The demand for large-scale components, weighing at least 10,000 lbs., has surged across sectors such as aerospace, defense, nuclear, oil, gas, renewables, and construction. However, traditional manufacturing techniques like casting and forging have declined in the U.S., leading to supply chain shortages as production increasingly shifts overseas. Oak Ridge National Laboratory (ORNL) researchers are initiating advanced manufacturing technologies to revitalize the production of these large metal parts via powder metallurgy-hot isostatic pressing (PM-HIP).

The global PM industry was in full force as individuals from 27 countries visited the WORLD PM2024 Congress in Yokohama, Japan, to “Make a better world with PM.”  The biennial World Congress included presentations on the latest PM technologies, suppliers introducing cutting edge products and services, and networking events to welcome the international community.

Minnesota-based Niron Magnetics has opened a commercial pilot plant to develop “Clean Earth Magnets” that are developed from iron and nitrogen. The company says the magnets have the potential to be used in electric vehicles, wind turbines, audio products, and defense applications. 

GKN Powder Metallurgy has developed a new generation of Porous Transport Layers (PTL) for Proton Exchange Membrane (PEM) electrolysis. The solution is designed to revolutionize hydrogen production by increasing efficiency while reducing overall environmental impact.

As the demand for large-scale metal parts continues to rise across sectors such as clean energy, aerospace, and defense, the Department of Energy’s Oak Ridge National Laboratory (ORNL) is spearheading research, supported by the Metal Powder Industries Federation and the Electric Power Research Institute, to re-establish U.S. manufacturing dominance in this area. Through advancements in powder metallurgy-hot isostatic pressing (PM-HIP), paired with additive manufacturing (AM) techniques, ORNL is offering what it considers a high-precision alternative to traditional casting and forging methods.