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Elmet Technologies Granted U.S. Patent for Tungsten Heavy Metal Alloy Powders
Elmet Technologies, a tungsten and molybdenum manufacturer based in Lewiston, Maine, has secured U.S. Patent No. 12,359,290, titled “Tungsten Heavy Metal Alloy Powders and Methods of Forming Them.” This is the fifth U.S. patent in this area, covering methods related to powders used in additive manufacturing and powder metallurgy applications.
The patented process leverages advanced spray drying and optional plasma densification techniques to produce substantially spherical, flowable, and highly densified composite particles. This material structure improves powder bed uniformity and thermal conductivity during sintering — key advantages for fabricating aerospace, defense, and industrial parts where mechanical strength and precision are critical.
“This patent reinforces Elmet Technologies’ commitment to materials innovation,” said Michael T. Stawovy, coinventor and director of research and development at Elmet Technologies. “Our approach enhances the production of tungsten heavy alloy powders with exceptional flowability and chemical uniformity — features essential to achieving repeatable, high-quality parts through additive manufacturing.”
Key features of the patented invention include tailored alloy compositions, improved powder morphology, and superior densification.
The technology also addresses a long-standing challenge in metal additive manufacturing: producing highly pure, flowable powders that retain their shape and properties under extreme processing conditions.
The resulting powders are suited for binder-jet printing and other powder-bed techniques, enabling the production of high-strength tungsten parts for extreme environments.
Nissan Introduces Cold-Sprayed Valve Seat in New e-POWER Engine
Nissan, Yokohama, Japan, is utilizing cold spray technology to manufacture valve seats in its new 1.5-liter turbocharged engine, designed exclusively for power generation within the third-generation e-POWER hybrid power train.
The first vehicle globally to feature this new e-POWER system is the Qashqai compact crossover, which began production at Nissan’s Sunderland, UK, factory in July.
To enable optimal performance in the hybrid system, Nissan developed a new valve seat using cold spray technology, a move the company reports is a world’s-first application in automotive engines. The process involves spraying dissimilar metal powders at supersonic speed onto the aluminum alloy cylinder head surface, forming a robust and durable coating that adheres strongly without melting the base material. This prevents the formation of excessive intermetallic compounds and porosity that are common in traditional fusion welding methods. As a result, cold spray coatings exhibit superior adhesion, durability, and reliability.
The process incorporates a specially developed cobalt-free, copper-based alloy with excellent thermal conductivity, in-house nozzles inspired by polishing techniques used in forged mold production, and AI-driven quality assurance systems.
Thermal Spray Pioneer and Inventor Passes Away at 92
Daniel R. Marantz, a significant contributor to the thermal spray industry, passed away on July 4 at the age of 92.
His innovations included developing two-wire electric arc spraying for corrosion-resistant coatings on steel structures, advancing plasma-transferred arc welding for hardfacing applications, and creating novel plasma spray torch systems. Collaborating with engineers across disciplines, Marantz pioneered new approaches to hardfacing and corrosion protection that remain influential today.
Marantz attended Lafayette College, Easton, Pa., in the 1950s and later served two years in the U.S. Army Radio Corps. After his military service, he held several engineering positions before founding Flame Spray Industries Inc. (FSI) in 1964. A one-person operation until 1988, FSI grew steadily under Marantz’s leadership, eventually employing a dedicated team. Though he officially retired in 2000, he continued to consult, advise, and regularly share his ideas with the FSI team as well as with other colleagues and friends.
He developed a large portfolio of devices and processes — many still in use today — including a composite feedstock for electric arc spraying, automated arc spray systems, plasma-
transferred arc welding equipment, high-velocity oxygen fuel torch systems, internal-feed multiplasma spray torches, and the plasma-transferred wire arc internal diameter plasma spray torch.
Marantz’s achievements were recognized with numerous patents and prestigious honors. He was named the 2009 Inventor of the Year by the Intellectual Property Owners Education Foundation and was inducted into the Thermal Spray Society’s Hall of Fame.
Marantz was also passionate about education. At the State University of New York at Stony Brook, he supported undergraduate and graduate programs, mentoring students on senior design projects and advising graduate research in thermal spray technology. His generosity with time, knowledge, and encouragement left a lasting mark on future generations of engineers.
Höganäs AB Presents Global University Challenge to Unlock New Applications for Metal Powders
Höganäs AB, Höganäs, Sweden, a producer of ceramic and metal powders, recently launched PowdrIQ, an international university challenge inviting undergraduate, master’s, and PhD students to propose innovative applications for metal powders.
Participants must identify new applications where metal powders are not currently used but could make a difference, focusing on three key areas: sustainability, performance and efficiency, and market needs.
“We are convinced that there is still significant potential for metal powders to contribute to more sustainable and innovative solutions across industries, and with PowdrIQ, we want to inspire students to explore new possibilities driving positive change,” said Emma Lefdal, VP group communication, brand and public affairs, Höganäs.
An internal Höganäs jury will evaluate submissions based on innovation, feasibility, sustainability impact, and industry relevance. Winners will receive cash prizes of up to €5000 (about $5796), with the first-place winner also awarded a study trip to a Höganäs site.
Arzell Marks 20 Years in Thermal Spray with New Modular Systems and EU Expansion
Arzell Inc., Cypress, Tex., a manufacturer of thermal spray systems, is celebrating its 20th anniversary with the launch of new modular systems and expansion into the European Union (EU) market.
The company develops proprietary equipment in-house, including plasma, high-velocity oxygen fuel, and combustion spray systems. It has recently introduced the Multus family of modular spray systems, including the Multus-C Cascade plasma system, featuring patented C+ and CV+ torches.
The company has also launched Arzell EU GmbH in Germany, strengthening its ability to serve customers across Europe, the Middle East, and Africa with faster response times and localized support.
Winners will be announced on Höganäs AB social media accounts in 2026.
GARDCO Transitions to PFAS-Free Products
Paul N. Gardner Co. USA (GARDCO), Columbia, Md., a manufacturer of physical and inspection instruments for the paint, coatings, and related industries, will phase out products containing per- and polyfluoroalkyl substances (PFAS) as of December 31. This move aligns with emerging international regulations and market expectations.
PFAS, known as “forever chemicals” for their persistence in the environment, cumulative nature, and ecological toxicity, have become the focus of increasingly stringent regulations worldwide. Several individual PFAS compounds are already restricted, and the European Union has set the first group-wide ban.
The transition to PFAS-free products offers advantages, including eliminating highly persistent and toxic chemicals and aligning with global standards. The company anticipates new business opportunities from customers seeking PFAS-free solutions and a reduction in regulatory workload across departments.
The company’s PFAS phase-out began in June 2024. The transition affects all products containing Teflon (Tefcrom applicators, Teflon-coated thermometers, disperser blades, etc.). Effective non-stick alternatives to PFAS, such as Cerakote and other substitute materials, are already in place for the affected product lines.
ATL Turbine Services Expands Thermal Spray Capabilities with System Investment
ATL Turbine Services, based in Dundee, UK, has invested in the Surface Two™ thermal spray system from Oerlikon Metco, Wohlen, Switzerland. This purchase enables ATL to deliver high-performance, precision-engineered coating solutions for turbine components across the aerospace, energy, and industrial sectors.
The Surface Two™ system is designed for scalable, IIoT-enabled thermal spray applications and offers increased capacity, automation readiness, and consistent process performance. With the ability to handle components up to 2000 mm (78.74 in.) in diameter and 1500 mm (59.06 in.) in height, the system suits ATL’s focus on servicing medium-to-large turbine parts.
The new system has been fully integrated into the company’s production environment, supporting both refurbishment and new component coating processes.