will be at the centre of reporting developments.

Nick Williams Managing Director Metal Powder Technology

Cover image

Rolls-Royce’s Spirit of Innovation aircraft, powered by YASA electric motor technology (Courtesy RollsRoyce plc)

METAL POWDER

51 Soft Magnetic Composites (SMCs) for electric motors: A new era driven by automotive and aviation electrification

The rapid global adoption of Electric Vehicles is taking Powder Metallurgy towards a promising new era in electric motor manufacturing. Soft Magnetic Composites (SMCs) offer an enhanced approach to motor design, reducing energy losses while enabling compact, innovative motor architectures. Beyond Electric Vehicles, the aerospace sector is seeking to leverage these lightweight and efficient PM electric motor technologies for aircraft propulsion systems.

In this article, John Morehead presents the various electric motor types used for vehicles and highlights applications and innovations around SMCs. >>>

61 Keep your powder dry: The overlooked impact of moisture in metal powders

Metal powders underpin many advanced manufacturing processes, yet one oftenoverlooked factor can significantly affect their performance: moisture. Excess moisture reduces flowability, accelerates oxidation, and increases the risk of porosity in finished parts. While standards exist, traditional testing methods rarely offer real-time insight.

In this article, Dr Peter Moir and Dr Martin McMahon examine how moisture interacts with metal powders, the impact on processing, and how emerging measurement techniques can help safeguard powder quality and consistency. >>>

71 PM-HIP: the alternative to casting and forging that improves supply chain flexibility and sustainability

Powder Metallurgy Hot Isostatic Pressing (PM-HIP) is an advanced manufacturing process that enables the production of large, high-integrity components with consistent, forged-like properties. As traditional casting and forging supply chains face growing challenges, PM-HIP offers a reliable alternative with shorter lead times and increased design flexibility.

Here, Amaero’s Eric Bono explains how the process supports resilient, domestic production of critical parts across sectors such as defence, energy, and aerospace, helping manufacturers reduce dependency on constrained supply chains while achieving demanding performance requirements. >>>

81 Producing copper powder from industrial waste: Destiny Copper’s sustainable recovery process

Destiny Copper has developed a patented, chemistry-based process to recover highpurity copper powder from mining and industrial waste streams. Using a zeroenergy, modified cementation process, the company extracts copper without the need for electrowinning or melting, significantly reducing energy use and emissions.

With support from federal and regional innovation programmes, Destiny Copper is now scaling up its operations to meet the growing global copper demand while turning hazardous waste into valuable materials for advanced manufacturing applications.

Here, the company’s Lead Scientist, Dr Josh Clarke, shares insight into the story so far. >>>

87 The 2024 Japan Powder Metallurgy Association Awards: Recognising innovations in PM

This year’s award winners showcase the latest achievements in performance, sustainability, and manufacturing efficiency, highlighting the industry’s ongoing evolution. From Electric Vehicle components to powders for PM and Additive Manufacturing, the awards demonstrate the versatility and potential of PM technologies in meeting the demands of next-generation applications across diverse industries. >>>

Advertisers’ index & buyer’s guide >>>

Our advertisers’ index and buyer’s guide serves as a convenient guide to suppliers across the PM supply chain.

In the digital edition of Metal Powder Technology magazine, available at www.metal-powder.tech, simply click on a company name to view its advert, or on the company’s weblink to go directly to its website.

Industry events >>>

GKN Powder Metallurgy and GKN Automotive set for AAM takeover in $1.44 billion deal

American Axle & Manufacturing (AAM), headquartered in Detroit, Michigan, USA, has agreed terms to acquire Dowlais Group plc, the UK-based parent company of GKN Automotive and GKN Powder Metallurgy. The $1.44 billion deal, consisting of cash and AAM shares, was unanimously agreed by the boards of directors of both Dowlais and AAM. Upon closing of the transaction, it is expected that AAM shareholders will own approximately 51% of the combined group and Dowlais shareholders will own approximately 49%. The combined company will be headquartered in Detroit and led by David C Dauch, AAM’s chairman and CEO.

“This announcement marks another key milestone in our continued longterm strategic growth plan,” stated Dauch. “We are excited to bring together these two outstanding companies to create a leading driveline and metal-forming supplier serving the global automotive industry as it continues to evolve. The combination will create significant immediate and long-term shareholder value while helping to power a more sustainable future. Together with Dowlais, we will have the powertrainagnostic product portfolio, global reach, commitment to innovation and financial strength to meet the needs of customers and succeed in a dynamic market environment.”

GKN Powder Metallurgy and GKN Automotive, together with the rest of the GKN plc, were taken over by Melrose Industries in 2018. In 2023, Melrose announced the demerger of

the GKN Powder Metallurgy, GKN Automotive and GKN Hydrogen businesses, forming the new independent holding company, Dowlais Group plc. GKN Hydrogen was acquired by Langley Holdings in August 2024.

“Today’s announcement marks a significant opportunity to build on the success of Dowlais Group. The combination of the two companies accelerates the execution of our strategy by leveraging our combined scale, resources, capabilities, and outstanding management teams,” added Liam Butterworth, Dowlais’ Chief Executive Officer.

“Our product portfolios and technological expertise are highly complementary, positioning us to better serve our customers and exceed their expectations. This transaction also combines our respective strengths in innovation,

technology, and talent, creating a solid foundation for delivering longterm value to our shareholders.”

GKN Powder Metallurgy employs over 5,000 people across its twentyseven manufacturing facilities in nine countries. The company lists 3,000 customers, ships 250,000 tons of metal powder each year and produces around ten million PM parts each day. Together with GKN Automotive, Dowlais’ businesses comprise over seventy manufacturing facilities in nineteen countries worldwide.

AAM is a Tier 1 automotive supplier that designs, engineers and manufactures driveline and metal forming technologies to support electric, hybrid and internal combustion vehicles. The company has over seventy-five facilities in sixteen countries. With a combined portfolio of products, the new company is expected to be well-positioned to serve a customer base spanning multiple geographies and support changing propulsion trends.

www.gknpm.com www.gknautomotive.com www.aam.com

GKN Powder Metallurgy ships 250,000 tons of metal powder each year and produces around ten million PM parts each day (Courtesy GKN)

Amaero secures $22.8 million loan to boost Additive Manufacturing powder production in the USA

Amaero International Limited, based in McDonald, Tennessee, USA, has executed a credit agreement for a $22.8 million direct loan from the Export-Import Bank of the United States (EXIM). The loan was extended to Amaero Advanced Materials & Manufacturing Inc, a wholly owned US-operating subsidiary of Amaero.

The US federal government credit agency will provide capital equipment financing and will directly fund the loan as part of EXIM’s ‘Make More in America’ (MMIA) initiative.

The financing also falls under EXIM’s China and Transformational Exports Program (CTEP). Amaero’s loan is the sixth MMIA loan to be approved and the first MMIA loan that supports advanced materials and Additive Manufacturing.

As indicated in its August 2024 Investor Presentation, the company expects capital expenditures over a three-year period of FY2024-2026 to total approximately $46.5 million.

The planned capital expense includes approximately $28.5 million for

With the commissioning of its first advanced atomiser and the ordering of a second and third, Amaero is reportedly set to become the largest domestic US manufacturer of refractory and titanium alloy powders (Courtesy Amaero International Limited)

Tekna’s fourth quarter results highlight continued growth in powder business

Tekna Holding ASA, Sherbrooke, Quebec, Canada, has announced its results for the fourth quarter of 2024, reporting growth across nearly all customer segments in its metal powder Advanced Materials business. Despite this growth, the company reported headwinds in its Systems business and posted overall revenue of CA $9.6 million, down 15.4% from Q4 2023.

“Our Plasma Systems product line faced headwinds, with reduced order intake and revenues as some projects in the pipeline have been delayed.

However, our focus on operational efficiency and price management has resulted in sustained contribution margins in 2024 YoY,” said Luc Dionne, CEO of Tekna Holding ASA. Dionne continued, “In Advanced Materials, the industry dynamics remained positive despite challenges stemming from global economic conditions, interest rates, and market fluctuations. In 2024, we have experienced growth across nearly all customer segments, with Medical up 29%, Aerospace up 24%, and Consumer Electronics up 24%.

capital equipment and approximately $18.0 million for facility improvements. The EXIM loan will be drawn against capital equipment purchases.

The $18 million in facility improvements remain on budget and on schedule to be substantially completed by the end of FY2025. The commissioning of Amaero’s second advanced atomiser also remains on budget and on schedule to be completed by the end of FY2025.

With the commissioning of the first advanced atomiser and with ordering the second and third advanced atomisers, Amaero is reportedly positioned to be the largest US domestic manufacturer of C103, refractory, and titanium alloy powders that are essential to Additive Manufacturing of missioncritical components for the space and aerospace sectors. Furthermore, Amaero’s experience in Powder Metallurgy Hot Isostatic Pressing manufacturing of large, complex near-net-shape parts is seen as an immediate solution to supply-chain gaps.

Amaero has provided material to several commercial parties for qualification and is advancing negotiations on several longterm commercial agreements. The company stated that it remains on schedule to transition to commercialisation in FY2026. www.amaeroinc.com

However, sales to 3D printer manufacturers reduced by 40%.”

The company’s adjusted EBITDA for Q4 2024 stood at negative CA $1.4 million (compared to negative CA $0.5 million in Q4 2023), reflecting the challenges in the Systems business. In 2024, cash flow from operations improved by CA $10.4 million compared to 2023, much due to a reduction of net working capital by CA $5.1 million during the year and CA $2.9 million from litigation settlement. This achievement comes despite the negative impact of CA $2.9 million on EBITDA due to a substantial reduction in Plasma systems revenue in the year.

www.tekna.com

Fuel Cell Technology

Manufacturing systems for fuel cell components from granular materials

High-performance uniaxial CNC powder presses up to 20´000 kN force:

Industrial press equipment built to purpose

Energy saving, high dynamic drives

Force or position controlled pressing cycle

Various powder and granulate filling systems for repeatable uniform powder beds

Customized pressing tools, also temperature managed

Handling and robot automation systems

Höganäs and Porite partner for sustainable near-zero sponge iron powder

Porite Taiwan Co, Ltd, Zhunan, Taiwan, and Sweden’s Höganäs AB have announced a strategic partnership in an effort to advance sustainable manufacturing practices. Under the agreement, Höganäs will supply Porite with its newly developed near-zero sponge iron powder, a product designed to achieve minimal carbon emissions during its production and lifecycle. The powder range is planned to gradually replace the standard sponge iron powders currently purchased by Porite from Höganäs.

“We are excited to partner with Porite in this ground-breaking initiative. Our near-zero sponge iron powder represents a significant

step towards sustainable manufacturing, and we are proud to support Porite in their commitment to reducing carbon emissions,” stated Andreas Jähnke, Powder Metallurgy Technologies President, Höganäs.

Höganäs’s process for industrial-scale production of near-zero sponge iron powder is said to significantly reduce its carbon footprint. The near-zero sponge iron powder will meet the same high specifications and stringent quality standards that Porite currently requires, ensuring no compromise in performance or reliability.

“Porite is dedicated to integrating sustainable practices into

USA Rare Earth achieves milestone with its first sintered rare earth magnet production in Oklahoma

USA Rare Earth, LLC, a company building a domestic rare earth magnet supply chain from mine to magnet, based in Tampa, Florida, USA, has announced the successful production of its first batch of sintered permanent rare earth magnets at its new Innovations Lab, currently under development in Stillwater, Oklahoma, USA.

USA Rare Earth’s Innovations Lab, once fully commissioned, will produce prototype rare earth magnets for the company in support of customer sales, product quality management, and the advancement of new innovations in rare earth magnet production.

“I couldn’t be prouder of the work of our incredible team in Stillwater, led by Bob Fredette, one of the leading magnet experts in the United States. Our new Innovations Lab, which we will finish building out in the coming months, is already flexing its muscles, helping us achieve a key step in our company’s evolution,” said

Joshua Ballard, CEO. “We will soon begin producing customer prototypes in support of future sales as we work towards starting commercial production at our manufacturing facility in 2026.”

China currently dominates the global rare earth magnet market, posing a significant vulnerability for US industries and national security. Rare earth magnets are essential for a wide range of applications, including:

• Defence: Missile guidance systems, radar, and other critical military technologies.

• Automotive: Electric vehicles, hybrid vehicles, and advanced driver-assistance systems.

• Renewable Energy: Wind turbines and other clean energy technologies.

• Electronics: Consumer electronics, industrial automation, and medical devices.

From left: Porite’s Leon Huel-Long Lee, Executive Officer of Sales, Marketing, R&D and CL Chu, CEO, with Höganäs’ Andreas Jähnke Division President Powder Metallurgy Technologies and Dean Howard, President NOAM/Market & Sales PMT (Courtesy Höganäs)

our operations. This partnership with Höganäs aligns with our goals of innovation and environmental responsibility. We look forward to the benefits this collaboration will bring,” said CL Chu, General Manager of Porite Taiwan.

www.hoganas.com www.porite.com.tw

USA Rare Earth has announced the successful production of its first batch of sintered permanent rare earth magnets (Courtesy USA Rare Earth, LLC)

The company previously announced that it has entered into a Business Combination Agreement with Inflection Point Acquisition Corp. II and IPXX Merger Sub, LLC, a Delaware limited liability company and a direct wholly owned subsidiary of Inflection Point, on August 21, 2024, which will result in the combined company being a publicly traded company. www.usare.com

EOS aluminium alloy powder now from 100% recycled feedstock

EOS GmbH, headquarted in Krailling, Germany, has announced that one of its most popular metal powders, EOS Aluminium AlSi10Mg, is now produced with 100% recycled feedstock. The company reported that

Demonstration part built on an EOS M 290 using AlSi10Mg (Courtesy EOS)

increasing the recycled content to 100% has resulted in a 77% CO2e reduction from the prior material, and it now achieves an 83% CO2e reduction compared to AlSi10Mg made from 100% virgin raw material.

EOS Aluminium AlSi10Mg was first added to EOS’ Responsible Products portfolio in April 2024 when it began incorporating 30% recycled feedstock, achieving a 25% CO2e reduction. While EOS Aluminium AlSi10Mg now employs 100% recycled feedstock, the resulting material maintains the same properties, characteristics and performance, ensuring existing customers do not need to requalify applications.

“We’re proud to have developed our first EOS metal material made

Gevorkyan announces successful 2024 with revenue up 23%

Gevorkyan a.s., headquartered in Vlkanová, Slovakia, has announced its preliminary financial results for 2024. The company reported an operating profit of €10.62 million (a 20% increase year-on-year). The company also recorded sales of €94.22 million and a statutory EBITDA of €26.05 million (up 23% and 26% from 2023, respectively). Compared to the company’s financial plan, this represents 101% fulfilment of revenue and 93% fulfilment of statutory EBITDA.

The total one-time costs relating to Gevorkyan’s acquisitions for the entire year 2024 reached €2.11 million; these items were thus used to normalise EBITDA and operating profit. Normalised EBITDA reached €28.16 million, slightly exceeding the plan. The normalised EBITDA margin reached 30%. The profit after tax (EAT) was reported at €4.57 million, representing a 22% increase compared to last year.

Despite company expansion, employment numbers dropped as a result of increased automation. Currently, the company covers

100% of its need for technical gases (nitrogen and hydrogen); photovoltaic panels will cover approximately 25% of total energy consumption after their installation is completed. The company has also installed batteries to balance consumption fluctuations, allowing further savings and back-billing to energy suppliers.

with 100% recycled feedstock and to have achieved so much in less than a year. We will continue to explore ways to reduce the carbon footprint of our customers’ applications with every EOS product – from materials and hardware to design optimisation – they all add up to a more responsible end-use product for our customers and the climate,” stated Sophia Heyl, product specialist at EOS.

Björn Hannappel, head of sustainability at EOS, added, “We are continuing our path towards Responsible Manufacturing and expanding our portfolio of Responsible Products stepwise. By minimising waste, reducing the environmental footprint and prioritising eco-friendly materials, organisations can both protect our planet and create a more efficient and resilient business model.”

www.eos.info

The acquisitions also aim to further diversify Gevorkyan’s customer portfolio and provide local technical and commercial support in the Southern Europe region. They will expand Gevorkyan’s capabilities beyond its product development department, tool production and acquisition of new customers and projects.

Updates on Gevorkyan’s European expansion and

acquisition strategy

In a separate announcement, Gevorkyan released updates on its 2024 acquisitions, including the transfer of business from companies acquired in Italy to Slovakia.

The company noted that its previous investments in capacity expansion, automation and digitalisation allowed it to integrate Powder Metallurgy plants in Poland and Sweden. These acquisitions are expected to bring in €12-14 million per year in sales, complementing Gevorkyan’s own organic growth from existing operations without any material impact on its operating margins or increased capex costs.

This strategy also includes new contracts for the aerospace industry and the development of sophisticated components for Additive Manufacturing, where Gevorkyan offers customers high-capacity and fast solutions.

“The integration of the new companies will preserve longstanding client relationships,” stated Artur Gevorkyan, CEO and Gevorkyan Chairman. “After the acquisition, our partners gain access to Gevorkyan’s strong product development, cheaper energy, and become members of a family of a global supplier for the whole world. We are confident that by combining our strengths with local professionals, we will be able to deliver even more value to our customers.”

www.gevorkyan.sk

Metal Powder Works merges with K-TIG, raises AUS $10M following ASX listing

Metal Powder Works, based in Clinton, Pennsylvania, USA, has merged with K-Tig Advanced Welding Systems, Mile End, Adelaide, Australia. The new partnership has successfully raised AUS $10M through the issue of shares and will be listed on the Australian Stock Exchange (ASX) with a market capitalisation of approximately $27.9 million. The two companies will operate under the Metal Powder Works name and retain ownership of their IP.

Co-Founder and Managing Director, John Barnes, stated, “From my previous time in Australia working at the CSIRO, our innovations were deemed a success once they listed on the ASX. The ASX understands minerals and metals better than any market anywhere, so being a

part of the ASX is significant to me personally, and professionally with Metal Powder Works as we progress to disrupt the metal powders market globally.”

“To have received such an overwhelming response to the capital raising was extremely pleasing and drives us further to deliver on the opportunities ahead. We appreciate the support of incoming institutions, high net worth shareholders and of course, the existing K-TIG shareholder base,” Barnes added.

Metal Powder Works has two primary revenue streams, with direct powder sales from in-house production generating approximately 80% of sales income in 2023, and machine sales accounting for roughly 20%.

Metal Powder Works shipped 1,500 kg of powder in 2024, predominantly focusing on its technological

advantage in producing copper, copper-nickel, and bronze alloy powder for the US Defence Industrial Base. The company believes its business model can scale effectively across multiple sectors as demand increases for both powder and machine sales.

Following the successful combination of Metal Powder Works and K-Tig, the company’s primary focus is the production of specialist Additive Manufacturing powders. However, K-TIG’s existing technology and operations will help serve overlapping end customers in sectors including defence, aerospace and nuclear.

Both Metal Powder Works and K-TIG generate revenue, with Metal Powder Works delivering $770,000 (AUS $1.24 million) in the first six months of its financial year (ending December 31) and K-TIG generating AUS $2.2 million in sales revenue in FY24.

www.k-tig.com www.metalpowderworks.com

US DoD awards IperionX up to $47.1M to strengthen US titanium supply chain

IperionX, based in Charlotte, North Carolina, USA, has announced that it has been awarded a contract for up to $47.1 million in funding by the US Department of Defense (DoD) to strengthen the US Defense Industrial Base by accelerating development of a resilient, low-cost, and fully-integrated US mineral-to-metal titanium supply chain.

This strategic partnership represents a combined investment of $70.7 million between IperionX and the DoD to fund a two-phase development programme over a two-

year period. The agreement aims to strengthen US titanium production capabilities, supporting national security and economic resilience.

As part of the initial phase, the DoD has obligated $5 million through the Industrial Base Analysis and Sustainment (IBAS) programme and IperionX will contribute $1 million, to expedite the Titan Critical Minerals Project in Tennessee to ‘shovelready’ status, an important milestone in securing a new domestic source of titanium, rare earths and zircon critical minerals.

Porite India celebrates second phase of facility expansion

Porite India Pvt Ltd, based in Pune, India, has celebrated the official opening of its newest plant, adding 15,000 m 2 to the company’s total manufacturing footprint. The new facility is part of the company’s second phase of expansion and construction.

Established in 2015 as a subsidiary of Japan’s Porite

Group, Porite India completed the construction of its first 25,000 m 2 manufacturing facility in 2017. From then, the company was able to begin commercial operations, supplying Powder Metallurgy parts to a wide range of customers in industries such as automotive, consumer goods, electronics, general industrial products, office

The remaining $42.1 million awarded under the contract is expected to be obligated by the DoD over the duration of the agreement, with the funds to be applied to facilitating vertical integration and increased titanium production capacity at IperionX’s Titanium Manufacturing Campus in Virginia.

IperionX CEO, Anastasios Arima, shared, “This award is a pivotal moment in IperionX’s mission to re-shore the US titanium industry. For too long, American industry has been reliant on foreign-controlled supply chains for this critical high-strength metal. IperionX’s proprietary technologies, combined with the Titan Project, offer a pathway for a resilient end-to-end US titanium supply chain. We are proud to be selected by the DoD as a key partner in strengthening US industrial and defence capabilities.”

Titanium is a critical material for the aerospace, defence, automotive, space, and consumer industries, but its high cost and reliance on foreign supply chains have limited its broader adoption. IperionX’s Hydrogen-Assisted Metallothermic Reduction (HAMR) and Hydrogen Sintering and Phase Transformation (HSPT) technologies are reported to provide a pathway to produce lowcost, high-performance titanium.

This funding from the DoD’s IBAS programme reflects the US government’s focus on securing domestic critical minerals and metals supply chains.

www.iperionx.com

equipment, electric home appliances, aviation technology, and green energy.

Porite India operates a wide range of equipment, including compacting presses in various sizes, advanced CNC hydraulic systems, conventional and high-temperature sintering furnaces, sinter hardening, sizing, machining and other finishing equipment. The facility has an integrated inspection system and a range of analysis instruments.

www.porite.co.in

IperionX has been awarded a contract for up to $47.1 million by the US Department of Defense (DoD) (Courtesy IperionX)

Rolls-Royce recycles RAF Tornado parts into powder for jet engine components

Rolls-Royce has reported its involvement in the ‘Tornado 2 Tempest’ programme, a recycling initiative that is turning old Royal Air Force Tornado components into metal powder. The powder is then used to additively manufacture new parts for the company’s Orpheus small engine concept. Orpheus is part of Europe’s Future Combat Air System (FCAS) project and demonstrates that the technique has the potential to be used for the next-generation Tempest combat air platform – a cornerstone of Rolls-Royce’s Grow Combat strategic initiative.

Many of the UK’s Ministry of Defence’s surplus assets, such as spare or broken components, contain strategic metals, including highquality steel, aluminium and titanium. The Tornado 2 Tempest project team came together to identify whether some of these could be atomised into feedstock for the AM of new parts.

Tornado components containing high-quality titanium, including jet engine compressor blades from a low-pressure air compressor, were cleaned and successfully atomised resulting in an additively manufactured nose cone and compressor blades being created from recycled parts. Working as one team, Rolls-Royce installed the additively manufactured nose cone onto an Orpheus test engine and ran it at test conditions to demonstrate the part’s suitability and safety for future use, with positive results.

The project was led by Defence Equipment and Support’s (DE&S) Defence Recycling & Disposals Team (DRDT) in partnership with the MOD FCAS team, Rolls-Royce and Additive Manufacturing Solutions Limited (AMS) based in Lancaster, UK.

Funded by UK Strategic Command’s Defence Support Organisation in relation to its Circular Economics for

Defence Concept Note, the project shows that turning old parts into new is viable and could bring benefits to the MOD and wider defence sector, increasing the accessibility of strategic metals to the UK defence industry and suppliers.

The team also demonstrated a Digital Product Passport by capturing and recording material allocation and protecting against the use of counterfeit materials.

“Not only can this solution reduce the costs and burden of sourcing critical and high-value metals, but it can also produce components that are lighter, strong and longer lasting than those made through traditional forging techniques, thereby further enhancing the MOD’s overall sustainability and effectiveness,” stated Thomas Powell, DRDT’s Strategic & Submarine Recycling Senior Commercial Manager.

A team of more than eighty people participated in this project, including DRDT’s commercial graduates and Rolls-Royce graduate apprentices, combining current skills and innovative technologies to deliver and maintain future capabilities.

Squadron Leader Rob, FCAS’ Sustainability Requirements Manager stated, “Innovative technology initiatives such as Tornado 2 Tempest could reduce the RAF’s dependence on lengthy and costly supply chains, allowing us to sustain operations for longer, with the associated benefit of reduced emissions and waste.”

“Through the expected lifecycle of the UK’s FCAS, we expect access to critical materials to be challenged, as global supply chains become increasingly disrupted and competitive. In parallel, there is a societal need to make the best use of the raw materials we already have,” Rob added.

The MOD’s Chief of Defence Logistics and Support (CDLS) recently awarded the Tornado 2 Tempest Rolls-Royce a CDLS Commendation in recognition of their commitment and dedication to the delivery and improvements of support to the frontline.

www.rolls-royce.com

Rolls-Royce has been involved in a recycling initiative that has turned old Royal Air Force Tornado components into metal powder used for AM components for the Orpheus engine (Courtesy Rolls-Royce)

Cyclic Materials sees series B funding round for rare earth recycling total $55M

Cyclic Materials, Kingston, Ontario, Canada, has received $2 million from InMotion Ventures, Jaguar Land Rover’s (JLR) investment arm, bringing its total Series B funding round to $55 million. The company intends to use the funds to expand North American and European operations, enhance processing capabilities, and refine its technologies.

“We are thrilled to welcome InMotion Ventures as a key investor, extending our Series B with an additional $2 million,” stated Ahmad Ghahreman, CEO of Cyclic Materials. “Their investment highlights the surging importance of sustainable solutions in the automotive industry. We are honoured to have one of the UK’s most active corporate funds as partners as we deploy our rare earth recycling infrastructure across North America and Europe.”

Rare Earths Elements (REEs) are an essential component in permanent magnets, found in everything from data centres and wind turbines to cell phones, electric vehicles, and power tools. Despite their current significance and the growing global demand, less than 1% of REEs are currently recycled. Cyclic Materials aims to increase this percentage via its proprietary MagCycle and REEPure technologies, which can recycle REEs from a wide range of used products, thus establishing a circular supply chain for recycled Mixed Rare Earths Oxides (rMREOs).

and recycling and, now, rare earth magnets recycling.

“Cyclic Materials is leading the way in creating a sustainable supply chain for rare earth elements and critical materials,” added Mike Smeed, Managing Director at InMotion Ventures. “Their innovative technologies address a vital need

for rare earth magnets recycling, supporting the automotive industry’s transition toward a cleaner and more resilient future.”

This Series B funding is backed by global industry leaders like Microsoft, Hitachi, BMWi and specialised funds ArcTern and Fifth Wall. Together, these investments are said to position Cyclic Materials as a key partner for companies seeking sustainable and circular supply chain solutions. www.cyclicmaterials.earth

www.ultra-infiltrant.com

The fund has invested in a range of technologies across the global value chain, including supply chain traceability, battery repair, re-use

Cyclic Materials extracts REEs from various end-of-life products; above are recycled EV and hybrid vehicle motors (Courtesy Cyclic Materials)

Ahno and Sandvik open new cutting tool factory in Zhuzhou

Suzhou Ahno Precision Cutting Tool Technology Co, Ltd, Suzhou, China, and Sandvik Manufacturing Solutions, headquartered in Stockholm, Sweden, have opened a new cutting tool factory in Zhuzhou, China. This follows on from Sandvik’s acquisition of a majority stake in Ahno from the previous majority owner, Ningbo Baosi Energy Equipment Co, Ltd and related parties.

The new factory is the largest investment project in Ahno’s history, and was estimated to cost around 500 million yuan ($69 million) when first announced. The facility is expected to create

400 jobs and achieve an annual output value of over 1 billion yuan ($138 million) when fully operational.

The opening was attended by over 500 guests, including government officials, representatives of Sandvik, Ahno management and customers.

During the ceremony, Ahno’s founder Dr Ke Yashi stated, “After twentytwo years of development, Ahno has become a comprehensive metal cutting solution provider, among which carbide inserts are a key business. The opening of Ahno Zhushou Insert Industrial Park has laid a solid foundation for our future success.”

Ceratizit to close German plants in Besigheim and Empfingen

The Ceratizit Group, headquartered in Mamer, Luxembourg, has announced plans to close its German manufacturing facilities in Besigheim and Empfingen in 2026. The company stated that the closures are necessary to strengthen its competitiveness in the global cemented carbide market. Production from these facilities will be transferred to other Ceratizit Group locations.

Facing ongoing high costs and challenging market conditions for

the foreseeable future, Ceratizit said it has decided to optimise its international production network. The optimisation measures aim to make greater use of economies of scale, synergies and location advantages while reducing duplicate resources, the company added.

Given its high dependence on the automotive business and the markets in Germany and Europe, the group’s cost-reduction efforts focus particularly on the sites in Besigheim and

China is considered a key growth market for cutting tools, with forecasts indicating yearly growth rates of more than 4% over the coming five years. To succeed in this market, analysts agree that local production and long-term commitment are becoming increasingly important.

Ahno’s main customer industries are general engineering and automotive, of which a significant portion is in electric vehicles. There is also a growing medical segment.

“Ahno’s competitive assortment and closeness to customers is a great platform to drive further growth of our tooling business in China,” said Nadine Crauwels, President of Sandvik Machining Solutions. “Much of the offering is focused on fast-growing segments, which makes Ahno a perfect fit with our strategy.”

www.ahno-tool.com

www.home.sandvik

Empfingen. The group is struggling not only with the prospect of a weak outlook for incoming orders but also with fierce international competition.

Manufacturing capacities for the affected products will be established at other European sites within the group. This, the company stated, will enable Ceratizit to maintain full production capacity and meet all its delivery obligations to customers in the future.

The sites’ managing directors plan to negotiate with employee representatives regarding a social plan and alignment of interests in the near future.

www.ceratizit.com

Ahno and Sandvik celebrated the opening of the new cutting tools factory in Zhuzhou (Courtesy Ahno)

Ahno’s main customer industries are general engineering and automotive (Courtesy Ahno)

Rio Tinto acquires Arcadium Lithium for $6.7B, forms new Li business

Rio Tinto, headquartered in London, UK, has completed the acquisition of Arcadium Lithium plc, Philadelphia, Pennsylvania, USA, for $6.7 billion.

Following the agreement, Arcadium Lithium will become Rio Tinto Lithium and will include the Rincon lithium project.

“Today we are delighted to welcome the employees of Arcadium to Rio Tinto,” stated Rio Tinto Chief Executive Officer Jakob Stausholm.

“Together, we are accelerating our efforts to source, mine and produce minerals needed for the energy transition. By combining Rio Tinto’s scale, financial strength, operational and project development experience with Arcadium’s Tier 1 assets, technical and commercial capabilities, we are creating a world-class lithium business which sits alongside our leading iron ore, aluminium and

copper operations.

“We believe we are well-positioned to deliver the materials needed for the energy transition while maintaining our focus on respecting local communities, minimising environmental impacts and delivering value for shareholders and other stakeholders,” Stausholm added.

Rio Tinto Lithium aims to increase the capacity of its Tier 1 assets to over 200 thousand tonnes per year of lithium carbonate equivalent (LCE) by 2028. The company explained that complementary technologies and geographies offer compelling value driven by accelerating volume growth in a rising market and project significantly higher EBITDA and operating cash flow in the coming years.

Rio Tinto will fund the acquisition by drawing on its existing bridge

Rio Tinto is accelerating efforts to source, mine and produce minerals needed for the energy transition (Courtesy Arcadium)

loan facility, which it plans to replace with long-term debt financing. In connection with the transaction’s completion, Arcadium Lithium’s shares and CHESS Depositary Receipts will be delisted from the New York Stock Exchange (NYSE) and the Australian Securities Exchange (ASX), respectively.

www.riotinto.com

Continuum opens sustainable metal powder production facility in Houston

Continuum Powders hosted the grand opening of its global headquarters and manufacturing facility in Houston, Texas, USA, on December 5. Reported to be North America’s largest sustainable metal powder production facility, the company company offered guests the chance to see the company’s low-carbon production methods firsthand.

The completion of the Houston facility is said to reflect the company’s commitment to environmental responsibility, with the entire building operating as a green manufacturing centre. The site is also pursuing green certification goals and is designed to maximise energy efficiency through renewable energy usage and recycling initiatives.

Continuum also stated that the opening of the new facility marks a significant step forward in delivering sustainable solutions that meet the demands of a rapidly evolving industrial landscape. With increased production capacity and multiple US locations, the company is now positioned to deliver products faster at reduced shipping costs, enhancing supply chain resilience for customers.

“Our new Houston facility not only expands our production capabilities but also allows us to scale our mission of decarbonising the manufacturing industry,” said Rob Higby, CEO of Continuum Powders. “We are committed to providing high-quality, cost-competitive metal powders while minimising environmental impact. Our technology represents a distinct advantage in the market, offering sustainable solutions that align with the needs of forward-thinking industries.”

The facility features Continuum’s proprietary Greyhound M2P (melt-topowder) plasma atomisation process, which enables the repurposing of

alloyed metal waste-stream products into high-quality metal powder in a single step. By enabling a cradleto-cradle process, the platform can reduce the need for transportation, product handling, primary melting, and extensive long bar processing operations, while also minimising the environmental impact by reducing the mining of elemental metal resources.

“Houston represents a leap forward in our operational efficiency and sustainability efforts,” said Rizk Ghafari, COO of Continuum Powders.

“By combining state-of-the-art technology with our commitment to decarbonisation, we are not only supporting our customers’ needs but also setting a new benchmark for responsible manufacturing in the industry.”

www.continuumpowders.com

The ribbon-cutting ceremony featured (left to right) Cory Steffek, Ara Partners, Betty Russo, Texas Economic Development & Tourism Office, Rob Higby, CEO of Continuum Powders, and Rizk Ghafari, COO of Continuum Powders. (Courtesy Continuum Powders)

Ampal expands US aluminium powder production with new powder line scheduled

for mid-2025

United States Metal Powders, Inc (USMP) has announced a new aluminium powder manufacturing line at its Ampal Inc subsidiary based in Palmerton, Pennsylvania, USA. Scheduled to start full production in the summer of 2025, the new line is expected to offer the capability for both nodular and spherical aluminium powder production. USMP, founded in 1918, is a leading provider of aluminium powders with two production

companies, Ampal Inc and Poudres Hermillon, based in La Tour-enMaurienne, France. Ampal, reported to be the largest producer of aluminium powder in North America, moved its production facility from Flemington, New Jersey, USA, to its current site in 1982 and has been operating in Palmerton for the past forty-two years.

The company’s products are sold globally to a wide variety of end markets. These include the

aerospace, defence, chemical, automotive, general industrial, consumer, construction, and energy sectors.

“We are excited to invest in this new capacity in the USA,” stated Eric Degenfelder, President of USMP. “We are committed to the highest level of customer focus and partnership. Our new production line is designed with state-of-the-art technology for safety, productivity and quality. This expansion both supports our growth ambitions and enhances our hallmark certainty of supply through production redundancy.

We are continuing to hire new team members in all functions as we grow the company.”

www.usmetalpowders.com

TekSiC debuts Xforge HT hightemperature induction furnace

TekSiC, based in Linköping, Sweden, has announced its new Xforge HT, a modular high-temperature induction heating furnace. The Xforge HT is designed for applied manufacturing applications such as post-processing of additively manufactured components, sintering, various diffusion treatments, material testing etc.

“The Xforge HT represents the next step in our evolution as a company,” stated Joachim Tollstoy, CEO of TekSiC. “This product is a result of our dedication to innovation, designed with the flexibility to meet the specific needs of processes in high temperatures, low pressures, and introduction of process gases. We engineered it to provide the highest performance in the most demanding environments while offering a modular solution that can be customised to each customer’s unique requirements.”

The Xforge HT is designed for high-temperature performance, reportedly able to stably exceed 2,500°C. Its pressure and gas management system is said to enable the precise regulation of the processing environment, allowing optimal conditions for complex heat treatment applications. The machine’s design is also focused on versatility, enabling the generation of high-vacuum environments while allowing the controlled introduction of multiple gases, including hydrogen. Its advanced control algorithms enable precise thermal management, making it even possible for processing refractory metals such as tungsten, niobium, and tantalum. Throughout its development, Xforge HT underwent industrial reliability testing at customer sites over several years, demonstrating its ability to function during extreme high-temperature applications. Additionally, Xforge HT is CE-marked, certifying compliance with EU health, safety, and environmental standards.

Kyhe Technology launches sustainable titanium alloy powders using innovative DH-S technology

Kyhe Technology (Ningbo) Co Ltd, based in Ningbo, China, is a newly formed company within the titanium alloy sector focused on providing cheaper, more sustainable materials to customers in industries such as aerospace, automotive, consumer electronics, and renewable energy using advanced recycling technologies and proprietary processes.

Kyhe Tech reports that it operates under a framework of sustainability and responsible manufacturing. Its 9,800 m 2 facility has ESG certification, integrating environmental, social, and governance principles into its operations. Additionally, the company is certified under the Global Recycled Standard (GRS).

By sourcing recycled titanium and minimising energy-intensive processes, the company has reported having achieved significant reductions in greenhouse gas emissions and waste generation. Kyhe Tech uses a dehydrogenation spheroidal (DH-S) technology for producing titanium alloy powders. Unlike conventional atomisation methods, the use of recycling and reprocessing titanium materials is said to make DH-S a more cost-effective and sustainable option. The powders produced are suitable for Additive Manufacturing, Metal Injection Moulding, and coating processes. DH-S technology is said to offer advantages that differentiate it from traditional Electron Beam

www.teksic.com

Inert Gas Atomisation (EIGA) methods. By accommodating a wide range of raw materials (e.g. titanium alloy scrap, CNC machining chips, and sponge titanium fragments), the DH-S process reduces dependency on virgin resources and significantly lowers production costs.

The metal powders produced are said to exhibit good mechanical properties – including high tensile strength and fatigue resistance – making them wellsuited to demanding applications in aerospace, automotive, and medical industries. The DH-S process achieves a reported 60% cost reduction compared to EIGA powders, enabling customers to access premium materials at lower prices.

With a single-batch yield rate of approximately 95%, the process minimises material waste while maximising yield. www.kyhe.tech

The new Xforge HT furnace (Courtesy TekSiC)

IperionX acquires breakthrough titanium technologies for sustainable US supply chain

IperionX, based in Charlotte, North Carolina, USA, has announced the successful acquisition of Blacksand Technology LLC’s assets and intellectual property portfolio. The acquisition secures IperionX’s exclu sive commercial rights to the patents and proprietary technologies, including Green Rutile, Alkaline Roasting Hydrolysis, Hydrogen Assisted Metallothermic Reduction and Hydrogen Sintering and Phase Transformation.

These complementary technologies offer significant advantages over the incumbent Kroll titanium produc tion process – with lower energy consumption, lower capex, faster cycle times, higher product yields and the ability to use 100% scrap titanium or upgraded titanium minerals as feedstocks.

IperionX is developing an ‘end-to-end’ American titanium supply chain solution, that spans from the production of US titanium minerals, upgrading these minerals to +99% TiO 2, to the production of highperformance, lower-cost titanium metal forged parts. IperionX’s technologies can produce a large range of high-strength forged titanium alloys, with class-leading sustainability and superior process energy efficiencies when compared to current industry methods.

The technologies provide IperionX with a sustainable competitive advantage and significant value uplift from upgrading raw titanium materials to finished titanium products compared to traditional titanium industry supply chains. IperionX’s proprietary technologies negate the need for titanium metal sponge and ingot, allowing direct manufacturing of higher-value titanium products from the billet stage onwards.

IperionX is now commercialising its technology portfolio at its Titanium Manufacturing Campus in Virginia. In August 2024, it successfully commissioned the new HAMR furnace and delivered the first titanium deoxygenation production run in Virginia. The successful titanium production cycle was a significant milestone in the application of HAMR technology and demonstrates the commercial-scale capabilities of IperionX’s titanium technologies.

Anastasios (Taso) Arima, IperionX CEO said, “The acquisition of the award-winning intellectual property portfolio is an important milestone for IperionX – delivering direct control of the technologies and innovations that underpin our plans to re-shore an end-to-end, lower-cost US titanium supply chain that is critical to America’s economic and national security.”

www.iperionx.com

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EOS expands metal powder range for Oil & Gas and semiconductor industries

EOS GmbH, headquartered in Krailling, Germany, has announced the availability of two more metal powders for use in its Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machines. The company has added EOS Nickel Alloy IN718 API, suited to applications in the Oil & Gas sector, and EOS Nickel NiCP, ideal for use in semiconductor industries.

EOS NickelAlloy IN718 API

This nickel-based material is said to offer high-impact toughness at low temperatures and good corrosion resistance for high-stress oil and gas applications; it has a tensile strength of 878 MPa and 27% elongation when combined with a specific heat treat-

A demonstrator gas injector part made using NiCP on an EOS M 290 (Courtesy EOS)

ment. Meeting the requirements for API 6ACRA standardisation, manufacturers can use IN718 API to additively manufacture components for downhole, injection and fixture, and fastener applications, among others. A leading inflow control technology organisation provided an early test case for IN718 API, producing a flow module component meeting API standardisation and high-strength performance while being subjected to the corrosive environment of oil and gas equipment.

“Additive Manufacturing has previously been out of reach as a solution for demanding downhole applications due to the stringent requirements of the oil and gas industry,” the customer stated. “With the development of EOS NickelAlloy 718 API, we are now able to evaluate industrial 3D printing’s business case for our manufacturing needs, while ensuring all facets of part performance remain unchanged.”

EOS Nickel NiCP

This material provides a tensile strength of 400 MPa and 49% elongation, making it well-suited for applications like gas injectors and corrosion-resistant components within semiconductor capital equipment.

Sandvik celebrates 50 years of Osprey at its South Wales metal powder facility

Sandvik AB, headquartered in Stockholm, Sweden, is celebrating fifty years of manufacturing its Osprey line of products at its Neath, South Wales, UK, facility. From humble beginnings, the unit has evolved to become a leading manufacturer of gas-atomised metal powders and a novel range of controlled expansion (CE) alloys.

“This milestone is a testament to the dedication, hard work, and

innovation of all employees, partners, and customers who have been part of the journey,” stated Andrew Coleman, VP Business unit Additive Manufacturing at Sandvik. “It demonstrates Sandvik’s longterm experience that makes us a trusted partner for customers in areas such as Additive Manufacturing and Metal Injection Moulding (MIM), and across a range of demanding industries.”

Traditionally manufactured applications in the semiconductor equipment industry often include electroless nickel plating to increase corrosion resistance in chemically harsh conditions. Parts manufactured entirely from NiCP are said to require no plating, thus extending component life.

“By additively manufacturing these parts, manufacturers can maximise machine uptime and availability, which in turn increases overall throughput of the wafer fabrication process and benefits the end user’s revenue,” stated Sophia Heyl, EOS Product Specialist. “Eliminating the electroplating process that generates hazardous waste offers a cleaner, more sustainable manufacturing process for the future.”

Dr Ankit Saharan, EOS Director of Metals Technology, added, “EOS Nickel NiCP has already been successfully deployed in production settings, demonstrating its reliability and performance. By making it more broadly available, we continue to strengthen our engagement with the semiconductor industry and our dedication to advancing their applications through innovative materials and processes. We look forward to working with our partners to push the boundaries of what’s possible with NiCP in Additive Manufacturing.”

www.eos.info

Today, the Neath production site is the cornerstone of Sandvik’s metal powder manufacturing capability. The company states that the Osprey range of metal powders is the broadest on the market with over 2,000 different alloys, specialising in fine and mid-fraction sizes.

This scope of its atomising technology also enables Sandvik to manufacture its range of HIPed CE alloys which are suitable for various applications, including those with extreme temperature variations.

www.metalpowder.sandvik

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3D Lab’s ATO Induction Melting System enables single-step alloying

3D Lab sp zoo, based in Warsaw, Poland, recently highlighted the use of its ATO Induction Melting System (IMS) – an optional module intended to enhance the company’s ATO ultrasonic metal atomisers – to design and manufacture metal powders in a single-step process.

By adding the IMS module, materials can be melted at temperatures of up to 1,700°C, enabling advanced material processing and alloy development. The module is also said to be highly effective when atomising materials with low melting points (e.g. copper and aluminium). 3D Lab’s ATO process is also said to prevent element evaporation during atomisation, enabling the stability of the alloy’s chemical composition.

3D Lab’s ATO Induction Melting System allows users to design and manufacture metal powders in a single step (Courtesy 3D Lab)

The crucible configuration allows melting and atomisation of feedstock in various forms, including chips, powders, pellets, and irregularly shaped materials, making it well-suited to material recycling and sustainable manufacturing.

Each crucible has a hole drilled in it that is not closed during the entire process, thus eliminating the possibility of contamination of the material via the plug. The material is then dosed from the crucible onto the atomisation platform using the pressure difference.

The rod version minimises contamination risk by eliminating contact with crucible materials, enabling the production of a

and designed on the ATO Induction Melting System

3D Lab)

AMES achieves zero defects recognition from Ford India

Powder Metallurgy parts maker

AMES, headquartered in Barcelona, Spain, has been recognised by Ford for achieving “Zero QR and Zero Warranty Claims in the Year 2024” for supply to Ford India’s Sanand Engine Plant in Gujarat.

This milestone is said to reflect the company’s commit-

ment to operational excellence, superior quality and customer satisfaction. The team’s continuous focus on improvement has been instrumental in achieving these results, AMES stated.

AMES operates production centres in Spain, Hungary, the USA and China, supported by a worldwide sales and technical support

high-purity powder suitable for demanding applications (e.g. in the medical industry).

Alloying

In addition to processing conventional materials, IMS enables the development of alloys via a singlestep process combining preparation, melting, and atomisation. This technology is said to result in powders with good sphericity and controlled particle size distribution (PSD), allowing users to produce different powder sizes suitable for various Additive Manufacturing technologies and applications.

An example highlighted by 3D Labs is the recent development of high-entropy aluminium using its IMS technology. The process went as follows:

1. Pure aluminium, iron, chromium and niobium were loaded

2. The aforementioned pure elements were melted and fully homogenised via stirring and argon gas

3. Molten metal was poured onto the atomiser via a pressure differential

4. Ultrasonic atomisation converted the molten material into fine powder

When the resultant HE aluminium alloy was analysed via SEM-EDS, the company reported its precise chemical composition, ideal sphericity and narrow particle size distribution, making it well-suited to Additive Manufacturing and other advanced metallurgy technologies.

www.metalatomizer.com

network serving over 1,000 customers across more than sixty countries. The company’s main products include sintered structural steel components, iron-based soft magnetic sintered parts, self-lubricating sintered bearings made from bronze and iron alloys, metallic filters and membranes manufactured from stainless steel and bronze, and porous titanium biomedical implants.

www.ames-sintering.com

SEM of unsieved raw AlFeCrNb metal powder produced

(Courtesy

Pfeiffer Vacuum+Fab Solutions expands production facility in Romania

Busch Group has expanded its production facility for Pfeiffer Vacuum+Fab Solutions in Romania, with the new premises officially inaugurated. The celebration took place at Nervia Industrial Park in Apahida, with Busch Romania also celebrating its 10th anniversary and announcing the establishment of a new company, Composites Busch Romania.

Sami Busch, Co-owner and co-CEO, and the managing directors of the three Romanian Busch Group companies –Andrei Varga of Busch Romania, Pascal Fesneau of Pfeiffer Vacuum+Fab Solutions in Romania, Ahmet Muderris, and Marius Nedelcu of Composites Busch in Romania – cut the ribbon together to inaugurate the new premises.

“By incorporating Pfeiffer Vacuum into the Busch Group, we can now offer our customers in Romania the best solutions for all vacuum technology applications,” explained Andrei Varga, Managing Director of Busch Romania.

Ahmet Muderris, Managing Director of Composites Busch, added, “This new facility paves the way for expanding our market presence in a competitive and qualitative manner.”

Pascal Fesneau, Managing Director of Pfeiffer Vacuum, shared, “We are proud of our skilled team that is eager to achieve the highest quality standards demanded by our customers.”

Christina Belce, the Mayor of the Apahida Municipality, attended the event. All 135 employees of the Busch Group in Romania were also invited.

The modern two-storey building extension at Nervia Industrial Park includes a canteen with a terrace and rest areas for employees. It features a new photovoltaic system which generates 10-15% of the company’s energy supply. The remainder is covered by electricity from renewable energy sources.

Pfeiffer Vacuum+Fab Solutions has been present in Romania since 2010. Busch Romania was founded in 2014. In 2018, the new Pfeiffer facility in the Nervia Industrial Park in Cluj was put into operation. In 2023, Busch and Pfeiffer merged at group level to form the Busch Group. group.pfeiffer-vacuum.com www.buschvacuum.com

• Simple, quick set-up

• High accuracy

• Low scrap rate

• Maximal machine utilization

• Increased productivity Upper punch with Macro Die with Matrix

Lower punch with Macro Core rod

The Busch Group celebrated the inauguration of its new Pfeiffer premises in Romania (Courtesy Busch Group)

Lamborghini Temerario incorporates YASA axial flux electric motors

YASA, a wholly owned subsidiary of Mercedes-Benz, headquartered in Kidlington, Oxfordshire, has announced that its axial flux electric motors, designed and developed at its UK-based R&D facility, will help power the all-new Lamborghini Temerario.

Earlier this year, YASA and Lamborghini officially announced their electric drive partnership, which began with the development of an optimised high-performance e-propulsion system for the Revuelto V12 hybrid hypercar. Building on this foundation, the Temerario is said to represent a leap forward, showcasing the latest technical, design and performance capabilities that YASA’s axial flux technology can deliver.

Graeme Cook, YASA Managing Director, commented, “Our evolving partnership with Lamborghini is a testament to our shared vision for the future of high-performance electric propulsion. The Temerario advances the path that the Revuelto established earlier this year, further exemplifying the pinnacle of our

collaborative efforts and showcasing YASA’s innovative technology.”

The Temerario’s axial flux electric motors will be built at YASA’s production facility near Oxford and have been honed for Lamborghini’s hybrid V8 supercar. The axial flux motors contain stators made from soft magnetic composite (SMC) powders.

Davide Bizzarri, Head of Vehicle Motion at Automobili Lamborghini, added, “At Lamborghini, our pursuit of perfection drives us to integrate the latest advancements in electric propulsion. Partnering with YASA allows us to push the technical and engineering boundaries of what’s possible, delivering unparalleled performance and driving experiences for our customers.”

By fostering a close partnership, YASA and Lamborghini engineering teams were able to design, develop, and optimise the e-propulsion system for the Temerario and its high-revving V8 internal combustion engine. Positioned on its front axle, the Temerario incorporates two YASA axial flux motors, delivering peak

The Temerario incorporates two YASA axial flux motors on its front axle, and one on the rear (Courtesy YASA)

torque of 300 Nm and peak power of 110 kW. Each motor weighs 17.3 kg, has a diameter of 295 mm and is 70 mm thick.

In addition to two front electric motors, the Temerario benefits from a third YASA electric motor on the rear axle, which is intended to ensure exceptional performance and driving dynamics.

Cook added, “Our partnership with Lamborghini shows what’s truly possible when two innovators commit to pushing the boundaries of technology. To have in place a longstanding technical partnership focused on progressing nextgeneration e-propulsion solutions with Lamborghini, one of the world’s foremost brands, is something I personally continue to be incredibly proud of.”

“To see our collaboration flourish so early, first with the development of the e-propulsion system for the Revuelto V12 hybrid hypercar and now the next-generation YASA electric motor design for the Temerario V8, is simply thrilling. But this is just the start of our partnership with Lamborghini – our intent is to continue to push engineering boundaries and challenge design norms,” Cook said.

www.lamborghini.com www.yasa.com

YASA’s axial flux electric motors are incorporated in the all-new Lamborghini Temerario (Courtesy Lamborghini)

Optimize Your Powder Production for Additive Manufacturing

In gas atomization metal powder production, the gas atmosphere impacts particle size and uniformity — so the variables that contribute to your atmosphere system are critical to the final composition of your powder.

Linde helps you control the atomization environment to achieve the best possible powder quality. We offer high-purity argon, nitrogen, and hydrogen to create the ideal conditions, minimize oxidation, and ensure uniform particles. Our technical experts work with you to optimize the composition for your product lines and balance the flows for cost-effective, consistent results.

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CNPC Powder establishes silver powder production line for EV manufacturer

CNPC Powder, headquartered in Vancouver, Canada, with metal powder production based in Fengyang, Anhui, China, reports it has officially launched a proprietary intelligent production line (Ag-AMP) for the manufacturing of ultra-high quality silver powder, designed and customised for a leading manufacturer of new energy vehicles. The line has an annual capacity of 30 metric tons, with products tailored for Additive Manufacturing and other advanced applications. Ag-AMP is also scalable to accommodate growth in the EV market and other advanced industries.

Silver’s unmatched electrical conductivity (6.3x10 7 S/m) makes it ideal for high-frequency and precision electronic components. Its low-temperature processability prevents thermal damage to substrates, giving it unique advantages in Cold Spray and Binder Jetting Additive Manufacturing technologies.

In Additive Manufacturing, silver powder demonstrates potential in the electronics, new energy and medical sectors, enabling applications such as conductive circuits, 5G/6G radio frequency devices, biosensors and Cold Spray coatings. This technology is said to excel in creating

complex porous or lattice structures to improve thermal management and minimise material waste, a key advantage for cost-sensitive precious metal applications.

CNPC Powder’s innovative production line delivers premium silver powder with:

Ultra-high purity (Ag >99.99%)

Superior sphericity (>92%)

High apparent and tap density

Minimal satellite particles and hollow powder

• Customisable particle sizes: 0-25 μm, 15-45 μm, 45-150 μm

The fully automated Ag-AMP line integrates quality control systems.

CNPC Powder notes the following key technological advantages as driving industrial improvements: Digital management: MES system enables full-process traceability from raw materials to finished products

• Purity assurance: 100,000-class cleanroom guarantees impurityfree production

• Precision grading: Airflow classification technology achieves particle size distribution CV<15%

• Customisation: Supports tailored specifications across 0-150 μm particle ranges

2025 edition of MPIF Standard Test Methods now available

The Metal Powder Industries Federation (MPIF) has released the 2025 edition of ‘Standard Test Methods’. This new volume contains fifty-two standards covering terminology and recommended methods of testing for metal powders, Powder Metallurgy and Metal Injection Moulding, PM equipment, and metal Additive Manufacturing.

The 2025 edition includes many revised standards and updated figures, as well as the following four new standards:

Standard 76 Determination of Ejection Stresses for Uniaxially Compacted Powder Metallurgy (PM) Test Specimens

Standard 77 Test Method for Preparing and Evaluating Un-notched Charpy Impact Energy Specimens of Materials Produced from Metal Powders by Sinter-Based Metal Additive Manufacturing (Metal AM) Technologies

Standard 78 Test Method for Preparing and Evaluating V-Notched

CNPC Powder has established a production line for the manufacturing silver powder for a leading EV manufacturer (Courtesy CNPC)

Ag-AMP incorporates a number of eco-friendly innovations, such as a closed-loop water cooling system that has a 30% reduction in energy consumption. CNPC Powder’s full life-cycle silver management system achieves a material recovery rate of over 99%, which significantly reduces customers’ precious metal costs.

CNPC Powder offers a comprehensive portfolio spanning materials based on aluminium, titanium, iron, nickel, copper and precious metals. These products meet a variety of advanced manufacturing needs in AM, MIM and cutting-edge technologies. Looking ahead, the company said it intends to sustainably drive innovation in high-end materials, offering customised solutions to accelerate technological progress and industrial transformation around the world.

www.cnpcpowder.com

Charpy Impact Energy Specimens of Materials Produced from Metal Powders by Fusion-Based Metal Additive Manufacturing (Metal AM) Technologies

Standard 79 Test Method for Preparation of AC and DC SoftMagnetic Powder Metallurgy (PM) Test Specimens

The most current versions of all included standards are required by quality assurance programmes in order to maintain full compliance. All earlier editions of ‘Standard Test Methods’ are now obsolete. www.mpif.org

Elementum 3D brings NASA’s GRX-810 high-temperature superalloy to commercial availability

Elementum 3D, based in Thornton, Colorado, USA, has announced the commercial release of GRX-810, an additively manufacturable nickel cobalt chromium oxide dispersion strengthened (ODS) superalloy. First developed by Dr Tim Smith and team at NASA Glenn Research Center, the metal powder is now commercially available from Elementum 3D through a co-exclusive licencing agreement.

Elementum 3D shipped the first commercially produced GRX-810 to a customer in October and has the capacity in place to produce 1.5 tons per week.

“I’m proud of how the Elementum 3D team rallied to quickly bring NASA’s GRX-810 alloy to market. Development of a qualified manufacturing process to mass produce GRX-810 in six months is a testament to our ability to turn

Typical performance data from NASA and Elementum 3D for Laser Beam Powder Bed Fusion manufactured GRX-810. As can be seen, the material offers superior high temperature creep and oxidation resistance compared to other available AM superalloys (Courtesy Elementum 3D)

EPMA’s 2025 Powder Metallurgy Thesis Competition opens for EU university

graduates

The European Powder Metallurgy Association (EPMA) has announced its 2025 Powder Metallurgy Thesis Competition is now open. The EPMA has been organising its thesis competition since 1994, with the aim of helping promote Powder Metallurgy research among European academics at both Masters and Doctorate levels.

The competition is open to all graduates of European universities whose theses have been officially accepted or approved by their respective institutions within the past three years. An international panel of project management experts from academia and industry will evaluate the submissions.

concepts into reality,” said Dr Jacob Nuechterlein, Elementum 3D CEO and founder.

This achievement is welcoming news for engineers eager to take advantage of the exceptional material properties offered by GRX-810, combined with the design complexity enabled by Additive Manufacturing. Potential breakthroughs include lighter and thinner engine parts, increased fuel efficiency, lower operating costs, increased durability, and higher operating temperature capability. Manufacturers in aerospace, space, and energy are particularly interested in this high-temperature superalloy material.

GRX-810 is designed to offer excellent mechanical strength and exceptional creep performance at high temperatures. As Elementum 3D explains, creep life is the duration a material can withstand continuous stress at high temperatures without failure. Enhanced creep performance can directly lead to longer part life and higher operating temperature and load capability.

GRX-810 is reported to result in 1,000-fold better creep resistance with a two-fold increase in strength and oxidation resistance, compared to other additively manufactured superalloys.

www.elementum3d.com

The competition has two categories, with the winner of the Diploma/Masters category receiving a cash prize of €500. The winner of the Doctorate/PhD Category will receive €1,000. Both will receive complimentary registration to the Euro PM2025 Congress and Exhibition and have the opportunity to give a three-minute presentation of the winning thesis during the opening plenary session.

The application deadline is April 23, 2025.

www.thesiscompetition.epma.com www.epma.com

Critical Metals announces $22.5M PIPE financing round to support rare earth and lithium mining

Mining development company

Critical Metals Corp, headquartered in New York, USA, has entered into a securities purchase agreement for a private investment in public equity (PIPE) financing that is expected to result in gross proceeds of approximately $22.5 million. The company plans to use the funds raised to continue supporting development across its pre-production rare earth and lithium mining projects.

“Critical Metals Corp has accomplished another key milestone by securing additional funding to support the continued execution of our vision to become a leading supplier of critical minerals to the West,” said Tony Sage, CEO and

chairman of Critical Metals. “Funds raised through the PIPE will support our efforts in developing both Tanbreez – a game-changing rare earth asset in Greenland –and our Wolfsberg Lithium Project, the first fully permitted lithium mine in Europe.”

Under the terms of the securities purchase agreement, the company is issuing an aggregate of approximately 4.5 million ordinary shares (PIPE Shares) at an Offer Price of $5.00 per share and warrants to purchase ordinary shares (PIPE Warrants) equal to 100% of the aggregate PIPE Shares, at a strike price of $7.00, each warrant with an expiry date of four years from issue. The shares

Critical Metals Corp focuses on advancing and acquiring high-potential projects with an emphasis on securing essential minerals for the expanding US and European markets (Courtesy Critical Metals Corp)

sold in the private placement are subject to resale registration rights.

“We look forward to welcoming the support of our new investors with deep experience in the metals and mining arena, and delivering long-term value to all of our shareholders,” Sage concluded.

www.criticalmetalscorp.com

Goodfellow targets £30m sales through global expansion and acquisitions in 2025

Goodfellow, a specialist metals and materials supplier based in Huntingdon, UK, has shared that international expansion and accelerating the acquisition trail will be key priorities for the company in 2025.

Goodfellow, which employs 140 people across its HQ in Huntingdon and sites in Europe, Asia and the US, has set its sights on increasing group sales to more than £30 million through a combination of new materials ranges, organic growth and targeting potential companies that add new capabilities, additional products or geographic reach.

CEO Simon Kenney believes that last year’s investment in an ERP system and the launch of a new website will be key to achieving these aims, not to mention tapping into significant demand from customers in the medical device, battery development, space exploration, and electrification and fusion technology industries globally.

He also outlined his firm’s ability to provide 98% of materials in 48 hours as a major differential and something he wants to build on.

“2024 was all about laying the foundations for growth this year, from enhancing operational performance and the customer journey through our digital transformation

project to the strategic purchase of Potomac Photonics,” Kenney explained.

“The latter represents our first US manufacturing facility and gives us microfabrication capabilities that we didn’t previously have and is the type of deal we want to do more of over the next twelve months,” he continued.

“The UK market has been challenging this year, not just for us but for other businesses in our area of expertise. International sales are where we see the big opportunity, with customers now present in more than sixty different countries.”

“For example, a new distribution agreement with MicroPlanet in 2024 is projected to boost turnover in the Iberian market by 50% alone,” Kenney shared.

Goodfellow, which received an investment from Battery Ventures in 2021, supplies a comprehensive range of metals, alloys, ceramics, polymers, compounds, and composites.

The company has built a reputation as a trusted supplier to firms involved in R&D, advanced engineering, space and the scientific sector, with subsidiaries across Europe, North America and China helping it extend its global reach.

From its HQ in Cambridge, the material specialist also provides a

Switzerland’s Schmelzmetall acquired by AMPCO Metal

Schmelzmetall Group, Gurtnellen, Switzerland, has been acquired by AMPCO Metal, a copper alloy manufacturer based in Marly, Switzerland.

Schmelzmetall offers a range of metal powders suitable for Additive Manufacturing and Metal Injection Moulding under its HOVADUR brand. The acquisition will see Schmelzmetall add AMPCO’s copper-based alloys to its own copper-based alloy portfolio.

In combining a wider international presence with its regional base, the company anticipates faster service, tailored support, and expanded access to its full product range worldwide. Through the integration of technical resources, Schmelzmetall will also be able to expand its production capabilities to include various casting technologies. www.schmelzmetall.com www.ampcometal.com

Goodfellow CEO Simon Kenney (Courtesy Goodfellow)

range of post-processing facilities, including rolling, electroplating, sputtering, heat treatment, disk punching/ turning and guillotining/sawing.

“We have seen increased demand for specialist metals and materials to support global R&D projects,” Kenney added. “Our ongoing investment in stockholding allows us to meet this requirement and there has been a definite shift towards needing materials quickly for prototype work, which is where our ‘no minimum’ order quantity really comes into its own.”

“Another important development in 2024 was increasing our 170,000strong product range even further with the addition of three new ranges, including custom alloy powders and high entropy alloy powders, metal microfoils and rare earth metal oxides,” Kenney continued. “The intention is to introduce a new collection of premium materials early into 2025.”

www.goodfellow.com

Schmelzmetall offers a range of metal powders suitable for Additive Manufacturing and Metal Injection Moulding under its HOVADUR brand (Courtesy Schmelzmetall Group)

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José Manuel Torralba appointed full member of Spanish Royal Academy of Engineering

Professor José Manuel Torralba, Director of the IMDEA Materials Institute and professor at the Carlos III University of Madrid (UC3M), has been elected as a new full member of the Royal Academy of Engineering of Spain (RAI). This appointment recognises Torralba’s career and contributions to the field of Powder Metallurgy.

A key area of Prof Torralba’s research has focused on developing and characterising metal powders and advanced consolidation methods such as Metal Injection Moulding, Additive Manufacturing and electric-fieldassisted sintering. His research has covered a range of materials, including low-alloy and stainless steels; super-, light and high-entropy alloys; and metal matrix composites. He has over 500 scientific publications and has supervised thirty doctoral theses.

“Powder Metallurgy is a key discipline for the development of more sustainable and efficient technologies,” Torralba stated. “I hope that this recognition will help to further highlight its importance in the development of new materials and in the technological challenges of the future.”

“Being elected a full member of the Royal Academy of Engineering is a personal and professional honour. It is always gratifying to know that the work of a lifetime is recognised by such a prestigious institution,” Torralba added. “It is also a recognition of the effort and dedication of all my colleagues at IMDEA Materials, UC3M and all the institutions with which I have had the opportunity to collaborate. Without them, many of the advances we have achieved would not have been possible.”

Throughout his career, Prof Torralba has held various important positions in both the academic and administrative fields, including Vice-Rector for Research and Innovation at UC3M and Director General of Universities and Research of the Community of Madrid; he currently leads the IMDEA Materials’ Sustainable Powder Technology research group. He has a doctorate in Metallurgy from the Polytechnic University of Madrid (UPM) and one in Armament from the Higher Polytechnic School of the Army.

“I hope to be able to represent at the Academy the sensibilities linked

MPIF announces 2025 Distinguished Service Award recipients

The Metal Powder Industries Federation (MPIF) Awards Committee has announced the recipients of the 2025 MPIF Distinguished Service to Powder Metallurgy (PM) Award.

The Distinguished Service to Powder Metallurgy Award was created to recognise individuals who devote the major part of their working careers to one or more segments of the field of Powder Metallurgy. This award recognises individuals who have actively served the North American PM industry for a minimum of twenty-five years and

deserve special recognition in the minds of their peers.

The 2025 Award Recipients are:

• Wiley Abner, formerly MPP

• Sundar Atre, University of Louisville

• John Blauser, Gasbarre Precision Tooling

• Roy Christensen, VALIMET, Inc

• Wayne K Daye, Kymera International

• Gregory (Jerry) Falleur, PMTII, AAM-Metal Forming

Professor José Manuel Torralba has been elected as a new full member of the Royal Academy of Engineering of Spain (Courtesy IMDEA Materials/Professor José Manuel Torralba)

to my two profiles as an engineer (Mining-Metallurgical and Armament) as well as my professional profile linked to Materials Science and Engineering,” he added.

Prof Torralba has also received numerous awards, including the FEMS Gold Metal (2021) and fellowships from both the European Metallurgy Association (EPMA) in 2018 and the American Powder Metallurgy Institute in 2015. In 2007, he received Honorary Doctorates from Romanian institutions the University of Craiova and, in 2001, from the Technical University of Cluj-Napoca.

www.euro-case.org www.materials.imdea.org

• Jason Gabler, PMT, Advantage Metal Powders, Inc

Jane LaGoy, Bodycote

• Ray Serafini, PMT, Messer North America

Mike Stawovy, Elmet Technologies

• Mark Thomason, PMT, Gasbarre Products, Inc

• Trevor Towns, PMT, Höganäs

The awards ceremony will take place during the PowderMet2025 International Conference on Powder Metallurgy & Particulate Materials, June 15-18, Phoenix, Arizona, USA. www.mpif.org

Blykalla and Höganäs partner to develop advanced materials for small modular nuclear reactors

Sweden’s Blykalla and Höganäs AB have announced a strategic partnership to develop specialised materials and manufacturing processes for Blykalla’s small modular reactor (SMR), called the Swedish Advanced Lead-cooled Reactor (SEALER). The partnership spans three key areas: industrialisation, qualification, and commercialisation. It focuses specifically on the industrial production of advanced corrosion-resistant materials needed to ensure the performance and durability of metal components in liquid lead environments.

Höganäs will leverage its expertise in advanced metal powder technologies to develop and produce corrosion-resistant alloys for cladding critical SEALER components,

in particular tubular products. These efforts will involve optimising laboratory-tested alloys for intended powder application processes, scaling them to industrial production, and meeting the stringent performance and safety standards required for liquid lead environments.

“This collaboration with Höganäs is an essential step in securing a strong and resilient value chain for SEALER technology,” said Jacob Stedman, CEO of Blykalla. “With their leading expertise in material development and manufacturing, and their process know-how of metal powder applications, we have found a world-class partner in our alloy development.”

Blykalla and Höganäs will also work together to ensure the scalability and qualification of these

materials for SMR deployment. The collaboration highlights the importance of building a reliable supply chain for advanced reactor technologies while driving broader innovation in clean energy.

“By combining our materials expertise with Blykalla’s innovative reactor technology, we are taking important steps toward making advanced SMRs a reality,” Hans Keller, Division President Coating & Brazing Technologies, Höganäs, stated. “Industrialising these solutions has the potential to unlock opportunities across multiple sectors, driving both sustainable growth and long-term prosperity.”

This partnership is one of the strategic collaborations intended to drive the advancement of the SEALER. It positions both companies as key contributors to next-generation clean energy systems in Europe and beyond.

www.blykalla.com

www.hoganas.com

Sandvik acquires Verisurf to enhance metrology solutions

Sandvik AB, headquartered in Stockholm, Sweden, has signed an agreement to acquire metrology software solutions provider Verisurf Software, Inc, Anaheim, California, USA, for an undisclosed purchase price.

This acquisition is intended to complement and enhance Sandvik’s position in industrial metrology and strengthen the combined digital manufacturing offering to small and mid-sized manufacturers (SMEs). The company will be reported as a separate business unit within Sandvik Manufacturing and Machining Solutions.

Verisurf is principally active in the North American market. The company serves a customer base of around 1,500 companies – SMEs as well as larger customers – with exposure in segments such as aerospace and defence. Verisurf offers modular-based software solutions for quality inspection, assembly guidance, and reverse engineering built on the Mastercam Design (CAD) platform.

Stellantis and CATL partner on €4.1B LFP battery plant in Spain

Stellantis and CATL, a Chinese battery manufacturer based in Fujian, have reached an agreement to invest up to €4.1 billion in a joint venture to build a large-scale lithium iron phosphate (LFP) battery plant in Zaragoza, Spain. The battery plant, designed to be carbon neutral, will be implemented in several phases and investment stages.

Production is targeted to begin by the end of 2026 at Stellantis’ Zaragoza, Spain, site. The facility could reach up to 50 GWh capacity, depending on Europe’s electrical market evolution and continued support from Spanish and EU authorities. Through this 50-50 joint venture, CATL and Stellantis will enhance Stellantis’ leading LFP offerings in Europe. This will enable the automaker to offer more high-quality, durable and affordable battery-electric passenger cars, crossovers and SUVs in the B and C segments with intermediate ranges.

In November 2023, Stellantis and CATL signed a non-binding MoU for the local supply of LFP battery cells and modules for electric vehicle production in Europe and established a long-term collaboration on two strategic fronts: creating a bold technology roadmap to support Stellantis’ advanced Battery Electric Vehicles (BEV) and identifying opportunities to further strengthen the battery value chain.

Stellantis Chairman John Elkann, shared, “Stellantis is committed to a decarbonised future, embracing all available advanced battery technologies to bring competitive electric vehicle products to our customers. This important joint venture with our partner CATL will bring innovative battery production to a manufacturing site that is already a leader in clean and renewable energy, helping drive a 360-degree sustainable approach. I want to thank all stakeholders involved in making today’s

“Verisurf will strengthen our metrology offering and ability to support the growing customer demand for precision measurement and quality assurance in manufacturing. The acquisition fits very well with our strategy to grow in digital manufacturing and provide comprehensive solutions for our customers to drive efficiency and productivity,” said Stefan Widing, president and CEO of Sandvik.

In 2024, Verisurf had revenues of approximately SEK 130 million ($12 million). The impact on Sandvik’s EBITDA margin and earnings per share is expected to be limited. The companies have agreed not to disclose the purchase price. The transaction is expected to close during the second quarter of 2025, subject to customary regulatory approvals. www.home.sandvik www.verisurf.com

announcement a reality, including the Spanish authorities for their continued support.”

CATL is working to bring stateof-the-art battery manufacturing technology to Europe through its two plants in Germany and Hungary, which are already operational. The Spanish facility will enhance its capabilities to support customers’ climate goals, further underscoring its commitment to advancing e-mobility and energy transition efforts in Europe and the global market.

Stellantis is employing a dualchemistry approach – lithium-ion nickel manganese cobalt (NMC) and lithium iron phosphate (LFP) – to serve all customers and is exploring innovative battery cell and pack technologies. Stellantis is on track to becoming a carbon net zero corporation by 2038, all scopes included, with single-digit percentage compensation of remaining emissions.

The transaction is expected to close in the course of 2025 and is subject to customary regulatory conditions. www.catl.com www.stellantis.com

Verisurf is to be acquired by Sandvik AB (Courtesy Verisurf Software, Inc)

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Globus introduces high-strength Alloy-X metal powder

Globus Metal Powders Ltd, based in Middlesbrough, UK, has introduced its Alloy-X metal powder, a nickel powder composed of alloying elements including molybdenum and tungsten, said to provide superior strength and durability compared to traditional materials. Its ability to maintain structural integrity under high heat makes it useful in sectors such as aerospace and automotive.

The alloy’s combination of molybdenum and tungsten provides a barrier against various forms of corrosion, including oxidation and sulfidation, stated Globus. This also makes Alloy-X suitable for use in chemical processing, marine environments and other corrosive settings.

In the aerospace sector, Globus expects to see increased adoption of Alloy-X for components like turbine blades and structural parts subjected to high temperatures and mechanical stress. The alloy’s lightweight nature also contributes to fuel efficiency, a critical factor in modern aerospace engineering.

Alloy-X is also ideal for manufacturing high-performance components (e.g. exhaust systems, turbochargers and other engine

components) in the automotive industry. The material meets demanding requirements for components that must withstand high temperatures while maintaining superior performance.

In the energy sector – and the Oil & Gas industry, in particular –Alloy-X is well-suited for drilling equipment and components exposed to harsh conditions, the company added. Its resistance to corrosion and wear enables components to remain functional and safe over extended periods.

Globus also highlighted AlloyX’s weight-to-strength ratio and longevity in comparison to traditional materials.

Costs

While the initial cost of Alloy-X metal powder may be higher than traditional materials, Globus stated, the long-term savings outweigh the upfront cost. This saving is realised through the longer service life of components made by Alloy-X, reducing the frequency of replacements and repairs, thus reducing costs associated with downtime, maintenance and labour.

Alloy-X can also enable cost savings through increased effi -

GRIPM Powder Materials copper powder manufacturing facility in Thailand now operational

Makin Metal Powders, a subsidiary of China’s GRIPM Group based in Rochdale, UK, has announced that the group’s new metal powder production facility, located in Thailand, is now operational. The GRIPM Powder Materials plant, located in Chonburi Province, is ISO 9001 certified and dispatched its first orders in July 2024.

The facility has the capacity to produce 5,000 tons per year of

electrolytic copper powder (ECP) and offers a full range, including light, medium, and heavy grades. ECP (sometimes referred to as dendritic) grades are manufactured by an electrolysis process followed by further processing to the final specification.

Typical ECP applications include additives to iron powder, improving properties of sintered parts (especially for thin walled parts, where

ciency (i.e. a component can be made lighter with Alloy-X, increasing fuel efficiency in the aerospace sector) and the ability to rely on fewer materials to achieve the same or better performances.

The future of Alloy-X

One area of research that has shown much potential is the optimisation of manufacturing processes integrated with Additive Manufacturing technology. Globus anticipates that the combination of this technology with Alloy-X will result in new opportunities for applications across a variety of industries.

Alloy-X is also being researched to help engineers better understand its behaviour in different environmental conditions, especially extreme ones. This area of research is intended to aid in the development of new applications and refine existing processes.

Globus intends the future of Alloy-X metal powder to be in sustainability. Researchers are exploring ways to enhance the recyclability of the material and reduce the environmental footprint of its production. By focusing on sustainable development, Globus hopes to position Alloy-X as a material of choice for industries that prioritise ecological responsibility alongside performance.

www.globusmetalpowders.com

The new GRIPM Powder Materials facility in Thailand is ISO 9001 certified (Courtesy Makin Metal Powders)

high green strength is required) and friction components, as well as decorative and architectural finishes, welding and brazing, diamond tooling, electrical contacts and more.

www.gripm.com www.makin-metals.com

● GAS AND ULTRASONIC ATOMIZERS FOR SPHERICAL POWDERS WITHOUT ANY SATELLITES for LPBF, MIM, Binder Jetting and other Additive Manufacturing applications. High purity, sphericity and wide range of reproducible particle size distribution.

● WATER ATOMIZERS FOR MORE IRREGULAR POWDERS ideal for recycling/refining process, press & sinter process and others.

● AIR CLASSIFIERS FOR THE PRECISE SEPARATION OF METAL POWDERS into fine and coarse powder fractions especially in the range < 25 µm

BMW i Ventures invests in Phoenix Tailings to scale US rare earth metal production

BMW i Ventures, Mountain View, California, USA, has announced an investment in Phoenix Tailings, a metals production company based in Woburn, Massachusetts, USA. The Series B financing, which was led by Envisioning Partners and included additional participation from Yamaha Motor Ventures and Escape Velocity, will enable Phoenix Tailings to scale its rare earth processing operations to produce ~200 tons of rare earth metals annually.

“Phoenix Tailings has made a breakthrough that will significantly advance the sustainable refining of rare earth elements – a crucial step forward as many clean energy technologies depend on these

critical materials,” said Kasper Sage, Managing Partner, BMW i Ventures.

“We’re excited to see how this innovation will reshape global supply chains and contribute to a more sustainable future.”

Phoenix Tailings is focused on refining rare earth metals into the final products essential for magnets used in various components. Through its innovative process, Phoenix Tailings extracts rare earth metals from both traditional ores and non-traditional feedstocks such as recycled materials and mining waste – known as “tailings” – without producing toxic byproducts. This approach allows the company to be cost-competitive with traditional

Remembering Peter Brewin – Powder Metallurgy pioneer and expert

It is with great sadness that we announce the death of Peter Brewin, former Technical Director and colleague at the European Powder Metallurgy Association (EPMA), on December 5, 2024. Peter, who celebrated his 80th birthday in September last year, died peacefully at his home in Kent, after suffering from Motor Neuron Disease for over two years.

Peter obtained his degree in mechanical engineering at Cambridge University and spent the first six years of his career in the chemical industry. He then embarked on a career in Powder Metallurgy and, in 1972, was invited by Imperial College London to develop technology using the water atomisation and vacuum reduction process to produce high alloy steel powders.

This research resulted in the establishment of a new company called Powdrex Ltd, and he became Managing Director in 1973. A major application for the high alloy powders

produced was in sintered automotive valve seats, as well as other applications. In 1987, following the acquisition of Powdrex by Wilshaw plc, Peter also joined the board of SG Magnets. He was given the Institute of Metals Stokowiecz Prize in 1988 for his work on high alloy steel powders. In 1995, he left Powdrex to start his own consultancy.

Throughout his career, Peter was involved in supporting the development of the PM industry and in 1986 became President of the British Powder Metal Federation. Peter was very much in favour of the initiative created by Dr Ivor Jenkins at the Institute of Metals to establish a trade association at a European level to represent the PM industry. In 1989, Peter, together with Lothar AlbanoMüller, Per Lindskog, Andre Matre, and Bernard Williams, worked to establish the EPMA.

In 2001 he was appointed the EPMA’s first Technical Director, which included responsibility for numerous

processes currently dominated by China and Russia. By delivering a sustainable and secure supply of rare earth metals, Phoenix Tailings is working to strengthen the US supply chain for defence manufacturing and meet the growing demand for these essential materials in commercial industries.

“As our reliance on advanced technology grows, so does our dependence on critical metals— particularly lesser-known materials like rare earth metals,” said Nick Myers, co-founder and CEO of Phoenix Tailings. “From automotive and defence to medical devices, rare earth metals are essential to modern manufacturing. At Phoenix Tailings, we are ensuring the United States can meet this surging demand through processes that are ethical, sustainable, and economically viable.”

www.bmwiventures.com www.phoenixtailings.com

collaborative research projects, sectoral working groups, PM summer schools and technical aspects of the association’s services. Prior to this role, he had been actively involved in the EPMA as coordinator for EU-funded Thematic Networks from 1997-2004. Peter retired as Technical Director of the EPMA in 2007.

In recognition of his many significant scientific and industrial contributions, he was awarded the prestigious Ivor Jenkins Medal by the IOM3 in 2009. In 2010 the EPMA presented Peter with its Distinguished Service Award.

Peter will be sadly missed by the many who knew him.

Peter Brewin, who died in December 2024 (Courtesy Caroline Brewin)

Kymera International acquires German thermal spray specialist Coating Center Castrop

Kymera International, a specialty materials company based in Raleigh, North Carolina, USA, has acquired Coating Center Castrop GmbH (CCC), a thermal spray and precision machining specialist. CCC provides comprehensive design, fabrication and finish machining solutions for the aerospace, marine propulsion, pharmaceutical and general industrial markets. Located in Castrop-Rauxel, Germany, CCC offers its European customers advanced engineering and thermal spray services that protect high-value components from extreme wear.

This strategic acquisition is reported to strengthen Kymera’s position in the thermal spray services market, bringing significant

benefits to both companies through the expansion of technological capabilities and a broadened global footprint that now includes the US, Canada and Germany. The addition of CCC brings advanced component engineering, fabrication and CNC machining capabilities to Kymera’s Surface Technologies business and a European HaloJet ID HVOF service centre, enabling localised aerospace landing gear service to key customers in the region.

“Kymera’s Surface Technologies business is differentiated by our ability to provide high-performing, comprehensive and customised thermal spray solutions with superior service and support,” said Barton White, CEO of Kymera International.

“The acquisition of CCC further solidifies our ability to provide regional service on a global scale and support our strategic growth initiatives in the aerospace industry with our HaloJet ID HVOF™ technology.”

“The acquisition of CCC helps to accelerate the trajectory of Kymera’s Surface Technologies business,” added Adam Shebitz, Partner and Head of Industrials at Palladium Equity Partners. “We expect its ideally located German footprint will unlock future growth within the European aerospace sector, enabling the expansion of Kymera’s HaloJet technology.”

“We are happy to have found a partner in Kymera who will continue on our path and complement it with further innovative spray technologies,” commented the CCC team. “This will enable us to offer our customers an even broader range of coating processes and services.”

www.coating-center.de www.kymerainternational.com

The Future of Powder Compacting is ELECTRIC OPP Multiplate Press Family

Simtec advanced digital twin simulation framework for HIP process optimisation

Simtec Soft Sweden AB, based in Lund, Sweden, has introduced a simulation framework for Hot Isostatic Pressing (HIP) processes that uses a digital twin to provide insights into the complex thermal, gas flow, and material behaviours during HIP operations. Simtec’s holistic methodology integrates advanced computational tools as well as robust mathematical and physical models.

Industries such as aerospace, automotive, energy and Additive Manufacturing demand precise material properties and defect-free components, explains Simtec. Traditional trial-and-error methods for HIP processes are costly, time-intensive, and inefficient.

Simtec’s digital twin simulation framework optimises thermal management, reducing operational costs, and enhancing product quality. By incorporating Computational Fluid Dynamics (CFD), advanced algorithms, and fully coupled physical models, Simtec delivers accurate predictions of temperature gradients, gas flow, and material responses, enabling consistent, high-performance results.

In addition to thermal field simulation modules, Simtec has developed a Solid Mechanics Module that offers fully coupled stress, strain, and deformation calculations based on 3D thermal history simulations.

Simtec’s simulation software models the entire HIP process using CFD methods, advanced algorithms and robust physical models to numerically solve the complete governing equations for heat transfer, gas flow, and material behaviour. Unlike simplified empirical formulas, Simtec’s models capture the intricate interactions of radiation, convection, and conduction within the HIP furnace and the material itself, providing detailed insights into thermal dynamics and temperature gradients throughout the machine.

Simtec’s models enable

1. Thermal profile analysis: Simulates heat distribution throughout the furnace

2. Gas flow dynamics: Captures interactions between gas flow and the sample

3. Thermal-mechanical behaviour: Predicts responses during heating, holding, and cooling

The mathematical framework looks to ensure precise predictions of thermal gradients, pressure distributions, and material behaviours at every stage of the HIP process.

Simtec software also offers

1. Multi-physics integration: Fully coupled simulations of flow, heat transfer, mass transfer, pressure, and chemical kinetics. It offers comprehensive modelling of specialised thermal processes, integrating thermodynamics, fluid dynamics, and kinetics.

2. High-Performance Computing (HPC) optimisation: Supports parallel computing and GPU acceleration using Nvidia GPUs. As well as high-performance algorithms to ensure rapid and reliable completion of complex simulations, overcoming convergence challenges often encountered with other software.

3. Efficient radiation modelling: Critical for high-temperature and high-pressure furnace processes and combustion. Simtec’s proprietary EERSM (Efficient and Enhanced Radiation Simulation Method) delivers efficient, accurate, and validated radiation results across various applications, including turbulent combustion and high-pressure processes.

4. Ultra Rapid Convergence (URC) method: Speeds up computations by over 30x without compromising accuracy. Tasks that previously required a full day are now completed in just over

half an hour, ensuring rapid turnaround times for demanding projects.

5. Reliability in complex scenarios: Simtec’s algorithms and HPC capabilities make it ideal for intricate simulations, including high-pressure, high-temperature, and chemically reactive environments. It avoids the convergence issues seen in other commercial simulation tools, ensuring reliable results for challenging applications.

Key features of Simtec’s digital twin

1. Thermal profile optimisation: Ensures uniform heat distribution across components to minimise thermal stresses and defects.

2. Energy efficiency: Optimises heating schedules, reducing energy consumption while maintaining material integrity.

3. Predictive analytics: Identifies risks like overheating or uneven cooling before they impact results.

4. Design validation: Virtually tests and refines part designs under specific thermal conditions.

Benefits for the HIP industry

With robust models and predictive capabilities, Simtec ensures HIP processes are efficient, scalable, and sustainable.

Simtec’s simulations help manufacturers optimise furnace performance, reducing cycle times and energy use. As well as minimising costs through waste reduction, it can enhance product quality with uniform material properties and minimal defects. By tailoring simulations to specific materials and processes, Simtec can meet client’s unique needs and deliver a transformative approach to HIP operations.

Simtec’s digital twin simulations extend beyond HIP processes to address Additive Manufacturing postprocesses such as debinding and sintering, as well as other thermal operations requiring precise control. www.simtecsoft.com

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Amazemet expands ultrasonic atomisation with new high-energy laser melting source

Amazemet Sp Zoo, based in Warsaw, Poland, has announced the development of a new high-energy laser source. Developed under an EU-funded project, the laser is intended to enable higher levels of efficiency and purity in the ultrasonic atomisation process.

Compared to conventional TIG or plasma-based melting systems, Amazemet states that the laserbased energy source provides a highly concentrated and cleaner heat source that enables more efficient atomisation of high-performance materials. The new melting source will seamlessly integrate into the company’s rePowder atomisation machine.

“Laser-beam unlocks new capabilities in ultrasonic atomisation,” stated Łukasz Żrodowski, inventor and CEO at Amazemet. “The integration of a precise and highly concentrated heat source allows us to expand the range of materials that can be effectively atomised. By eliminating contamina -

tion risks associated with traditional plasma sources, we achieve cleaner, more controlled atomisation with improved powder quality. The ability to fine-tune the energy input of a 6 kW laser through advanced scanning strategies enables new level of process control for high-performance materials, like C103. We are confident that laser-based ultrasonic atomisation will redefine industry standards in powder manufacturing.”

Attributes of the higher-energy laser source

The high-intensity laser enables the atomisation of a range of materials, from lightweight aluminium to materials like titanium and niobium with higher melting points.

Amazemet also states that its process eliminates the need for the consumable electrodes found in TIG and plasma torches, thus avoiding tungsten contamination and minimising undesired element evaporation.

Laser-melted and ultrasonically atomised C103 powder (Courtesy Amazemet)

The laser is also said to enable precise energy input on the sonotrode surface, enabling advanced scanning strategies that can optimise material melting, enabling users to opt for Laser or Electron Beam Powder Bed Fusion (PBF-LB and PBF-EB, respectively).

The ability to integrate the laser-based melting system into Amazemet’s rePOWDER machine is hoped to act as a step forward in sustainable metal powder production. The company continues to develop its material processing capability and is taking active steps to develop and protect its IP, with its atomisation platform protected by an extensive patent portfolio.

www.amazemet.com

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Laser-based ultrasonic atomisation process patented by Amazemet (Courtesy Amazemet)

Metalysis installs Tekna spheroidiser for advanced refractory alloy powder production

Metalysis, based in Rotherham, UK, has acquired a 40 kW spheroidiser from Tekna Holding ASA, Sherbrooke, Quebec, Canada. The spheroidiser is designed to produce spherical powders for niche markets with high added value, and for the discovery of new alloys at development scale.

This acquisition comes as Metalysis is scaling up production of its refractory alloys – which includes tantalum and high-entropy alloys – and plans to serve the hightemperature niobium market with materials such as niobium C103 and FS85. Metalysis explained that this underscores its ongoing commitment to enhancing efficiency, sustainability and innovation in Powder Metallurgy.

Using the patented FFC Cambridge electrolysis process, Metalysis reduces metal oxides

in the solid state, a method that contrasts with traditional melting processes. Typically, this process outputs powders with an angular shape, but the spheroidiser can be used to produce spherical particles for Powder Metallurgy applications. Use of the spheroidiser enhances Metalysis’ in-house capabilities, improving attributes such as powder flowability, reducing internal porosity, and delivering higher packing density. This can meet the most demanding Powder Metallurgy applications, including Additive Manufacturing, Metal Injection Moulding, Spark Plasma Sintering, and Hot Isostatic Pressing.

A key feature of the Metalysis FFC Cambridge technology is the ability to tailor particle size for

SINTERING SINTERING

HEAT TREATMENT HEAT TREATMENT

a given process while generating minimal under- or oversize particles. This characteristic is maintained post-spheroidisation, resulting in negligible waste powder being created compared to conventional atomisation processes, and, consequently, energy is not consumed in the generation of scrap powder.

Nitesh Shah, CEO of Metalysis, shared, “The acquisition of a 40 kW spheroidiser marks a major step forward in Metalysis’ capability to produce advanced powders in-house and serve our niche but high-value markets – particularly in refractory alloys and lightweight refractory high entropy alloys. By controlling our spheroidisation processes, we’re not only reducing lead times and mitigating global supply chain risks, but also reinforcing our sustainable footprint. This is a pivotal moment for Metalysis as we strengthen our position in the critical materials supply chain – now able to provide spheroidised powders in-house.” www.metalysis.com

Established in Barcelona, We are the biggest manufacturer of mesh belts for sintering furnaces with global presence around the globe.

Soft Magnetic Composites (SMCs) for electric motors: A new era driven by automotive and aviation electrification

It seems that the stars are finally aligning for the use of metal powderbased parts in the electric motor industry. This is primarily due to the rapid growth of the Electric Vehicle (EV) industry, which started to take off in 2015 when Battery Electric Vehicle (BEV) sales jumped 70% over the previous year to a significant figure of over half a million units. In 2024, global sales of fully electric and plug-in hybrid vehicles rose by 25% over the previous year to over 17 million cars. The use of metal powder-based motor cores in EVs has, however, been a long time coming.

It was over thirty years ago that the metal powder industry recognised that significant growth potential existed for Powder Metallurgy parts in the electric motor industry. At the time, it was discovered that when plastic microencapsulated iron powder – known as Soft Magnetic Composites (SMCs) – was used to replace electrical steel lamination stacks in electric motors, eddy current losses, particularly

as the motor’s operating frequency increased, could be significantly reduced. As a further bonus, insulated iron powder metal motor cores would have a three-dimensional flux-carrying capability that is impossible in conventional laminated steel motor cores.

Additionally, PM’s unique shapemaking capabilities opened up new

and improved motor design and production possibilities. In 1994, the total value of iron and steel powder shipments was estimated at around $500 million (338,000 tons), while the market for electrical steel laminations and related materials that could be addressed was more than $2.5 billion and was, therefore, a very promising growth market.

Fig. 1 In 2019, Ferrari introduced the SF90, first production car with an SMC motor. Developed by YASA, the motor was used in a hybrid configuration where the motor fits between the internal combustion engine and gearbox (Courtesy Ferrari S.p.A.)

“A lot of development work was accomplished

on microencapsulated iron powders for electric motor applications, but, until recently, technology developments in

the electric motor industry occurred at a glacial pace.”

A lot of development work was accomplished on microencapsulated iron powders for electric motor applications. However, technology developments in the electric motor industry occurred at a glacial pace until recently. Surprisingly, for an industry that’s well over a hundred years old, real innovation has only happened over the past fifteen years or so, much of it driven by the EV phenomenon.

One of the early target applications for these new SMCs was AC motors operating at variable speeds using a Variable Frequency Drive (VFD), which controls motor speed by adjusting the supply frequency above or below the normal line frequency. In such an application, an SMC motor core would have significantly less core loss than a lamination stack at just slightly over a 50-60 Hz line frequency.

Understanding innovation – or lack of – in the electric motor industry

The one area in which legacy electric motor manufacturers had the least depth of engineering resources was materials – still a shortcoming today. Early on, this was further complicated by motor companies’ focus on National Electrical Manufacturers Association (NEMA) and International Electrotechnical Commission (IEC) motor standards, which led them to produce semi-commodity products. So, designing a stator using something other than steel laminations was an obstacle. However, while users demand higher efficiency, they are often unwilling to pay a premium for it in a semi-commodity market.

The introduction and adoption of new technologies in the electric motor industry has historically been very difficult because, until recently, it could be considered a bastion of the ‘not invented here’ (NIH) syndrome. For example, every year, five to ten new motor technology companies come into being. These are startups based on a new electric motor topology or other innovation, often of a proprietary nature. They secure seed funding to develop and prototype their motor technology and hope to land an OEM customer of sufficient significance to enable them to secure production funding.

Nine out of ten of these newcomers disappear within three to five years, even after trying to license their technology to a legacy motor manufacturer when they fail to land that ‘angel’ OEM. Concerningly, many of these failed motor technology companies tried to partner with existing electric motor manufacturers without success.

The AC motor market

Despite the market potential of the AC motor sector, it has been understood for decades that designers need to incorporate PM from the start to fully exploit its advantages. For electric motor designers, this

Fig. 2 A Somaloy® SMC powder particle produced by Sweden’s Höganäs AB (Courtesy Höganäs)

Fig. 3 Volkswagen’s APP 310 Radial Flux electric drive as used on vehicles such as the ID3. This drive is a permanent magnet brushless motor. The designation APP derives from the arrangement of the drive and the gearbox in parallel with the axle, whilst the numerical sequence that follows derives from the maximum torque of 310 Nm (Courtesy Volkswagen)

posed a challenge. Apart from the industrial NEMA and IEC frame AC motors, the largest segment of AC motor production was for the appliance or white goods market, which primarily consists of fractional horsepower motors. This market is driven by cost reduction, and the potential energy savings from such small motors are relatively insignificant in terms of monetary value.

Permanent Magnet Synchronous Motors (PMSM). These consist of a rotor with embedded permanent magnets and a stator with windings that create a rotating magnetic field when energised by an AC power supply (inverter). PMSMs have very high efficiency and high power density, along with moderate cooling requirements. However, PMSM motors use rare earth magnets and are more costly than Asynchronous Induction Motors.

Asynchronous Induction motors In less demanding EV applications, or those with multiple motors, Asynchronous Induction Motors are commonly used. In these motors, three-phase AC voltage from an inverter is applied to the stator windings, generating a rotating magnetic field. This induces a voltage in the rotor, causing current to flow which produces a rotating magnetic field in the rotor which lags behind the magnetic field of the stator. The force between these two magnetic

Radial flux motors: the status quo

The global Electric Vehicle market today uses various electric motor types, which are continuing to expand as new motor technologies develop. Radial flux motors are, however, the most prevalent. The key radial flux motor types are as follows:

Permanent Magnet Synchronous Motors

Most EVs on the road today –including Tesla (Models S, X, 3 and Y), Nissan (Leaf), BMW (I3), Kia (EV6) and Hyundai (Ioniq 5) – use

“EV applications that are not quite as demanding (or which feature multiple motors) often use Asynchronous Induction Motors where three-phase AC voltage from an inverter is applied to the stator windings to produce a rotating magnetic field.”

“What is exciting for the PM industry are the relatively new axial flux motors, which are comparatively short. To increase power, the diameter is made larger – think pancake shape.”

fields causes the output shaft to turn. Typical efficiency is 90%.

These motors are relatively economical to produce but have lower power density, meaning they are physically larger and have more cooling requirements. Asynchronous Induction Motors are found on the Volkswagen Group MEB platform, Mercedes (EQC) and front-wheel drive of most Tesla models.

Electrically Excited Synchronous Motors

Electrically Excited Synchronous Motors (EESMs) are rare earth magnet-free motors that use an inverter to provide alternating current to the stator, thus creating a rotating magnetic field. Direct current is concurrently supplied to the rotor through either brushes, slip rings or inductive excitation to generate a magnetic field that aligns synchronously with the stator’s rotating field, and the interaction between the rotor and stator magnetic fields produces torque to propel the vehicle. By eliminating rare earth magnets, the EESM is less costly and has very high efficiency. Still, there is a potentially shorter lifetime before significant maintenance due to the use of brushes, which are wear parts. BMW and Renault use this type of motor.

Axial flux motors: SMC’s big opportunity

The three aforementioned motor types are all radial flux motors, meaning that to increase power, the motor is made longer – think sausage shape. What is exciting for the PM industry are the relatively new axial flux motors, which are comparatively short. To increase power, the diameter is made larger –think pancake shape.

The axial-flux motor was first demonstrated by Michael Faraday in 1821. Since then, its application has been mostly limited to a few high-value applications in the servomotor field. In 2005, an Oxford PhD student, Tim Woolmer, was working

Fig. 4 This double-sided Axial Flux motor design (one stator, two rotors) is regarded as the most efficient concept using SMCs and is referred to as the Yokeless And Segmented Armature (YASA) concept (Courtesy Höganäs AB)

Fig. 5 The YASA motor as used in the Ferrari SF90, and later in the 296 GTB (Courtesy Höganäs AB)

on a project focused on finding lightweight, torque-dense electric motors to power the world’s first hydrogen sports car.

This car was to use four motors, each budgeted to weigh 20 kg. Woolmer found that all the off-theshelf motors of appropriate power weighed 50-120 kg. This meant he had to come up with a new motor that was 2.5x lighter than any available at the time.

The research found that axialflux motors might have the potential torque density Woolmer was seeking, but none were available off-the-shelf, as axial flux motors were rare because they were very difficult to produce. Instead of stacking laminations, the lamination material had to be wound in a spiral and then processed via water jet or EDM. The windings were challenging to produce, and the existing axial flux designs exhibited poor cooling characteristics.

Trying to figure out a novel way of overcoming these production problems and undertaking further research into materials for electric motors led Woolmer to discover that he could segment the axial flux motor into discrete ‘pole-pieces’ which could be easily manufactured using soft magnetic composite parts made from microencapsulated iron powders. This new patented design was termed the ‘Yokeless and Segmented Armature’ (YASA) motor.

YASA Motors Ltd was spun out of the university. Its first product boasted a torque density of 28 Nm/ kg and its 650 Nm of torque was sufficient to eliminate the need for the motors’ originally planned gearboxes.

The pancake-like YASA axial flux motor was the ideal configuration for an in-wheel motor. In 2019, Ferrari introduced the first production car with a YASA motor, but in a hybrid configuration where the motor fits between the Ferrari SF90’s internal combustion engine and gearbox. The company’s axial flux motors have also been used in a variety of Lamborghini vehicle applications.

exploded

“The pancake-like YASA axial flux motor was the ideal configuration for an in-wheel motor.

In 2019, Ferrari introduced the first production car with a YASA motor, but in a hybrid configuration where the motor fits between the Ferrari SF90’s internal combustion engine and gearbox.”

Fig. 6 Top: a YASA axial flux motor is shown on the left (24 kg/ 5 l, 800 Nm) and a conventional radial flux motor is shown on the right (50 kg, 10 l, 400 Nm). Below: an

view of a YASA motor (Courtesy YASA)

In July 2021, Mercedes-Benz AG announced the acquisition of YASA Ltd, with the aim of deploying YASA’s axial flux EV motors for the next generation of all-electric AMG performance models. One of the oldest Mercedes-Benz plants in Berlin has been refitted to focus on the mass

production of YASA powertrains for future models.

With recent activity and interest in electric aviation, Woolmer founded Evolito to develop axial flux motors for electric flight. This may be the ideal application for SMCs, as aviation companies are willing to pay

many thousands of dollars to save just one kilogram, compared to a few dollars at a carmaker. In 2021, RollsRoyce’s Spirit of Innovation aircraft (Fig. 7) set a record as the world’s fastest all-Electric Vehicle, reaching 623 km/h (387.4 mph), powered by YASA technology.

YASA started the axial-flux-motorwith-SMC-components ball rolling. In the years since its introduction, other motor technology companies have further added to the development of axial flux motors utilising the benefits of SMC.

Torev Motors in the US has developed a unique double axialflux electric motor stator structure that significantly reduces rare earth metal consumption while operating at extremely high levels of power and efficiency. Working with MPP on the SMC stator, the solution simulations show an astounding 98% peak efficiency in 150 kW motors.

CorePower Magnetics has received $1 million from the US Department of Energy. It will

Fig. 7 Rolls-Royce’s Spirit of Innovation aircraft set a record in 2021 as the world’s fastest all-electric vehicle, reaching 623 km/h (387.4 mph), powered by YASA electric motor technology (Courtesy Rolls-Royce plc)

Fig. 8 Evolito’s D500 Axial Flux Motor: stacked for increased torque and power up to 1 megawatt (Courtesy Evolito)

leverage this support to create a high-performance electric motor that combines high torque, efficiency, and power density without relying on rare earth elements. The innovative design will utilise nanocrystalline soft magnets and position the company to make significant contributions to this field.

India’s first production-ready axial flux motors were developed by Torus Robotics Pvt Ltd in partnership with Höganäs India, focusing on the threewheeler EV segment and industrial applications. Their parallel magnetic flux path design – which optimises magnetic field distribution – enables significant weight and size reduction without compromising performance.

The European Union-funded MAXIMA consortium comprises eleven partners from six European Union member states. It aims to create a low-cost modular permanent magnet axial-flux electrical machine with improved performance and low environmental impact that caters specifically to the needs of the automotive market. Soft magnetic composites will be considered in the manufacturing and recycling processes for axial flux electrical machines.

Brazilian niobium supplier CBMM is working with WEG, a major motor manufacturer, in an innovative project aimed at using nanocrystalline material featuring niobium in axial-flux electric motors. The nanocrystalline material with niobium provided a significant reduction of 53% in the motor’s total losses, increasing its efficiency level by a substantial 6.7% compared to the same project focused on silicon steel.

Axial- and radial-flux motors

In 2022, supercar manufacturer Koenigsegg caught the electric motor world’s attention with a 28.6 kg motor that develops 335 hp and nearly 600 N·m of torque in a package just 30.5 cm in diameter and 11.4 cm thick. Called the Quark, it

Fig. 10 India’s first production-ready axial flux motors were developed by Torus Robotics Pvt Ltd in partnership with Höganäs India, focusing on the three-wheeler EV segment and industrial applications (Courtesy Torus Robotics)

Fig. 9 Torev Motors worked with Metal Powder Products, Inc (MPP) on the SMC stator for this unique double axial-flux electric motor, which shows an astounding 98% peak efficiency in 150 kW motors (Courtesy Torev Motors)

Fig. 11 Koenigsegg’s Quark combined both radial- and axial-flux constructions in what it termed ‘Raxial Flux’. Although it didn’t claim any SMC content, the Raxial concept has spurred other motor technology developers to explore similar topologies (Courtesy Koenigsegg)

“One US company, Elemental Motors, has developed a novel transverse-flux topology utilising SMC that folds six axial and three radial airgap shear areas into the same case size as a conventional motor. In robotic applications, the motor’s high torque density can eliminate a single-stage planetary gearbox...”

combined both radial- and axial-flux constructions in what Koenigsegg termed ‘Raxial Flux’ to offer a good balance between power and torque (Fig. 11). Although it didn’t claim any SMC content, the Raxial concept has spurred other motor technology developers to explore similar topologies. One such US company is Modal Motors, which has developed what it terms a ‘unique 3D flux path stator’ that would use SMC to enable easier automated production.

Transverse flux motors

Instead of winding copper coils around the stator teeth, the coils in a transverse-flux motor wrap around the axis of rotation in a circumference, which allows for a 3D magnetic flux flow. The 3D flow of magnetic flux enables increased low-speed torque and efficiency to the extent that these motors can be direct-drive actuators without requiring a gearbox for torque

multiplication. Due to their unique construction, transverse-flux motors are ideally suited for the 3D flux-carrying capabilities of SMC.

One US company, Elemental Motors, has developed a novel transverse-flux topology utilising SMC that folds six axial and three radial airgap shear areas into the same case size as a conventional motor (Fig. 12). In robotic applications, the motor’s high torque density can eliminate a singlestage planetary gearbox and do so at roughly one-fifth of the weight of similar torque-capability servomotors. This showcases that metal powder components in electric motors, therefore, are not limited to mobility applications.

Chinese EV manufacturer GAC, through its Ruipa Power Technology Company, recently introduced a new EV motor based on an amorphous alloy they claim is the most advanced soft magnetic material in the world. It is claimed to be very easy to magnetise and has an ordinary magnetic permeability of 20-100x that of silicon steel sheets. Supposedly 90% thinner than traditional silicon steel sheets, the iron loss is reduced by more than 50%. GAC claims the new motor technology achieves up to 98.5% efficiency, with a 13 kW/kg power density at 30,000 rpm.

Now a fast-developing field, Australian company Kite Magnetics is commercialising a novel nanocrystalline magnetic core material with a 2.0 Tesla magnetic flux density (developed at Monash University) for motors and generators. The company will offer stator cores to motor manufacturers that reduce core losses by up to 97% compared to traditional electric steel cores. Its new Aeroperm® cores offer a 3% increase in torque density over conventional materials, allowing motors to be more compact and powerful.

Another exciting development is an EU-funded project in which Norwegian materials company Elkem has developed a new specialised soft magnetic iron

silicon powder, which may allow the Additive Manufacturing of components for electrical motors (Fig. 13).

Summary

In the past five years, we have entered an era of more exciting electric motor technology development than in the previous fifty years. The driving force has been the global electrification phenomenon, which now encompasses not only everything on wheels but also what flies or floats.

While the traditional automotive manufacturers will play an important role, we must realise that newcomers like BYD, Tesla, Rivian and others will likely take the lead in terms of electric motor innovation. The prospects for embryonic motor technology companies are better than ever because established vehicle manufacturers are looking for innovative ways to reduce time to market.

But if there’s a clue to the future of metal powder-based parts in electric motors, it may lie in Tim Woolmer’s observation that clients in aviation will pay a thousand times what their automotive counterparts are prepared to pay in order to lightweight their crafts.

Author John Morehead Principal Consultant

Motion Mechatronics LLC

104 East State Street, #1 Sycamore Illinois 60178

USA

john@motionmechatronics.com www.motionmechatronics.com

13 Elkem has developed a new specialised soft magnetic iron silicon powder, which may allow the Additive Manufacturing of components for electrical motors (Courtesy Elkem)

“...if

there’s a clue to the future of metal powder-based parts in electric motors, it may lie in Tim Woolmer’s observation that clients in aviation will pay a thousand times what their automotive counterparts are prepared to pay in order to lightweight their crafts...”

Fig. 12 Elemental Motors’ Quantum Flux Gen 4 115 mm frameless motor (Courtesy Elemental Motors)

Fig.

Keep your powder dry: The overlooked impact of moisture in metal powders

Metal powders underpin many advanced manufacturing processes, yet one often-overlooked factor can significantly affect their performance: moisture. Excess moisture reduces flowability, accelerates oxidation, and increases the risk of porosity in finished parts. While standards do exist, traditional testing methods rarely offer real-time insight. In this article, Dr Peter Moir and Dr Martin McMahon examine how moisture interacts with metal powders, the impact on processing, and how emerging measurement techniques can help safeguard powder quality and consistency.

The saying “Keep your powder dry,” once crucial advice for preserving gunpowder, is still highly applicable in today’s world of Additive Manufacturing. For a very long period, metal AM powder specifications focused primarily on chemical composition and particle size distribution, while moisture content was largely overlooked. However, as the industry continues to evolve, it is becoming clear that moisture is a critical factor that can significantly impact performance. In high-stakes industries, such as aerospace and medical, where quality and precision are paramount, even trace amounts of moisture in metal powders can introduce serious challenges. While moisture control has long been a consideration in some metal powder consuming industries, it is only in recent years that users of newer technologies such as Additive Manufacturing have recognised the critical importance of managing moisture levels to ensure optimal powder quality. For certain metals, monitoring moisture levels is much

more important than for others, and their mismanagement can affect powder performance before, during and even after the AM build process. For instance, even trace amounts of moisture can compromise powder flowability, increase the risk of oxidation, and lead to high

levels of porosity in the final parts. Sometimes, the negative impact of moisture is not even realised until the post-processing stages, particularly when heat treatment is involved.

In this article, we will discuss some of the shortfalls of the current

Fig. 1 For certain metals, monitoring moisture levels is much more important than for others, and their mismanagement can affect the performance of the powder (Chang Yong Lee/stock.adobe.com)

“Moisture can affect the flowability of powders by inducing clumping that reduces flowability or even prevents flow entirely. During Powder Bed Fusion (PBF) AM processes, this can lead to inconsistent layer coverage; in Direct Energy Deposition (DED), clumping can block feed tubes.”

metal powder test methods used and introduce an alternative technique that relies exclusively on measuring the dynamic changes in relative humidity in the presence of powders.

Additive moisture

Moisture can affect the flowability of powders by inducing clumping that reduces flowability or even prevents flow entirely. During Powder Bed Fusion (PBF) AM processes, this can lead to inconsistent layer coverage; in Direct Energy Deposition (DED), clumping can block feed tubes, and high levels of moisture can also lead to powder sticking to the tube walls or feed nozzles. Within powder hoppers, clumping can take the form of a crust on the top of the stored powder that also prevents it from flowing when the machine needs it.

Within build environments, the moisture expelled from metal powders can affect several parts of the machine. Filters, including the housings, can become damp or even blocked due to excessive water content. Furthermore, the accumulation of moisture during the build process has been known to lead to condensation forming within AM machines. This can affect optical components (e.g. the focusing lens) and, in the very worst scenarios, even cause drops of water to form.

Many metal powders become more volatile in the presence of moisture, with even trace amounts potentially causing a reaction. This, in turn, can increase oxidation and degrade the quality of the powder. Oxides that tend to lock in water in the form of hydrated compounds, such as hydroxides, are more likely to cause further issues in the built parts. These problems can include porosity and/or a decrease in other material properties, such as tensile strength. Additionally, residual moisture in powders can vaporise during fusion-based AM processes, creating pores in the melt that become trapped in the microstructure, ultimately reducing density and, thus, structural integrity. However, some metals have much higher levels of solubility of hydrogen and oxygen when in the molten state than in the solid state. These gases are present in the melt when water is vaporised and can be trapped in much higher concentrations than would be found in conventional alloys because of the rapid solidification. It is only during subsequent heat treatment that this trapped gas can move, and it can cause serious problems. For instance, during the early days of the development of the aluminium alloy AlSi10Mg, massive increases in volume were detected following solution treatment and ageing. The large dimensional changes were later discovered to have been caused by the formation of pores as the entrapped hydrogen escaped the solid solution.

The status quo of measuring moisture

As the AM sector has increasingly recognised the importance of moisture in powder, it is now being addressed in the relevant international standards, such as ASTM (American Society for Testing and Materials) F3606-22 – Feedstock Materials – Testing Moisture Content in Powder Feedstock. However, there remains a need to ensure that test methods for measuring moisture levels are tailored to the specific AM use cases. The standard also references other ASTM standards for measuring water content, which rely on techniques like mass loss during heating or the Karl Fischer titration method.

The loss of mass – commonly referred to as the Loss on Drying (LOD) method – measures the amount of volatile matter, including water, driven off from a test specimen under specific temperature and time conditions. The most generic international standard for this, ASTM E1868 , has already been applied to metal powders, and there are also more specific use cases, such as ASTM D2216 , which was developed primarily for testing soil and rock samples. The LOD method is straightforward and cost-effective but can be less specific, as it measures the total loss of volatile substances, not just water.

Karl Fischer Titration (KFT) is a precise method for determining water content. It employs two main techniques: volumetric and coulometric titration. Volumetric titration is suitable for samples with moderate to high water content (>100 ppm), where iodine is added directly to the sample until the reaction is complete. Coulometric titration, on the other hand, is ideal for trace amounts of water, generating iodine electrochemically within the titration cell. The sensitivity of coulometric titration can detect water levels as low as 1 ppm. When measuring water content in metal powders, the choice of method should depend on the associated

risks with high water contamination. For this reason, coulometric titration is preferred for its higher sensitivity and ability to handle small sample sizes, such as aluminium and titanium alloys. However, currently, there are no specific ASTM standards for measuring water content in metal powders using Karl Fischer Titration. The most relevant standards are ASTM E203-16 for water using volumetric KFT and ASTM D6869 , which cover both methods for the determination of moisture in plastics, including powders. The main issue with the KFT methods is the cost of equipment and consumables to carry out the tests.

Both of these methods are gaining in popularity, but there is still a lot to be learned about their accuracy and relationships to the actual pointof-use impact on metal powders. Perhaps the first time the validity of these methods was assessed and compared in the context of AM was in the publication of SAE (Society of Automotive Engineers) 7033 , the aerospace material specification for powder feedstock of the highstrength aluminium alloy 2A05.50 (commonly known as A205). During the development of this standard, it was noted that certain suppliers carried out LOD measurements and considered anything lower than 1,000 ppm to be acceptable. Users of AM equipment and other aluminium powders, however, found that the critical limit for good flowability was less than 400 ppm when measured by KFT. In the end, a compromise was reached for this particular materials specification where two limits were offered under guidance, as long as the actual test method was identified. However, this level of uncertainty can easily lead to confusion when comparing data.

Fig. 2 Moisture can affect the flowability of powders by inducing clumping that reduces flowability or even prevents flow entirely. During Powder Bed Fusion (PBF) AM processes, this can lead to inconsistent layer coverage (mari1408/ stock.adobe.com)

A new alternative to measuring moisture

If one considers the condition of metal powders immediately after atomisation or formation, then it’s possible to imagine them as being

perfectly dry. Especially since most atomisation requires a lot of heat; even mechanical methods of powder production generate a lot of heat. The issue that was initially overlooked was how much water was subsequently adsorbed by the powders as they cooled and then went on to be stored, not forgetting that in bulk metal powder production, the powder often isn’t sealed into containers until days before final shipment. Even if Intermediate Bulk Containers (IBCs) are used, they are not necessarily airtight.

The relative humidity of the storage and handling environment largely influences the amount

of water absorbed by a batch of powder. Of course, the affinity to moisture is also dependent on alloy type since some metals naturally attract more water than others. This latter fact can be heavily influenced by the oxide layer on a metal, something that is very relevant to certain metal powders.

One company that has come to realise the importance of relative humidity and has been able to exploit this to measure water content in metal powders is Relequa, based in Co Waterford, Ireland. Relequa has developed a moisture profiling technology that introduces a novel approach for detecting and under -

standing the real-time moisture release of metal powders. The company believes that this new method could enable AM users and other industrial parts producers to enforce zero-tolerance policies regarding moisture in powders.

For over ten years, Relequa has been leading the development of new technologies for measuring moisture interactions in materials. Through extensive research, the company introduced the concept of the Water Vapour Equilibrium Point (WVEP). This concept is derived from a novel protocol that precisely determines the equilibrium point as a characteristic of a material and its moisture content. Initially, this research focused on pharmaceutical materials, where moisture control is essential not only for stability and performance but also for cleanliness. A chance encounter between two like-minded individuals – in this case, the authors of this article –then led to the consideration of the technology of powders used in metal AM.

However, after twelve months of dedicated research into how moisture is adsorbed in metal powders, it became evident that they behave fundamentally differently from pharmaceutical materials. Unlike hygroscopic substances commonly found in pharmaceuticals, metal powders do not follow traditional moisture absorption and release patterns. This discovery necessitated the development of a new, specialised protocol explicitly tailored

for metal powders, capable of measuring moisture at exceptionally low ppm levels while capturing their unique moisture interactions. Hence, Relequa adapted its Moisture Profiling technology to meet the stringent demands of AM powder quality control, providing dynamic, real-time insights into moisture release at levels beyond the capabilities of the aforementioned conventional methods.

Why zero tolerance for moisture is critical

The concept of zero tolerance for the presence of moisture in metal powders used in Additive Manufacturing stems from the need for absolute reliability in critical applications. These are found in highly regulated industries such as the aerospace and medical sectors, where there is already zero tolerance for defects or non-compliance in many other aspects of the respective manufacturing supply chains. For example, components such as turbine blades, large airframe structures, and engine parts, both standardised and patient-specific implants, prosthetics, and surgical instruments must all meet stringent performance criteria. These are driven by extreme mechanical and thermal stresses, or by biocompatibility in human implant load-bearing applications. If AM parts exhibit any porosity or other defects caused by moisture in the feedstock powders,

“This discovery necessitated the development of a new, specialised protocol explicitly tailored for metal powders, capable of measuring moisture at exceptionally low ppm levels while capturing their unique moisture interactions.”

this could represent a serious compromise to the integrity of the parts. The consequences of such an outcome would likely be reduced fatigue resistance, increased risk of early and potentially in-use component failure, and a shortened allowable operational lifespan.

Given the high stakes involved in the everyday use of parts in these sectors, manufacturers require absolute assurance from their suppliers. For these industries, a zero-tolerance policy towards noncompliance on specified maximum moisture levels should be not only desirable but essential for ensuring product quality.

Everything is relative

The term ‘humidity’ is used loosely in weather forecasts, where the ‘relative’ descriptor is often dropped. If humidity describes the amount of moisture in the air, then what does the word relative have to do with it, and where does temperature fit in? This is where it gets a bit more tricky, but it is absolutely essential to understand why everything is ‘relative’.

You will have heard and seen on weather reports that humidity is given as a percentage (%). This is where ‘relative’ comes from; implicit in the science behind this is the fact that air, and any other substance or material, can only hold a certain amount of water vapour. Or, putting that in simpler terms: when clouds have formed and keep building up, at some point, it has to rain because the air is saturated to the point that it cannot hold any more water vapour, meaning that the droplets that are heavier than the air are formed and fall to Earth.

To understand how saturation influences humidity, imagine you are in a 5 x 5 x 5 metre room, and the temperature is 21°C. The air in the room could hold about 9 kg of water vapour and would be saturated. If that amount of water vapour were present, you would soon be damp and uncomfortable.

Halving the amount of water to 4.5 kg would give a relative amount equivalent to 50% of the saturation level. Now, the 21°C room is at 50% relative humidity (RH), making for a much more comfortable environment.

Now, let us imagine invisible water molecules moving around in the air, just like the water that leaves your body in every breath (and most of the time, it is invisible). Now, consider that most materials absorb water to a greater or lesser extent. Logically, the water molecules moving around in the air will come into contact with any materials in the same environment, and one of two things must happen: the water sits on the surface of the material (adsorption), or the water at the surface penetrates into the material (absorption).

Assume that there is insufficient water at the surface to cause condensation and that we are still thinking about the invisible water molecules. The water on the surface can evaporate back into the air or move into the material. Water that has already penetrated into the material can stay there or move back to the surface and evaporate into the air. Where the water is lost into the surrounding air, this is known as ‘desorption’.

This process of absorption and desorption is dynamic, with water molecules entering and leaving the material. If, at some point, the amount of water entering and leaving the material is the same (balanced), then we can say there is an ‘equilibrium’. This is one of the key metrics measured by Relequa, the Water Vapour Equilibrium Point (WVEP), which provides insight into a material’s hygroscopic properties under specific working conditions. If the WVEP is established at a low % RH (i.e. below 30%), the material is very hygroscopic. The consequence of this, under everyday typical working conditions of 40-65% RH or higher, is that the material would quickly adsorb moisture. In the

Table 1 Showing the effect of increasing temperature on the water content of air at a fixed relative humidity

case of metals, absorption only really occurs when there is significant oxidation, and instead, the process is dominated by adsorption.

In real terms, a simple consequence of moving a drum of metal powder from a cool storage area to a warmer handling environment is that the relative humidity of the air around the drum will increase. If the drum cools the air enough, then condensation on its surface will occur. Opening this cool drum and exposing the cool metal powder will cause moisture to condense onto the powder; this can be really subtle and completely invisible. Exposing the colder powder could result in an increase in relative humidity at its surface that could be greater than the powder’s equilibrium point. Any relative humidity value above the WVEP causes moisture uptake by the powder. Hence, in Powder Metallurgy, maintaining a low RH is crucial to prevent degradation and

ensure the quality and performance of metal powders.

Studies of metal powders at 50°C / 80% RH have shown different alloys to take up moisture to varying extents. A strict relationship exists between relative humidity and temperature. The table below shows the impact of increasing the temperature but keeping the %RH the same. As Table 1 shows, at the higher temperature the powders are exposed to nearly nine times as much moisture indicated by the arrow.

Moisture profiling: a new paradigm

Relequa – the name of which is derived from the concept that relative humidity can stabilise at an equilibrium point – took some of the very loosely explained theory above and developed its MP-1000 machine (Fig. 3) to target

Fig. 3 Relequa’s patented MP-1000 Moisture Profiling (Courtesy Relequa)

“In essence, knowing the complete profile of any given metal powder’s moisture release behaviour may allow AM users to determine whether it’s safe to use a powder without having to carry out separate moisture content tests.”

the pharmaceutical industry for testing powder ingredients used for medication. RH measurements sit at the very heart of its Moisture Profiling Technology (MPT), which addresses two limitations of currently accepted methods for measuring moisture content. Firstly, both LOD and KFT methods offer just a single snapshot of the moisture content from very small samples tested under lab conditions. Secondly, there’s no consideration of the activity of the water that is present in metal powders with respect to the surrounding environment, thus providing no information about moisture release dynamics. The significant change is, therefore, not attempting to measure the water content but instead monitoring the water release characteristics for given conditions. By offering a dynamic, real-time approach to moisture analysis as a function of relative humidity, it seems that it should be possible to track how powders release moisture over time. Consequently, this aims to provide actionable insights for quality assurance in terms of powder handling and storage. In essence, knowing the complete profile of any given metal powder’s moisture release behaviour may allow AM users to determine whether it’s safe to use a powder without having to carry out separate moisture content tests.

One unique aspect of the Moisture Profiling technique is that it can detect water molecule activity in powder that corresponds to levels of moisture below 10 ppm. This is well below what is currently believed to be the critical limit for typical metal powders used in AM. The powder samples can also be reused since there are no physical changes such as those in the LOD and KFT methods. Hence, Moisture Profiling could be considered a form of nondestructive testing that preserves the powder samples for re-testing. It is then possible to have a given sample stay with any single batch of the originating powder and for it to always be considered representative of the original batch.

Fig. 4 Relequa’s patented MP-1000 Moisture Profiling (Courtesy Relequa)

Blink and you’ll miss it

The test method itself proves to be very quick and easy to use, with no special training or understanding required. It’s particularly apt for AM users because the stainless steel sample holder is a part made by metal Additive Manufacturing. AM also enabled a specially designed porous stainless steel holder that ensures even air circulation and unobstructed moisture passage. This design minimises interference while providing a direct pathway for released moisture to reach the sensing device.

The RH is set in the instrument’s sealed test chamber using a control element. This step ensures that MPT testing avoids any external influence from the RH in the lab or any environment where the test is being carried out. Importantly, this means testing does not require clinically clean lab conditions either. A suitable RH is chosen based on the properties of the test powder, ensuring sensitivity to small amounts of moisture release.

With a simple press of a button, a valve opens, and moisture release from the powder sample is tracked dynamically over time, capturing data at set intervals. Key metrics such as the chamber RH (displayed graphically) and temperature are captured, with automatic conversion to absolute humidity being tabulated on the fly.

Case study: detecting moisture release in metal powders

Without knowing the absolute moisture content of any given sample, and, therefore, not knowing if any significant amount of water was held in a given powder sample, Relequa had to set up a controlled experiment using a novel approach. This involved adding 2.0 μl of water to 20 g of AM-grade metal powder via an undisclosed technique (the company is very secretive about this stage as it believes there is

205_ST_A1_MM 72h 80%RH 40s

205_ST_A1_MM Baseline

205_ST_A1_MM 72h 80%RH

205_ST_A1_MM Baseline

potential to exploit this intellectual property further elsewhere). While Relequa accepts that a very small quantity of this water may have dissipated into surrounding air during sample mixing, it does not believe it was significant enough to have affected any test results.

The methodology thus involved a baseline test that was first carried out on the as-received powder, which was then compared to two other samples. The first was from powder that had been exposed for seventy-two hours at high RH, and the second was from the ‘wetted’ powder.

The striking result from the first series of six repeat dynamic moisture release profiles from a sample of the A205 aluminium

powder is the low level of variability (Fig. 5). The plotted average profile demonstrates a consistent moisture release behaviour, with the standard deviation (SD), represented by the dotted lines, increasing over time. Relequa believes this increase is most likely due to the nuanced nature of moisture desorption from the powder’s surface, where variations in surface interactions contribute to slight differences in release rates across repeated tests.

The moisture profile for the same A205 alloy powder after exposure at 80% RH was also quite remarkable, and to add a high likelihood of moisture being adsorbed into the powder, a separate sample was also shaken in the high humidity environment for forty seconds.

Fig. 5 Reproducibility of dynamic moisture profiling in aluminium powder (Courtesy Relequa)

Fig. 6 Moisture release profiles for A205 alloy after exposure for 72 h in high humidity (Courtesy Relequa)

205_ST_A1_MM 80%RH 40s

205_ST_A1_MM Baseline

Aluminium Powder 80%RH 40s

Aluminium Powder Baseline

from 10 ppm moisture release (Ni, Steel, Copper alloys)

In the case of the A205 alloy, the apparently already dry powder did not seem to have a high risk of adsorbing more water (Fig. 6). It should be stated, however, that it’s very important not to jump to any conclusions since the high humidity test was also carried out at ambient room temperature. In sealed condi -

tions with this higher level of humidity, there could be a risk of condensation of droplets of water as the temperature decreases.

This last risk was highlighted in the wetting test, where the equivalent of 100 ppm of water was mixed with the powder. In this instance, it is very clear that the powder has

“In sealed conditions with this higher level of humidity, there could be a risk of condensation of droplets of water as the temperature decreases.”

taken up water. For comparison, the company’s data also included a profile for a wetted sample of the AlSi10Mg alloy supplied by a wellknown Laser Beam Powder Bed Fusion (PBF-LB) machine vendor. Both moisture profiles, after being shaken at high humidity (80% RH) for forty seconds in the presence of physical water droplets (2 μ l water added to 20 g of powder), clearly show moisture release, and the A205 alloy released significantly less than the AlSi10Mg powder (Fig. 7). However, bearing in mind the novelty of this approach, it might be prudent to consider if this could also indicate that one alloy has a greater capacity to hold onto adsorbed water. It’s likely that if this were the case, it would depend on the base chemistry of the alloy and the characteristics of any oxides that formed on the powder.

But everything is relative

Relequa’s initial data also included a number of other standard powders obtained from a well-established metal machine OEM and an aerospace industry parts supplier. These powders additionally included 316L stainless steel, Ti6Al4V, nickel alloy 625, and copper alloy CuCrZr (Fig. 8). Each of these powders can be seen to have a different moisture release profile when tested under the same conditions. Inconel 625 indeed released its moisture at a higher rate than the other three alloy samples, approaching the equivalent of 10 ppm of water after just two minutes. However, this shouldn’t yet be taken as an indication that this sample of Inconel 625 had the highest initial level of moisture. The same powder was also tested with a baseline RH set at 45%, compared to 40% RH in the first tests. In the second test, the release profile showed an increase of only about 2.5% compared to the 6.5% in the first test. Hence, the important takeaway message is this: in each case, there was sufficient water in the powder for it to be released into the atmosphere naturally. Could it

Fig. 7 Moisture retention at 100 ppm water and 80 %RH (Courtesy Relequa)

Fig. 8 Moisture release profiles of common Additive Manufacturing alloys (Courtesy Relequa)

then be interpreted that any water present in powder feedstock leads to a potential risk to part quality when used to build an AM part? Remember, of course, that the % RH inside an AM machine is very likely to be much lower than in any open room, factory floor, or even lab environment.

From this initial test data, perhaps another relationship is illustrated in the profile for Ti-6Al-4V. In a very similar fashion to both previously mentioned aluminium alloys, the titanium alloy powder also seems to have released moisture at a comparatively lower rate. Could this be tied to the intrinsic reactivity of these metals? The profile that Relequa has presented for Ti-6Al-4V (Fig. 9) has a more erratic profile, which it says is most likely due to natural fluctuations in moisture desorption. The company states that experience has shown that powders releasing moisture more rapidly tend to smooth out these fluctuations. In contrast, those with a slower release rate exhibit greater variability in their moisture profiles. It could follow that without any other external influence, i.e. the addition of external heat, these more reactive metals achieve a WVEP under typical working environments of 40-65% RH at room temperature.

powder could be trapped within the machine. The consequence of this could be misting on the laser window, in the case of PBF-LB, or condensation and water droplets forming on cooled surfaces.

Conclusion

The importance of this last part would only really become apparent when the powder is used in an AM build. Consider, for instance, that humidity can also affect the function and process stability of the AM machines. Inside a machine where either the relative humidity is very low or there can be significant increases in temperature in the part of the machine where the powder is stored before being processed, any moisture released from the

As Additive Manufacturing continues to push the boundaries of innovation, the reliance of some AM technologies on metal powders means that precise moisture control is no longer optional. Where safety is the paramount concern, there must be zero tolerance for deviations from allowable limits. However, current moisture testing relies on techniques that only offer a spot analysis on a single sample that then offers no insight into how the powder reacts with its environment. Metal powders are typically dried by placing them inside an oven or heated cabinet, but there is currently little or no understanding of how they might react with

subsequent environments – if that environment is even immediately known. Powders could be placed back into storage, fed directly into a machine, or simply left in an IBC until needed. The Moisture Profiling Technology put forward by Relequa is an approach to address this challenge head-on. While not providing a quantitative ppm value, the company is offering the Powder Metallurgy sector a potentially transformative solution to developing zero-tolerance policies for moisture in metal powders.

Authors

Dr Martin McMahon M A M Solutions martin.mcmahon@mamsolutions.uk www.mamsolutions.uk

Dr Peter Moir Consultant, CEO & Founder Relequa Analytical Systems Ltd peter.moir@relequa.com www.relequa.com

Fig. 9 Dynamic Moisture Release of Ti-6Al-4V and Inconel powders (Courtesy Relequa)

PM-HIP: the alternative to casting and forging that improves supply chain flexibility and sustainability

Powder

Metallurgy Hot Isostatic Pressing (PM-HIP) is an advanced manufacturing process that enables the production of large, high-integrity components with consistent, forged-like properties. As traditional casting and forging supply chains face growing challenges, PM-HIP offers a reliable alternative with shorter lead times and increased design flexibility. Here, Amaero’s Eric Bono explains how the process supports resilient, domestic production of critical parts across sectors such as defence, energy, and aerospace, helping manufacturers reduce dependency on constrained supply chains while achieving demanding performance requirements.

At its core, Hot Isostatic Pressing (PM-HIP) is a highly adaptable manufacturing process used to produce large, critical components with exceptional material properties and short lead times. Users can expect properties similar to forged components, but with the opportunity for greater complexity, design flexibility, and the capacity to handle more intricate and thicker sections than traditional casting or forging processes.

PM-HIP uses high-quality, spherical, gas-atomised powders to produce isotropic material properties in components up to 1.5 m (5’) in diameter and over 3 m (10’) in length. The powder is placed into a canister, typically constructed from sheet metal and welded together. This canister is evacuated of volatile compounds, air, and moisture, then sealed using hydraulic pressure and welding (Fig. 1). The powder container is then hot isostatically pressed (HIPed) at high temperature and pressure to fully densify the powder. The small powder particle

Fig. 1 The standard PM-HIP process (Courtesy Amaero)

Relative Comparison Of Cost, Performance And Complexity

■ PM-HIP ■ Investment Casting ■ Forging and Welding

Fig. 2 Relative comparison between PM-HIP, Investment Casting and Forging and Welding across cost, material performance and complexity. PM-HIP allows significant complexity with favourable costs and excellent material properties [7] (Courtesy Amaero)

“...PM-HIP is poised to become critical to the defence industry.

High-precision components such as jet engine rotors, blisks (bladedisks), nuclear pumps, valves, and oil and gas manifolds are today produced using PM-HIP – and more applications are being developed in order to overcome supply chain challenges.”

sizes result in small metallurgical grains, leading to material properties similar to forged components, but with the aforementioned benefits of more complex shapes and thicker sections.

Given the strength of these advantages over conventional processes, PM-HIP is poised to become critical to the defence industry. High-precision components such as jet engine rotors, blisks (bladed-disks), nuclear pumps, valves, and oil and gas manifolds are today produced using PM-HIP – and more applications are being developed in order to overcome supply chain challenges.

PM-HIP: from an alternative process to a preferred solution

During the COVID-19 pandemic, vulnerabilities in the casting and forging supply chain were exposed as the industry experienced long lead times and low flexibility when procuring components. Since 2020, the industry has seen increased offshoring and heightened regulations as a result of rising global tensions, with bottlenecks preventing the necessary modernisation of both the defence and commercial markets.

As a US-based company, we have kept an especially keen eye on the state of the industry in the United States. In 2023, the Office of the Under Secretary of Defence for Acquisition and Sustainment – Innovation Capability and Modernization Office stated that “the supply chain for cast and forged components for the Defense Industrial Base has shrunk by 80%” [1]. This drop in the industry has made it increasingly difficult for US-based companies to procure domestically produced castings and forgings as required by Federal Acquisition Regulation (FAR), Defense Federal Acquisition Regulation Supplement (DFARS) and Department of Energy Acquisition Regulation (DEAR) clauses.

As a necessarily more flexible, sustainable and faster alternative, PM-HIP helps alleviate these challenges for metal and composite components. Already, more companies worldwide are adopting the technology to meet the demand for HIP as a post-processing technology. This directly leads to greater supply chain flexibility for purchasers of PM-HIP components, as the same companies that operate presses for HIP as a post-processing technique can also support PM-HIP as a production process. This flexible approach reduces the carbon foot-

print per part and allows PM-HIP component producers to select partners more efficiently, based on schedule, capability, and need, rather than relying solely on proximity.

Developed in the mid-1950s at the non-profit science and technology development organisation Battelle Memorial Institute, Columbus, Ohio, USA, PM-HIP was originally targeted at bonding zirconium cladding and zirconium-uranium alloys for the institute’s naval nuclear propulsion programme [2].

Over time, the process has been adopted for hundreds of thousands more safety-critical parts; the oil and gas industry has embraced PM-HIP for components such as down-hole drilling equipment, manifolds, valves, and pumps. The nuclear industry is exploring PM-HIP to produce small modular reactor (SMR) vessels and heads, pumps, valves, piping, and other components. In addition, nearly all hot-work tool materials used today start as PM-HIP billets.

Key advantages

PM-HIP is versatile and capable of fabricating components in a range of complexities, from simple billets to highly complex near-net-shape parts with excellent material properties thanks to isotropic and fine microstructures [4]. Using PM-HIP offers advantages over conventional manufacturing methods through part consolidation, multi-material manufacturing [4] and fewer issues with welding [5]. Its ability to decrease welding by increasing component complexity can, in the example of HIPed manifolds, reduce necessary welding by 70-90% [6]. This not only lowers associated failure risks but also reduces the time and cost involved in pre-weld processing, post-weld processing, and inspections. PM-HIP can also avoid some of the challenges that advanced technologies such as Additive Manufacturing can face with certain alloys. Indeed, PM-HIP could provide

Cost (low volume)

Properties (isotropic)

Lead

(low volume)

Complexity

Inspectability

additional long-term transformation opportunities by custom-tailoring alloy compositions or manufacturing bi-metallic components for specific applications [3].

The technology is also considered to be more sustainable than conventional methods. Beyond supporting the continued use of legacy machines with spare parts, it offers increased material utilisation and reduces machining and scrap. It also produces components

that are easy to inspect, enabling faster delivery and manufacturing times.

Properties

The small grain size achieved through PM-HIP results in excellent material properties, comparable to forged components and significantly better than cast alternatives. The equiaxed grains also result in

“Using PM-HIP offers advantages over conventional manufacturing methods through part consolidation, multi-material manufacturing and fewer issues with welding. Its ability to decrease welding by increasing component complexity can, in the example of HIPed manifolds, reduce necessary welding by 70-90%.”

Table 1 Comparison of PM-HIP, Castings, Forgings, PBF-LB and DED (Courtesy Amaero) PM - HIP Casting Forgings

HT = Heat Treatment | SA = Solution Anneal

Table 2 Comparison of material properties for select alloys in different conditions (Courtesy Amaero)

isotropic properties and enhanced ultrasonic testing (UT) inspectability. Table 2 compares material properties for select alloys in different conditions, showing the close alignment between Hot Work (HW) and forged properties to those of PM-HIP.

Materials

PM-HIP can be used with virtually any material, including those that other manufacturing processes such as Laser Beam Powder Bed Fusion (PBF-LB) or Directed Energy Deposi -

Table 3 Examples of various alloy groups which can be processed using PM-HIP (Courtesy Amaero) Ferrous materials

Grade 91 Steel [12]

A508 4N

D2 [4]

D7 [4]

H13 [4]

PM23 [4]

PM30 [4]

PM60 [4]

A11 [4]

M4 [4]

T15 [4]

316L [12]

316LN [12]

17-4PH [4]

410, 420, 440 [4]

2205, 2507 [4]

254 SMO [4]

654 SMO [4]

S31254 [4]

F51 [13]

Ni600 [4]

Ni625 [12]

Ni690 [4]

Ni718 [4] Astroloy [4]

Ni MMC [14] X-750

Waspaloy [15] Monel K-500

Co 6 [4] Co 12 [4] Co F [4]

Ta [16,17] Nb C103

Ti-6Al-4V CP-Ti

MMC = Metal Matrix Composite

GRCop-84 [18] Al MMC

tion (DED) Additive Manufacturing may struggle with. Crack-prone materials, such as hot-work tool steels, can be efficiently processed using PM-HIP, as can oxygensensitive or reactive materials such as titanium alloys and aluminium composites. Examples of materials are presented in Table 3. Due to the PM-HIP process being in a solid state, the grain size can be controlled to achieve different properties depending on the application. For example, a lower temperature and shorter hold time can result in stronger and tougher material due to the small grain sizes, while longer holds or higher temperatures can be used to improve creep strength or ductility. A specific example of this includes the modification of HIP cycles A508 4N for nuclear applications where room temperature toughness was impacted by oxygen migration, and longer HIP hold times resulted in an improvement [19, 20].

Qualification

Although PM-HIP is generally considered a non-traditional manufacturing process, it is well-studied and widely accepted for specific applications. Several standards and codes have been developed to support the qualification process, ensuring the material meets performance requirements.

The ASME Boiler and Pressure Vessel Code (BPVC) Section II allows for the qualification of PM-HIP components made from nickel and stainless steels for non-nuclear applications. Military specifications such as MIL-DTL-32681, MIL-DTL-32683, MIL-DTL-32715, and MIL-DTL32716 support the use of PM-HIP components for the Naval Nuclear Propulsion programme.

The PM-HIP process

Preparation

The thin-walled HIP canister is typically made using sheet metal fabrication, although Additive Manufacturing is becoming more prevalent for its production. The powder is handled in an inert atmosphere to minimise the pick up of oxygen and/or nitrogen, which can be detrimental to the material’s performance.

Nearly any powder can be used for PM-HIP. In the case of Amaero, we use both in-house atomised powders (Fig. 4) and powders from third parties. High-quality spherical powders, typically made using IGA, EIGA, VIGA, or other gas atomisation methods, are generally preferred. Spherical powders offer better flowability and can be tightly packed, thus improving the accuracy of the final part and reducing the risk of canister distortion.

publicly,

outside

are some typical projects that we work on, although sizes are routinely over several tonnes. (a) 500 kg titanium valve component can; (b) 5 kg 316L globe valve can; (c) 50 kg Ni625 gate valve can (Courtesy Amaero)

PM-HIP using water-atomised powders is still in its infancy due to the irregular shape of the powder and the risk of contaminants. Still, the lower production costs of this process may entice users to opt for powders manufactured via this atomisation method, hoping to achieve significant cost benefits.

For US manufacturers, domestic sources of powder atomisation are increasing, with several companies adding capabilities and capacity. Of note is our new premium EIGA, which boasts a 200-ton annual capacity; one unit is already operational, while a second is on order and a third is under negotiation.

This alone represents 600 tons of additional domestic powder production capacity that will be online in 2026 or sooner. Additional atomisation capacity and capabilities are being planned for our McDonald, Tennessee, facility and will be announced when available.

Densification

HIP is used to densify the powder from approximately 70% of bulk density to full density. HIP furnaces typically operate from approximately 500-1,300°C and at pressures between 100-310 MPa. Cycle times can range from one to over twelve

Fig. 3 The vast majority of the components we work on cannot be shown

particularly

of the can. Here

(a)

(b)

(c)

Fig. 4 Niobium alloy powder produced at Amaero’s facility in Tennessee (Courtesy Amaero)

Good response to Thermally Induced Porosity (TIP) test (1,200°C/4 h)

hours, depending on the material and cross-sectional thickness. Amaero uses proprietary simulation tools to model this process, ensuring the first component conforms.

Testing

After the HIP process, routine density and Thermally Induced Porosity (TIP) tests are performed to ensure the performance of the HIP process.

Density can be tested using Archimedes methods or via a crosssection of metallurgical samples

along with image analysis; crosssectional image analysis is the preferred method to avoid erroneous measurements when the true density of the material is not known.

TIP testing involves exposing a metallurgical sample to a high temperature, typically up to 65°C above the HIP temperature, in a vacuum or an inert atmosphere for between 2-4 hours. The sample is then evaluated for porosity via crosssectional and image analysis. Fig. 6 shows an example of TIP testing results with a poor response.

Canister removal and postprocessing

In many cases, canister removal is not necessary. Canisters can be made from either the same or different materials as the densified component or from different materials and can serve as a functional surface in cases where enhancements in wear and/or corrosion resistance are needed. If removal of the can is desired, conventional processes such as machining or chemical milling can be used, as well as processes such as Electro-Chemical Machining (ECM), Pulsed ECM (PECM), and Electric Discharge Machining (EDM).

Post-processing of PM-HIP components is performed using conventional manufacturing methods, including welding, heat treatment, machining, surface treatments and coatings, etc. Components that are too large for today’s HIP units can be welded using conventional or advanced methods such as Electron Beam

Welding, a technique currently being explored by Rolls-Royce to produce nuclear reactor pressure vessels [23].There are virtually no

Fig. 5 A Quintus Technologies, LLC QIH 286 URC® (Courtesy Quintus Technologies)

Fig. 6 Cross-sectional and image analysis evaluation of porosity via TIP with bad response. Reproduced from [7]

Ni-based superalloy powders, as-HIPed & TIP-tested

Bad response to TIP test

(a) (b)

Amaero: PM-HIP as a supply chain

Modified can results

7 Amaero’s proprietary simulation software predicts densification behaviour and allows virtual canister modification to achieve geometric accuracy. The simulation can predict the localised density of powder at time steps, allowing our designers ultimate control of the PM-HIP process (Courtesy Amaero)

limits to the post-processing steps that can be utilised to gain additional functionality.

A transition to near-net shape production

While PM-HIP was first used as a way to consolidate materials for billet production or cladding application, today the technology is increasingly used for large near-net-shape components that require excellent isotropic material properties. Adding complexity to near-net-shape components, however, requires technical expertise for the canister design to achieve final dimensional conformance. To best take advantage of the technology, efforts need to be made towards a PM-HIP version of the much-discussed ‘Design for Additive Manufacturing’ concept, whereby engineers leverage the process’ unique abilities to design the best component, rather than simply replicating a component designed for a conventional manufacturing process.

of approximately 0.1- 0.5%). This is especially important to study as parts this large are not currently feasible to produce via AM, given the high cost of the technology with respect to part complexity, size and weight.

In addition to the densification prediction, Amaero is applying its combined experience in powder and advanced manufacturing to modify canister designs to optimise densification behaviour (Fig. 7). As canister designs evolve to support more complex near-net shape components, advanced manufacturing methods are needed to meet this increased complexity.

Summary

PM-HIP is a robust advanced manufacturing process that provides isotropic forged-like material properties and cast-like complexity in near-net-shape performance. From custom billets to highly complex components, nearly any shape can be manufactured using PM-HIP – and materials available for the process are nearly limitless.

Contact

Eric Bono CTO

Amaero Advanced Materials and Manufacturing 130 Innovation Dr SW McDonald, TN 37353 USA eric.bono@amaeroinc.com www.amaeroinc.com

References

[1] Defense and Munitions. (2024, July 19). Department of Defense program aiming to transform U.S. metal manufacturing, casting, and forging industry. Retrieved from https:// www.defenseandmunitions. com/news/defense-departmentprogram-aiming-to-transformus-metal-manufacturing-castingforging-industry/ accessed 7/19/2024

Amaero is leading modelling efforts to predict densification in three dimensions, achieving first component accuracies of approximately 6.35 mm on components up to 1.52 m across (accuracy

Amaero is leading the way in this technology with our advanced knowledge of materials processing and experience deploying the most advanced simulation and modelling techniques in the industry.

[2] Boyer, C B. (1992, January). Historical review of HIP equipment. In Hot Isostatic Pressing—Theory and Applications: Proceedings of the Third International Conference Osaka, Japan 10-14 June 1991 (pp. 465-510). Dordrecht: Springer Netherlands

Fig.

CAD model

Cross section

Filled can

Post-HIP

[3] Gandy, D W. (2015). HIP research for structural and pressuring retaining applications within the electric power industry (No. NEANSC-WPFC-DOC--2015-9)

[4] Introduction to PM HIP Technology, European Powder Metallurgy Association, 2012, www.empa.com

[5] Jones, S. (2023). Advanced manufacturing applied to nuclear fusion—challenges and solutions. Journal of Physics: Energy, 5(4), 042001

[6] Hjorth, C G, & Hebeisen, J C. (2005, January). Subsea manifolds: an alternate fabrication strategy using HIP PM near net shapes. In ASME Pressure Vessels and Piping Conference (Vol. 4191, pp. 507-513)

[7] Bampton, C., Goodin, W., VanDaam, T., Creeger, G., & James, S. (2005, January). Net-shape HIP powder metallurgy components for rocket engines. In International Conference on Hot Isostatic Pressing HIP 2005

[8] ASM Handbook, Powder Metallurgy, Volume 7, 1998

[9] Special Metals. (2024, July 19). Inconel alloy 706 technical information. Retrieved from http:// specialmetals.ir/images/technical_info/nickel-base-alloy/ inconel-alloy-706.pdf

[10] MatWeb. (2024, July 19). MTP641 – Material Property Data. Retrieved from https://asm.matweb. com/search/SpecificMaterial. asp?bassnum=MTP641

[11] Berglund, T., Östlund, M., & Larsson, L. (2015). Properties of HIP’ed Materials: Impact Toughness of PM HIP’ed vs. Conventional 316L. In European Congress and Exhibition on Powder Metallurgy. European PM Conference Proceedings (p. 1). The European Powder Metallurgy Association

[12] Gandy, D. et al, “Program on Technology Innovation: Manufacture of Large Nuclear and Fossil Components Using Powder Metallurgy and Hot Isostatic Processing Technologies,” EPRI Report 1025491, May 2012

[13] Bjurström, M., & Hjorth, C G. (2009, January). Producing HP pump barrels utilizing powder metallurgy and hot isostatic pressing. In ASME International Mechanical Engineering Congress and Exposition (Vol. 43772, pp. 335-341)

[14] Sergi, A., Khan, R H., Irukuvarghula, S., Meisnar, M., Makaya, A., & Attallah, M M. (2022). Development of Ni-base metal matrix composites by powder metallurgy hot isostatic pressing for space applications. Advanced Powder Technology, 33(2), 103411

[15] Lherbier, L W., & Radavich, J F. (2007, May). An Evaluation of PM Waspaloy. In Proceeding of 11th International Symposium on Advanced Superalloys–Production and Application

[16] Busom Descarrega, J., Calviani, M., Hutsch, T., López Sola, E., Pérez Fontenla, A T., Perillo Marcone, A., ... & Weißgärber, T. (2020). Application of hot isostatic pressing (HIP) technology to diffusion bond refractory metals for proton beam targets and absorbers at CERN. Material Design & Processing Communications, 2(1), e101

[17] Kim, Y., Kim, E P., Noh, J W., Lee, S H., Kwon, Y S., & Oh, I S. (2015). Fabrication and mechanical properties of powder metallurgy tantalum prepared by hot isostatic pressing. International Journal of Refractory Metals and Hard Materials, 48, 211-216

[18] Ellis, D L., Loewenthal, W S., & Yun, H M. (2012). Tensile Properties of GRCop-84 (No. E-17784)

[19] Ridgeway, C D., Nolan, T., & Pyle, J M. (2024). Identification of the Mechanism Resulting in Regions of Degraded Toughness in A508 Grade 4N Manufactured Using Powder Metallurgy–Hot Isostatic Pressing. Journal of Manufacturing and Materials Processing, 8(4), 132 [20] Ridgeway, C D., Nolan, T. (2024). Process and Property Trends for Powder Metallurgy HIP A508 Grade 4N, Presentation at PowderMet2024

[21] ASTM Standard A988/A 988M07, Standard Specification for Hot Isostatically-Pressed Stainless Steel Flanges, Fittings, Valves, and Parts for High Temperature Service

[22] ASTM Standard A989/A 989M07, Standard Specification for Hot Isostatically-Pressed Alloy Steel Flanges, Fittings, Valves, and Parts for High Temperature Service

[23] Warner, T., Sulley, J., Wallace, P., Stewart, D., Jones, G., & Thatcher, D. (2022, July). Further Developments in Nuclear Pressure Vessel Manufacture Using the Hot Isostatic Pressing Process and Thick-Section Electron Beam Welding. In Pressure Vessels and Piping Conference (Vol. 86175, p. V04AT06A004). American Society of Mechanical Engineers

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Producing copper powder from industrial waste: Destiny Copper’s sustainable recovery process

Destiny Copper has developed a patented, chemistry-based process to recover high-purity copper powder from mining and industrial waste streams. Using a zero-energy, modified cementation process, the company extracts copper without the need for electrowinning or melting, significantly reducing energy use and emissions. With support from federal and regional innovation programmes, Destiny Copper is now scaling up its operations to meet the growing global copper demand while turning hazardous waste into valuable materials for advanced manufacturing applications. Here, the company’s Lead Scientist, Dr Josh Clarke, shares insight into the story so far.

Destiny Copper, a Canadian cleantechnology startup, is developing a new chemistry-based approach to copper powder production. This process recovers high-purity copper powders from industrial and mining waste by selectively extracting copper metal from dissolved copper in hazardous waste streams. This provides both waste management solutions and premium copper products with purities exceeding 99.9%.

Recent federal recognition underscores Destiny Copper’s potential: in March 2025, the Member of Parliament responsible for FedDev Ontario announced $2.5 million in funding at the company’s pilot facility. This support helps Destiny Copper transition from pilot to demonstration scale, allowing the company to sustainably address the growing global demand for copper.

Founded in 2017 by CEO Greg Hanna, Destiny Copper emerged from Brock University’s BioLinc incubator. At Brock, Hanna

partnered with Professor Ian Brindle, Dean of Mathematics and Science and President of Research, who finalised the now-granted patent. In 2023, the company relocated to the Bioveld in Ontario’s Niagara

Region, where it quickly expanded its technological and operational capabilities. The dedicated team now comprises twelve specialists, including three PhD-level scientists.

Fig. 1 The Thorold Multimodal Hub (Bioveld 1) offers access to marine, rail, and water treatment infrastructure. It serves as Destiny Copper’s headquarters and accommodates several other enterprises (Courtesy Destiny Copper)

Zero-energy copper recovery

At the heart of Destiny Copper’s breakthrough lies its zero-energy process, known as cementation, which extracts copper from acidic solutions using ferrous scrap as a reducing agent. While this process

has been known since antiquity, traditionally, cementation processes faced multiple limitations due to poor selectivity, high-iron contamination, and poor product morphology made it unsuitable for broad Powder Metallurgy applications. Destiny Copper’s technology addresses these challenges with its highly efficient

exchange that produces industryready copper materials.

Destiny Copper’s treatment reduces copper ion concentrations to less than 100 ppm from feed solutions in a matter of hours and delivers copper metal at over 99% purity. By eliminating conventional energy-intensive steps, such as electrowinning or melt-atomisation, the company’s process significantly reduces both energy usage and carbon emissions, presenting a sustainable alternative for copper powder production.

Beyond copper metal powders, Destiny Copper’s process facilitates sustainable production pathways for speciality copper chemicals, including cuprous oxide (red), cupric oxide (black), and basic copper carbonate powders. These products are essential to diverse industries, such as antimicrobial coatings, pigments, ceramics, electronics, agriculture, marine paints, and chemical manufacturing.

Fig. 2 A large crystal of copper recovered from an industrial waste stream. While large crystals like this can be produced, finer powders can also be obtained based on reaction conditions (Courtesy Destiny Copper)

Fig. 3 Destiny Copper’s core specialty products (Courtesy Destiny Copper)

Advanced copper powder applications

Destiny Copper manufactures copper powders with a variety of morphologies – from highly dendritic crystals to uniform shapes. These powders can be efficiently spheroidised for Additive Manufacturing and tailored to a broad range of particle size distributions based on the application.

Dendritic copper powders significantly enhance thermal management systems, particularly improving heat transfer efficiency in Electric Vehicle (EV) battery cooling. In collaboration with Mohawk College, Destiny Copper produced the world’s first additively manufactured copper heat sink from mining waste. This waste was sourced from a Chilean gold mine as the copper-containing effluent recovered after gold extraction. Ongoing research with the

Fig. 5 Build-ready copper powders for AM obtained using sustainably sourced Destiny Copper powder feedstocks (Courtesy Destiny Copper)

Fig. 4 SEM image of an irregular copper powder product produced using the low-energy recovery (Courtesy Destiny Copper)

University of Waterloo’s MultiScale Additive Manufacturing Lab continues to unlock further potential in Additive Manufacturing applications.

Pilot plant success and expansion plans

Operating at Technology Readiness Level (TRL) 7, Destiny Copper’s pilot plant at Thorold demonstrates commercial viability by recovering copper from diverse waste streams, including industrial effluents and mining residues. Pilot tests consistently demonstrate copper recovery efficiencies exceeding 98%, with product purity levels surpassing 99%. The copper extraction process requires minimal energy and has low operational complexity, making it particularly well-suited for regions with unreliable power infrastructure or limited economic feasibility for large-scale electrolysis. The exceptional selectivity of the process allows for efficient copper extraction even from highly contaminated sources, including leachate, bioleach solutions, and pregnant liquor solutions.

The current pilot plant operates at a 5,000 litre scale, with plans to expand to a demonstration plant in the near future. Located at the ‘Bioveld 1’ site, the facility benefits from convenient access to rail, road, and marine transport via the St. Lawrence Seaway.

Destiny Copper operates within a 1850 m 2 facility located in a 110,000 m 2 former paper mill site, which supplied paper for the Chicago Tribune before ceasing production in 2014. The BMI Group later acquired the site and is now Bioveld, a Multimodal Hub home to fifteen companies. Destiny Copper is actively scaling its operations, aiming to take more real estate within the industrial complex and have a demonstration plant operational next year. Concurrently, modular copper recovery units are being designed for direct deployment at industrial and remote sites, minimising logistical complexities and maximising sustainability.

Industry recognition and leadership

Destiny Copper’s innovative approach has earned substantial recognition and support from prominent organisations, including FedDev Ontario, NGen, MICA, NRCIRAP, and OCI. The company has received prestigious awards from the Greater Niagara Chamber of Commerce, the World Economic Forum’s Sustainable Mining Uplink Program, Foresight Canada 2050, and Canada Clean50. Additionally, Hanna was recently a finalist for Entrepreneur of the Year at the Canadian SME National Business Awards.

Meeting global copper demand

Global copper demand is projected to surge from the current annual output of 22 million tonnes to an estimated 50 million tonnes by 2050. Bloomberg estimates that mining and industrial wastes globally contain copper valued at approximately $2.4 trillion. Destiny Copper’s innovative recovery technology unlocks these resources, offering both economically attractive and environmentally sustainable solutions. Destiny Copper aims to drive sustainability within the Powder Metallurgy industry by recovering copper from waste. With a focus on setting new standards in sustainable manufacturing, the company is actively seeking collaborations with industry and academic partners to explore innovative applications in Additive Manufacturing and advanced materials.

Authors

Josh Clarke, PhD, Lead Scientist, and Gabe Delle Monache, PhD(c) Sr. Scientist

Destiny Copper 3363 Davis Rd., Thorold, ON. L2V 1J1 Canada

jclarke@destinycopper.com gdellemonache@destinycopper.com www.destinycopper.com

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The 2024 Japan Powder Metallurgy Association Awards: Recognising innovations in PM

The 2024 JPMA Awards, organised by the Japan Powder Metallurgy Association (JPMA), celebrate outstanding innovations in Powder Metallurgy across product development, process improvement, and material advancement. This year’s award-winners showcase the latest achievements in performance, sustainability, and manufacturing efficiency, highlighting the industry’s ongoing evolution. From Electric Vehicle components to powders for PM and Additive Manufacturing, the awards demonstrate the versatility and potential of PM technologies in meeting the demands of next-generation applications across diverse industries.

Grand Prize

Axial Flux Motor Stator Core Sumitomo Electric Industries, Ltd won the Grand Prize for components that form the stator core of an Axial Flux Motor (AFM) used in air cleaners (Fig. 1). In response to the growing focus on miniaturisation, weight reduction, and improved motor efficiency, AFMs offer both compactness and high torque. They have gained significant attention and are expected to replace conventional radial flux motors made from Laminated Steel Sheets (LSS), which experience a reduction in torque as they are thinned due to structural limitations. Compared to LSS, Soft Magnetic Composite (SMC) cores are suitable for the three-dimensional magnetic circuit required for AFMs due to their magnetically isotropic properties and high shaping flexibility.

To increase the facing area between the SMC parts and the magnet, the company has developed a shape with pole shoes extended on

both the top and bottom sides. As a result, high dimensional accuracy of the distance between the surfaces of the double pole shoes (total length of double pole shoes’ cores) and the QC superiority of the SMC compared to the competing material, LSS, have both been achieved.

Firstly, the superiority of motor performance using the double pole shoes’ cores was verified. Then, an 18% increase in motor torque and a

Fig. 1 Development of Soft Magnetic Composite cores with double pole shoes to enhance the performance of axial flux motors (Sumitomo Electric Industries, Ltd)

New Design awards

Electric solenoid valve bushings

Diamet Corporation won an award for bushings that support the plunger shaft of an automotive solenoid valve (Fig. 2). The solenoid valve is a component that generates an axial force from the output part by electrical input. In recent years, automatic transmissions have become more popular than manual transmissions, and this component is expected to be installed in an increasing number of vehicles. Since this product is used as a bearing that supports the shaft, it is necessary to maintain good sliding properties during the shaft’s linear movement. In addition, unlike standard bearings, magnetic properties are also required in order to function as a solenoid, so sliding performance and magnetic properties must be compatible.

2.6% increase in efficiency, compared to the conventional method of using the SMC without the pole shoe, was demonstrated. However, it was difficult to eject the core with double pole shoes from the mould using conventional compacting methods. Therefore, the company focused on changing the direction of compaction and developed a new method of integrally compacting both pole shoes and teeth. This development has made it possible to combine the formability of the SMC with improved motor performance.

The newly developed compacting technology meets the required dimensional accuracy for the thickness of the double pole shoes, which

has been reduced by 70% compared to conventional compacting technology. This is because the dimensional accuracy of the core thickness is primarily influenced by the accuracy of the compaction tools, rather than being affected by the powder fill volume. In addition, the new technology has reduced manufacturing costs compared to the former method, as it results in only one part rather than two, and half the compaction tools.

Following these developments, the company has begun massproducing the cores for double pole shoes for AFMs, which contributed to the popularisation of AFMs using SMC technology.

“In addition, the new technology has reduced manufacturing costs compared to the former method, as it results in only one part rather than two, and half the compaction tools.”

When choosing the material, magnetic properties were essential, so an iron-based material was selected. Graphite is typically added to iron-based materials to provide sliding properties; however, increasing the graphite content can reduce magnetic properties. Therefore, the company considered the optimal ratio that achieves both magnetic and sliding performance and selected a Fe-Cu-C-based material. When considering the shape, cost, usage conditions, and assembly, the company determined the optimal design through repeated discussions with the customer. They were able to satisfy the strict cleanliness standards for preventing foreign matter contamination by examining barrelling conditions that would remove burrs without damaging the sliding surfaces and implementing measures such as protective covers within the manufacturing process. Through these developments, the company was able to meet multiple requirements and successfully switch from conventional cast material to sintered material.

Fig. 2 Sintered bushings that enable the manufacture of high-performance electric solenoid valves (Diamet Corporation)

Vane pump side plate

Fine Sinter Co, Ltd won an award for its side plate for a vane pump used in a transmission oil pump (Fig. 3). With the accelerating shift to EVs, there is an even greater incentive for conventional automotive technologies to further reduce CO 2 emissions and to be quieter. This requires a higher levels of performance from every part of an ICE powertrain. Therefore, transmission oil pumps are being replaced by vane pumps, which have less vibration and higher volumetric efficiency than conventional rotor-type pumps.

“Green machining process conditions were optimised through a detailed investigation of the

required cutting depth

This product has a blind groove 2 mm wide and 9 mm deep and a blind groove 3.5 mm wide and 5 mm deep on the opposite side, creating a unique curved groove shape. These grooves are difficult to form through compacting and, when using standard machining, lead to burr formation and high costs. Thus, efforts were made to solve these problems through a green machining process that suppresses the generation of burrs. Reduced

to

prevent chipping during processing,

product

gripping conditions

to prevent cracking, and peripheral speed and cutting depth to avoid cutter breakage.”

iron powder was chosen as the material to ensure adequate green strength. A Fe-Cu-C alloy system was then selected to meet the requirements.

Green machining process conditions were optimised through a detailed investigation of the required cutting depth to prevent chipping during processing, workpiece clamping conditions to prevent cracking, and peripheral speed and cutting depth to avoid

cutter breakage. These developments enabled the manufacture of a product with complex grooved features. A cost reduction of about 20% was achieved with the adoption of green processing, which reduced the torque required for the machining process down to 10% or less compared to that for sintered bodies. It allowed for the miniaturisation of equipment, shortened processing time, and eliminated the need for burr removal.

Fig. 3 Vane pump side plate (Fine Sinter Co, Ltd)

Process development awards

Magnetic particle inspection automation machine

Diamet Corporation won an award for this fully automated machine that uses robotics and an AI system to apply the magnetic particle inspection method for detecting cracks in induction-hardened products

(Fig. 4). The development covers the complete process of the magnetic particle inspection method, including pre-processing (magnetisation and magnetic powder coating), observation (flaw detection), evaluation, and post-processing (demagnetisation). The composite magnetisation method is applied for a pre-processing stage because of process efficiency, which allows stable detection even if the

crack direction is changed (either circumferential or radial direction). In addition, a robot handling method prevents magnetic powder from being peeled off from the surface of products.

For the process of inspection and evaluation, the AI system was trained and optimised with thousands of samples to enable it to make judgements that are close to the capabilities of an expert inspector. In a case where the amount of magnetic powder liquid remaining on a part’s surface is more than the adequate level, this can result in false positives and/or over-detection. Therefore, the development applied some technical measures to control the right amount of magnetic powder and liquid at the inspection spot; finally, false positives of 0% and over-detection of approximately 5% were achieved.

Although this is the first example of an automatic process for a sintered parts inspection system, it has already been approved by multiple customers. Furthermore, this technology has obtained a higher and more stable level of inspection quality by eliminating discrepancies of various skilled operators and improved inspection accuracy. Also, a human inspector’s judgement is sometimes affected by a lack of concentration or fatigue; this system eliminated such errors and even improved the working environment, reducing inspector workload and fatigue.

New powders

Tool steel powder for AM

Daido Steel Co, Ltd won an award for this tool steel powder with high ‘printability’ in Powder Bed Fusion (PBF)-based Additive Manufacturing, reducing stresses during a build and making it possible to manufacture moulds larger than 150 mm in width. The practical use of die-casting moulds and plastic injection moulds manufactured by metal AM is now advancing. Typically, AM moulds are made from 18% Ni maraging steel

Fig. 4 Full automatic machine for the magnetic particle inspection of induction-hardened products (Diamet Corporation)

Fig. 5 Tool steel powder for Additive Manufacturing (Daido Steel Co, Ltd)

powder. However, maraging steel powder contains a high amount of cobalt, which is regulated under the ordinance on prevention of hazards in Daido Steel Co, Ltd’s chemical substances specifications. It is also designated as a ‘list-controlled’ item under Japan’s Security Export Control regulations. Therefore, the demand for AM using JIS-SKD61 hot work tool steel powder has been growing.

However, SKD61 powder has an issue regarding its use. Due to its high hardness in the as-built state, this powder cannot withstand the stresses generated during Additive Manufacturing, making it prone to cracking and difficult to additively manufacture. Thus, the company developed a novel hot work tool steel powder with higher build performance, which can suppress stress cracking during the production of large-scale additively manufactured moulds. The chemical composition of this raw material powder, based on JIS-SKD61, is designed to reduce the amounts of carbon, silicon, and vanadium and to

add 6% nickel so that the martensite transformation start temperature (referred to as the Ms point) is set around 200°C, equivalent to that of maraging steel. With this chemical composition design, a supercooled austenite state is maintained during printing at temperatures higher than the Ms point, thus decreasing hardness. Consequently, the stress caused by thermal stress generated from melt-solidification by laser and the subsequent cooling process is relieved through the slight deformation of the super-cooled austenite. Additionally, once Additive Manufacturing is complete, switching off build plate preheating allows the object to cool gradually, enabling marquenching. The volumetric expansion of the object during marquenching further reduces stresses. This mechanism has made large-scale AM possible. Furthermore, the quenching process can be eliminated, as the object naturally forms a martensitic structure. As a result, this raw material is expected to contribute to process simplification and energy efficiency.

High-density iron-based pre-mixed powder

Kobe Steel, Ltd won an award for a new concept for an iron-based premix that combines increased density in sintered parts – achieved by reducing the amount of lubricant – with improved powder flowability. Powders with good compressibility can achieve high green and sintered density, contributing to the overall improvement of sintered part qualities. Reducing the amount of lubricant in the premixed powder is an effective method for increasing green density without additional equipment such as warm compaction or die-wall lubrication compaction. Therefore, there is a growing demand for lubricants that provide effective performance in low quantities. However, lubricants with enhanced lubricity often exhibit strong adhesion, leading to agglomeration with iron powder and reduced flowability in the premixed powder, making it challenging to balance lubricity and flowability. As a new approach, a substance with low adhesion to the lubricant

Fig. 6 High-density iron-based pre-mixed powder with improved flowability (Kobe Steel, Ltd)

“These developments have reduced oil leakage and improved reliability and have made it possible to use the motor in a downward position. As a result, the bearing was adopted for ECU cooling fans for ADAS, where ball bearings had been the mainstream.”

has been introduced on the surface of the iron powder, achieving both improved lubricity and flowability. This material has achieved a 30% reduction in shear adhesion stress compared to conventional powder, with improvements in die fillability and a reduction in weight variation during continuous compaction. The green and sintered properties are consistent with the density obtained, making this powder mix a promising solution for the easy production of high-density parts, with its widespread adoption in the industry expected.

Effort prizes

ECU cooling fan bearings

Porite Corporation won a prize for bearings used in ECU cooling fans that manage Advanced Driver Assistance Systems (ADAS) (Fig. 7). In recent years, ever more ADAS ECUs have been installed in conjunction with connected, automated, and electrified systems. Since increased processing speed is essential for the ADAS ECUs to perform their respective functions, heat generation is high and cooling fans must be installed. This product is a bearing

for a fan motor that faces downward and requires countermeasures against oil leakage due to oil expansion and viscosity decrease at high temperatures. As countermeasures, the outer diameter chamfer was enlarged to secure an oil retention space, and the inner diameter chamfer angle was reduced from 45° to 30° to strengthen the capillary force and make it easier to retain oil. In addition, a groove is provided on the outer diameter to allow air to escape during motor assembly and motor operation. For the impregnating oil, the company has ensured durability by selecting a unique oil with low viscosity change with temperature and low evaporation for long life in response to the demand for use in a wide range of temperatures from -40°C to 105°C. These developments have reduced oil leakage and improved reliability and have made it possible to use the motor in a downward position. As a result, the bearing was adopted for ECU cooling fans for ADAS, where ball bearings had been the mainstream.

Sintered actuator components

Fine Sinter Co, Ltd won a prize for components for a four-wheel drive vehicle transfer actuator (Fig. 8). This is a vital power transmission component that supports high traction performance and driving stability on a wide range of on- and off-road conditions by dividing power from the engine to the front and rear wheels in four-wheel drive vehicles. It consists of a plate, which receives the output from the motor, and a sintered gear that provides output to the rack. Sintered gears require tensile strength and wear resistance so that they are able to withstand driving force, and the joints require rotational torque strength to withstand power transmission and vertical gear pull-out strength.

Given that this is an assembled component, the assembly phase for the gear teeth and plate also needed to be devised. For the sintered gear materials, a Ni-Mo alloy steel was chosen, which achieved the required

Fig. 7 Development of ECU cooling fan bearings for ADAS (Porite Corporation)

strength and wear resistance by sintering without the need for heat treatment, and the green density and heating/cooling conditions during sintering were further optimised to obtain a tensile strength of 700MPa or more. Caulking was adopted for the joint, and the joint shape was that of a petal-shaped boss, where the size and number of petals were

studied to obtain torque strength, and the slit width was designed to prevent phase errors.

The gear end surface shape was devised with clearance/allowance to avoid unwanted displacement or angular misalignment. These developments have succeeded in realising a mass-produced actuator that combines different materials.

“Sintered gears require tensile strength and wear resistance so that they are able to withstand driving force, and the joints require rotational torque strength to withstand power transmission and vertical gear pull-out strength.”

Contact

Japan Powder Metallurgy Association

Matsuda Shoji Bldg. 3-42-7, Taito, Taito-ku, Tokyo 110-0016, Japan

www.jpma.gr.jp info@jpma.gr.jp

Fig. 8 Sintered actuator components (Fine Sinter Co, Ltd)

Advertisers’ index & buyer’s guide

Our advertisers’ index and buyer’s guide serves as a convenient guide to suppliers across the PM supply chain. In the digital edition of Metal Powder Technology magazine, available at www.metal-powder.tech, simply click on a company name to view its advert, or on the company’s weblink to go directly to its website.

GKN Powder Metallurgy 08 www.gknpm.com

Höganäs AB IFC www.hoganas.com

Jiangmen Hongjia New Mat. Tech. Co., Ltd 47 en.hongjiakj.com

Kymera International 06 www.kymerainternational.com

Mimete S.r.l. 21 www.mimete.com

Rio Tinto QMP 04 www.riotinto.com

AM MACHINES

InssTek, Inc. 13 www.insstek.com

FURNACES

Carbolite Gero Ltd. - Verder Group 17 www.carbolite-gero.com | www.verder-scientific.com

ATM Qness GmbH - Verder Group 17 www.qatm.com | www.verder-scientific.com

BluePower Casting Systems GmbH 43 www.bluepower-casting.com

ELTRA GmbH - Verder Group 17 www.eltra.com | www.verder-scientific.com Granutools 22 www.granutools.com

Microtrac Retsch GmbH - Verder Group 17 www.microtrac.com | www.verder-scientific.com

COMPACTION PRESSES, TOOLING & ANCILLARIES

www.dorst.de

Komage Gellner Maschinenfabrik KG

www.komage.de Osterwalder AG 45 www.osterwalder.com

SACMI Imola 41 www.sacmi.com

System 3R International AG

www.system3r.com

CONSULTING & TOLL SINTERING

DSH Technologies, LLC

www.dshtech.com

Alphabetical index

APMA

apma2025.scimeeting.cn Euro PM2025

www.europm2025.com

www.mim2026.org Plansee Seminar 2025

www.plansee-seminar.com PM China 2026 79 en.pmexchina.com

PowderMet2025 / AMPM2025 70 www.powdermet2025.org / www.ampm2025.org

RAPID + TCT 2025 80 www.rapid3devent.com EVENTS

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