The Additive Manufacturing Consortium (AMC), operated by EWI, is pleased to announce its 2025 research portfolio, which includes two continuations and two new projects:
- Faster L-PBF Consolidation Rates Via High-Powered Lasers (continued) – The goal of this project is to evaluate pathways to a 4-6x improvement in consolidation rates in L-PBF on a single-laser basis. All experiments are conducted on EWI’s open architecture L-PBF system, enabled with a high-power laser (3-kW near-infrared) and a compatible galvanometer-scanner. Additionally, print experiments are expected to be executed in a nitrogen atmosphere.
- Post-Finishing Evaluation and Powder-Removal Verification Techniques (continued) – There has always been concern around the roughness of metal additive manufacturing (AM) parts and how they can be post-processed to enhance surface quality. Additionally, the challenge of removing trapped powder from internal channels and subsequently confirming its removal remains a key issue. This interest in internal channels has grown as companies look to use AM for heat exchangers. The aim of this project is to determine whether the improved surface finish reduces the secondary processing needed and/or if other OEM’s that produced rougher surfaces require longer secondary processing but produce parts in an overall faster timeline
- Additive Manufacturing in High Entropy Alloys (new) – High-entropy alloys (HEAs), or multi-principal element alloys (MPEAs), offer unique properties, such as high-temperature stability, enhanced specific strength, wear resistance, and excellent corrosion performance in harsh environments. This project will develop L-PBF process parameters for AlxCoCrFeNiCux HEA, as well as the post-process heat treatment to improve the anisotropic microstructure and mechanical properties. The balanced chemical composition of this alloy provides excellent mechanical properties, wear resistance, and thermal performance in extreme environments and elevated temperatures.
- Alternative Alloys to Ti64 for both Powder and Wire Titanium Metal Additives (new) – This project aims to evaluate Ti-6242 alloy, an alternative Ti alloy better suited to the AM process. The Ti-6242 is a near alpha alloy, with comparable ambient mechanical properties to Ti64, but designed to be used in aircraft engine components, airframe parts, and structural components that require high strength and resistance to high temperatures. Additionally, it is ideal for equipment and piping in chemical processing plants due to its corrosion resistance, and its biocompatibility allows it to be used in orthopedic implants and other medical devices.
The goal of the AMC is to support and accelerate the manufacturing readiness of metal additive manufacturing technologies. Members meet quarterly to discuss advances in AM, progress on consortium projects, and future topics for collaborative research. Member companies come from a broad range of sectors including aerospace, defense, automotive, medical, oil and gas, and consumer/commercial products. The membership base draws from industry, academia, and government, as well as equipment and manufacturing suppliers.
To learn about the AMC or find out how to become a member, contact Howie Marotto at [email protected] or Susan Witt at [email protected].