Abstract This article introduces "Smart Repair," an integrated scan-to-repair workflow that advances robotic cold spray additive manufacturing (CSAM) beyond the traditional trade-off between flexible manual repair and rigid, pre-programmed robotic repair. Built on CSIRO's Continuous3D software platform, the system uses in-cell 3D scanning to generate a live digital model of a damaged component, automatically identifying repair regions and generating collision-free, optimized robotic toolpaths without manual coding or reliance on CAD files. A case study restoring a PT6 gearbox housing demonstrates that this approach enables efficient, high-quality automated repair of one-off and variably damaged parts that were previously impractical to automate.
Abstract This technical spotlight examines how rotating beam fatigue (RBF) testing can be a faster and more economical alternative to conventional axial fatigue testing for characterizing material endurance limits. The article contrasts the high setup costs, alignment sensitivity, and time-intensive nature of axial testing with RBF's self-centering collet design, higher testing frequencies (up to 100 Hz), and surface-sensitive stress measurement, which together enable dramatically reduced test times and costs. While acknowledging that axial-torsion testing remains necessary for applications requiring complex, multi-axis loading replication, the authors argue RBF is democratizing fatigue data generation for materials researchers, quality managers, academic labs, and testing facilities alike.
Abstract The second installment of a three-part series traces the expansion of nickel-based superalloy 718 beyond aerospace turbines into critical applications, including large power turbine rotors, rocket engines (notably the Space Shuttle Main Engine), cryogenic systems, nuclear reactors, oil and gas production tooling, and high-strength fasteners. The article highlights how alloy 718's combination of high strength, weldability, corrosion resistance, and performance across extreme temperature ranges—from liquid helium to 1200 °F—drove its adoption. It also details key metallurgical developments, such as delta-phase control and specialized heat treatments, that enabled its use in increasingly demanding environments.
Abstract From the 1930s through the 1950s, Metal Progress — the flagship publication of the American Society for Metals (now ASM International)—featured bold, distinctive cover designs. The artwork ranged from oil paintings and geometric abstractions to exquisite photography, all unified by a common thread: some reference, however stylized, to the processing or application of metals. This article features several striking examples of covers from that period.
Abstract The Aluminaire House, the first all-metal residence in the U.S., pioneered aluminum and steel construction as a scalable, affordable housing prototype. Designed in 1930-1931 by A. Lawrence Kocher and Albert Frey, the structure demonstrated that factory- produced components—aluminum columns, steel decking, sheet metal cladding, and plate glass—could be rapidly and affordably assembled into a habitable dwelling. The house was recently restored and reinstalled at the Palm Springs Art Museum.
