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About this Abstract
Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Additively Manufactured Refractory Alloys for Structural Applications Above 1200 °C
Author(s) Saket Thapliyal, Haozhi Zhang, Julio Rojas-Ortega, Brian Jordan, Timothy Horn, Sebastien Dryepondt, Michael Kirka
On-Site Speaker (Planned) Saket Thapliyal
Abstract Scope Considering the vast component design space enabled by fusion-based additive manufacturing (F-BAM) processes, the scale-up manufacturing of Nb-alloys with F-BAM is advantageous for structural applications. Furthermore, leveraging the ‘high-entropy’ concept in Nb-rich alloys potentially provides a pathway for designing synergistically strong and lightweight ultra-high temperature alloys. However, the processing of these alloys remains challenging due to their high tendency to undergo impurity-induced embrittlement. Additionally, the microstructural heterogeneities that are prevalent within the F-BAM-processed alloys have significant implications for the room- and elevated-temperature mechanical behavior. In this talk, we discuss the F-BAM processability, solidification behavior, and mechanical behavior of Nb alloys, including a Nb-rich refractory-high entropy alloy. Implications of F-BAM-generated microstructurally heterogeneous regions for room- and elevated-temperature tensile behavior and damage mechanisms are revealed. Considerations in fabricating crack-free components with F-BAM are discussed. The chemistry-processing-structure-properties relationships as discussed in this work will enable design of scalable and high-strength refractory alloys.
Proceedings Inclusion? Planned: Post-meeting proceedings

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The Alloy Optimization Software (TAOS)
The Effects of Gravity on Track Integrity During Collaborative Robot-Assisted Wire Arc Additive Manufacturing
The Influence of Hot Isostatic Pressing Process on the Fatigue Life of EB-PBF Printed Ti-6Al-4V
Thermal Exposure Optimization for Enhanced Interlayer Strength in FFF-Printed ABS: A DOE and Microstructural Investigation
Thermal History Prediction of More Complex Geometries for DED Based on SciML
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards Scalable and Energy-Efficient Extrusion Additive Manufacturing of Thermoplastic Polymer Composites
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Train Small, Predict Big: Scalable Thermal Surrogate Modeling for LPBF Using MODAL
Transfer Learning for Process–Microstructure–Property Mapping in Micro Selective Laser Sintering
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding Sources of Spatial Density Variation in Green Parts Produced by Binder Jetting
Understanding the Effect of Heat Treatment on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Na3V2(PO4)3-Based Electrodes for Sodium-Ion Batteries
Vat Photopolymerization of Ultra-Soft Polymer Foams
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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