Ames Lab debuts high‑temperature metal powder system to speed fusion materials

Researchers at Ames Laboratory introduced a refractory metal powder atomization system capable of processing up to 3400°C at about 1 kg per minute using a transferred-arc plasma method, locally melting feedstock to atomize powder while forming a protective skull in a water-cooled copper hearth. This enables faster development, testing, and scaling of extreme-environment materials for gas turbines and fusion energy, addressing a critical powder-supply gap; although yields for high-temperature alloys are typically 10–20% (vs 50–60% for conventional alloys), the system broadens access and could accelerate adoption by U.S. industry.