The goal of this project is to develop advanced components from high gamma prime alloys (Haynes 282/Nimonic 105) via innovative manufacturing approaches to enable high temperature/high pressure operation and realize high plant cycle efficiency for advanced ultrasupercritical steam systems (with relevance to gas turbines also). There are several key challenges currently confronting the additive manufacturing (AM) processes for high gamma prime alloys. It is universally recognized that the internal microstructures and performance under load are all dependent on the manufacturing process. Due to the large parameter sets applicable in AM processes and their impact on achievable materials properties and quality, a design of experiments (DOE) approach will be utilized to achieve the optimal crack-free microstructure with acceptable density. For AM of high gamma prime alloys, where the understanding of the effects of feedstock properties, deposition rates, thermal history, cooling rates, defect formation and residual stress is still in an early phase, the DOE approach will achieve the optimal part properties (density/mechanical properties), surface finish and performance, similar to the rolled plate material. Collaboration between ORNL and Siemens will provide the unique opportunity of developing the process parameters, part microstructure/surface finish and bulk properties for Haynes 282 and Nimonic 105. The final goal is to fabricate Haynes 282 and Nimonic 105 components that are of interest to the advanced ultrasupercritical (A-USC) program.