ORNL PM-HIP Breakthrough Targets Larger Critical Metal Parts

Oak Ridge National Laboratory has developed a manufacturing method that could make large critical metal parts faster to produce, easier to customize, and less dependent on conventional casting and forging supply chains.

The U.S. Department of Energy laboratory announced on May 14 that its researchers used additive manufacturing to fabricate custom canisters for powder metallurgical hot isostatic pressing, known as PM-HIP. The process is used to consolidate metal powder into fully dense parts for demanding applications such as turbine components, pressure vessels, aerospace structures, energy systems, and medical equipment.

In traditional PM-HIP production, canisters are formed through several steps that can include metal forming, machining, and welding. Those steps add cost, extend lead times, and can introduce defects. ORNL’s approach uses 3D printing to build the canister closer to the final geometry of the part, allowing more complex shapes while reducing waste and production time.

The process works by filling the printed canister with metal powder, vacuum sealing it, then applying high heat and pressure inside a hot isostatic press. That combination compresses the powder into a dense metal component with minimal internal defects. ORNL reported that the team used several printing methods, including laser- and wire-based techniques, and previously demonstrated a 2,000-pound PM-HIP canister using 410NiMo, a stainless-steel alloy.

For specialty metals and fabrication teams, the development matters because PM-HIP metal manufacturing can support advanced alloys built for corrosion resistance, high-temperature stability, radiation resistance, and structural reliability. Those properties are valuable in next-generation nuclear systems, hydropower, aerospace, and other environments where conventional parts may face long lead times or limited supplier capacity.

The work also adds a digital manufacturing layer. ORNL researchers are using mechanics-based computational models to predict shrinkage and distortion during PM-HIP processing, reducing trial-and-error development and improving confidence before production begins.

If the process scales, manufacturers could gain a more flexible route for large, near-net-shape metal components. That could strengthen U.S. industrial capacity in sectors where material performance, lead time, and supply chain resilience now carry strategic weight.

Article & Image Source: Oak Ridge National Laboratory