Authors:
Didier Bouvard (Univ. Grenoble Alpes, France), Luis Olmos (Universidad Michoacana de San Nicolas de Hidalgo, Mexico), Jorge Chavez (Universidad de Guadalajara, Mexico), Rogelio Macías (División de Estudios de Posgrado e Investigación, TecNM|Instituto Tecnológico de Morelia, Mexico)
Abstract:
This works proposes a methodology for fabricating materials with specific characteristics tuned for replacing human bones. A Ti64 alloy powder is used as the base materials and it is mixed with Ag, Ta, TiN and salt particles to obtain different features. A knee-bone like component is fabricated, including a highly porous core of Ti64|25Ta|5Ag and compact outer of Ti64|5Ag that is supposed to improve corrosion and osseointegration. Besides, a harder top surface in Ti64|10TiN composite should increase the wear resistance. The green component is sintered at 1260°C in argon. Its stiffness is close to the one of bones thanks to the added porosity, which also provides a permeability close to the one reported for trabecular bones. Tribocorrosion behavior in simulated body fluid is improved by TiN addition. In conclusion, the proposed processing route is able to produce complex components fulfilling specific features required for human bone replacement.
DOI:
https://doi.org/10.59499/WP225371364
-
Authors:
Laura Grau (Pforzheim University, Germany), Carlo Burkhardt (Hochschule Pforzheim | STI, Germany)
Abstract:
The rare earths are some of the most critical raw materials, yet electromobility and green energy strongly rely on Rare Earth Permanent Magnets (REPM). To secure the supply and improve the ecological footprint of REPM, a hydrogen-aided powder-metallurgical reprocessing route was successfully established and continues to be improved. A remaining obstacle is the sourcing and demounting of REPM-containing scrap. Demounting must especially be optimized towards achieving a maximum yield of high-quality material in conjunction with economic efficiency.Electric traction motors, which will be an abundant but dissipated scrap REPM source in the future, are often very hard to demount. To exploit this important raw material source, their design must accommodate efficient recycling. This paper deals with how design choices of the most common rotor permutation, the V-shaped internal Permanent Magnet Synchronous Motor rotor (VPMSM), impact the recyclability of the integrated magnets and provides a design for recycling framework.
DOI:
https://doi.org/10.59499/WP225367983
Authors:
Arnaud Fregeac (1), Méyane Hurtault (1), Céline Larignon (1), Yannick Beynet (1), Romain Epherre (1)
1-Norimat, France
Abstract:
Sinter Based Additive Manufacturing (SBAM) processes are receiving much attention as an alternative to LPBF processes for the rapid production of metal and ceramic components with reduced cost and environmental impact. On the other hand, the sintering step is sometimes difficult to perform for green parts from SBAM process resulting in high residual porosity. This paper proposes a versatile alternative with FAST/SPS hybridisation. The FAST/SPS process is recognised as an R&D method capable of producing high performance parts from a wide range of materials. In recent years, significant progress has been made in overcoming the two main limitations of the technology: production capacity and geometric constraints. An important industrial breakthrough is presented here, with the development of a unique hybrid process that enables the consolidation of 3D SBAM parts by FAST/SPS. It allows green parts to be fully densified (porosity <1%) immediately after printing in a single step and with less than 2 hours of thermal treatment.
DOI:
https://doi.org/10.59499/EP246276973
-
Authors:
Arnaud Fregeac (1), Méyane Hurtault (1), Céline Larignon (1), Yannick Beynet (1), Romain Epherre (1)
1- Norimat, Labège, France
Abstract:
Sinter Based Additive Manufacturing (SBAM) processes are receiving much attention as an alternative to LPBF processes for the rapid production of metal and ceramic components with reduced cost and environmental impact. On the other hand, the sintering step is sometimes difficult to perform for green parts from SBAM process resulting in high residual porosity. This paper proposes a versatile alternative with FAST/SPS hybridisation. The FAST/SPS process is recognised as an R&D method capable of producing high performance parts from a wide range of materials. In recent years, significant progress has been made in overcoming the two main limitations of the technology: production capacity and geometric constraints. An important industrial breakthrough is presented here, with the development of a unique hybrid process that enables the consolidation of 3D SBAM parts by FAST/SPS. It allows green parts to be fully densified (porosity <1%) immediately after printing in a single step and with less than 2 hours of thermal treatment.
DOI:
https://doi.org/10.59499/EP246281550
-
Authors:
Markus Schneider (GKN Sinter Metals Engineering GmbH, Germany), Jack Schwarz (GKN Sinter Metals GmbH, Germany), Wolfgang Schütz (GKN Sinter Metals GmbH, Germany), Alessandro DeNicolo (GKN Sinter Metals Spa, Italy)
Abstract:
MIM 42CrMo4 is a versatile low alloy steel and commonly used in the forging industry. Its properties can be varied with a tailored hardening and tempering treatment over a wide range of strength|ductility combinations. Its high ductility is beneficial for gears, connecting rods, crankshafts, pistons and other automotive and machinery components. This makes that steel grade also attractive for the Metal Injection Molding and Additive Manufacturing industry. Therefore, MIM 42CrMo4 hardened was chosen as third material – after MIM 8620 case-hardened and MIM 100Cr6 hardened – for the internal high cycle fatigue and notch sensitivity study. As presented in the years before, two different injection molding methods and resulting weld line positions were compared. Moreover, the mean stress sensitivity, notch sensitivity, scatter and further s-N line parameters were discussed and compared with the previously characterized MIM steel grades. Its response on a variety of tempering regimes was investigated too.
DOI:
https://doi.org/10.59499/WP225369499
Authors:
Sara Varetti (Leonardo S.p.a, Italy) Luca Margaria (Politecnico di Torino, Italy) Antonio Coluccia (Politecnico di Torino, Italy) Giorgio De Pasquale (Politecnico di Torino, Italy) Alessandro De Zanet (Leonardo S.p.a., Italy) Evanthia Pappa (Leonardo S.p.a., Italy) Abhishek Kumar (Leonardo S.p.a., Italy) Mattia Cabrioli (F3nice, Norway) Matteo Vanazzi (F3nice, Norway)
Abstract:
Joining technologies in aviation ares considered as a backbone. Traditional mechanical methods, like rivets and fasteners add weight, require complex assemblies, and can damage the configuration of composites such as continus fibre breakage during handling. These challenges highlight the need for alternative solutions. The EU-funded MIMOSA project proposes a novel approach for joining metal (AlSi10Mg from Additive Manufacturing, AM) and CFRP, addressing these limitations. The proposed technology focuses on the implementation of mechanical interlocking mechanism between CFRP and 3D metal anchors based on AM (patented design and manufacturing process). The AM process associated with heat treatmens requires customized fatigue characterization of the material to measure the S-N curves as function of some fundamental fabrication parameters (part orientation, surface finishing and heat treatment). This study reports the experimental results of the fatigue tests to assess the feasibility of producing the innovative multi-material joints proposed.
DOI:
https://doi.org/10.59499/EP256766258
-
Authors:
Milad Bemani Lirgeshas (Eurecat, Spain) Marc Mares (Eurecat Centro Tecnológico de Cataluña, Spain) Sergi Parareda (Eurecat Centro Tecnológico de Cataluña, Spain) Michel Encrenaz (HP Printing and Computing Solutions S.L, Spain) Rocio Muñoz Moreno (HP Printing and Computing Solutions S.L, Spain) Antonio Mateo (UPC University, Spain) Raj Das (RMIT University, Australia) Andrey Molotnikov (RMIT University, Australia) Daniel Casellas (Eurecat Centro Tecnológico de Cataluña, Spain)
Abstract:
This study applies rapid fatigue testing, the stiffness method, to assess the fatigue resistance of 17-4 PH metal binder jetting (MBJ) precipitation-hardened martensitic stainless steel. Traditional fatigue tests are costly and time-consuming, limiting the generation of comprehensive data about the different stages of the fatigue mechanism. Especially for additive manufacturing (AM) parts in which the process-induced defects and anisotropy could result in different fatigue resistance and pending to be characterized compared to conventionally fabricated counterparts. The stiffness method has been validated for metal sheets and AM products recently and can estimate the fatigue limit within a day. This brings instrumental value for accelerating the AM industrial adoption ramp when fatigue performance is required. In this work, the method was used to evaluate the fatigue limit of MBJ specimens printed in different directions, showing its ability to estimate the fatigue limit with 90% time and cost savings compared to conventional methods.
DOI:
https://doi.org/10.59499/EP256779339
-
Authors:
Tugce Tekin (1,2), Francesco Naclerio (3), Rasim Ipek (2), Alberto Molinari (1), Matteo Benedetti (1)
1- University of Trento, Trento, Italy
2- Ege University, Izmir, Turkey
3- Pontillo Officine Meccaniche & C., Scafati (SA), Italy
Abstract:
The axial fatigue strength of maraging steel produced by Laser Powder Bed Fusion (L-PBF) was investigated for different heat and surface treatments The following treatments were considered: Direct Aging of the as-built material and a duplex surface treatment consisting in a plasma nitriding followed by a PVD coating. The surface treatment increases the fatigue strength by 40% at 107 cycles, but the improvement decreases with increasing stress amplitude. The improvement is due to the hard diffusion layer, which causes a transition from a surface-initiating failure to an interior-initiating failure at low stress amplitude.
DOI:
https://doi.org/10.59499/EP246281494
-
Authors:
Carlos Romero (Universidad Carlos III de Madrid, Spain), Davide Benedetto (Universidad Carlos III de Madrid, Spain)
Abstract:
Bipolar plate (BP) materials and designs are critical for the performance of a PEMFC and a PEMEC due to their role as reactant and product distributor and electron transporter between cells. With the goal of increasing the power density of the PEMFC stacks, especially for transportation, the weight of the bipolar plate is also an important parameter. Titanium is a material that is a promising alternative to stainless-steel to manufacture light, metallic-based BP if some of its challenges are addressed, one of them being the passivation of its surface during operation, that creates ohmic losses. The aim of this work is to assess the use of powder metallurgy to manufacture titanium-based bipolar plates with the ability to obtain alternative designs for the flow field and the use of suitable surface modification techniques that can improve the performance.
DOI:
https://doi.org/10.59499/WP225370544
-
Authors:
Valerie Goettgens (University of Innsbruck, Austria), Gerhard Leichtfried (University of Innsbruck, Austria), Stefan Mitsche (FELMI-ZFE, Austria)
Abstract:
Bulk metallic glass composites (BMGCs) overcome the unfavorable lack of plastic deformation of completely amorphous alloys by adding ductile metallic shares. This is the first study that attempts to produce a partially amorphous alloy in an inexpensive and straightforward system of Ti-6Al-4V – 15 wt.% Cu using laser powder bed fusion (LPBF) with in-situ alloying. Local chemical inhomogeneities are desired, as they allow simultaneous solidification of different microstructures. In the produced alloy, fabricated with a single melting and a pulsed remelting strategy, partly X-ray amorphous material was found. The remelting strategy led to the increase of the X-ray amorphous phase and caused the number of grains < 1 µm to increase from 7.8 % (single melting) to 14 %. This study shows the feasibility of producing a partly X-ray amorphous alloy in which the amount of X-ray amorphous shares can be controlled with process parameters.
DOI:
https://doi.org/10.59499/WP225367219
-
Authors:
Asier Lores (1), Naiara Azurmendi (1), Iñigo Agote (1), Xabier Gomez (1)
1- TECNALIA, Basque Research and Technology Alliance (BRTA) Donostia/San Sebastian, Spain
2- TÉCNICAS REUNIDAS, Madrid, Spain
Abstract:
In response to the recent demand for innovation in new sustainable energy sources, nuclear fusion emerges as a highly relevant and significant process. Given the international effort invested in manufacturing functional reactors, Additive Manufacturing (AM) stands out as a technology that can contribute to meeting the challenges and objectives of applications requiring advanced designs. This study explores the manufacturability of P91 alloy using Binder Jetting (BJ) for high-pressure applications, including those within prospective fusion reactor systems. Following the optimization of the AM process, subsequent adjustments in sintering, Hot Isostatic Pressing (HIP), and various required heat treatments have resulted in excellent material quality in terms of microstructure. Therefore, this study validates the successful use of BJ technology for employing P91 alloy.
DOI:
https://doi.org/10.59499/EP246283206
Authors:
N. Azurmendi (1), A. Lores (1), I. Agote (1), C.M. Fernandes (2), D. Figueiredo (2)
1- TECNALIA, Basque Research and Technology Alliance (BRTA), Mikeletegi Pasealekua 2, 20009 Donostia-San Sebastián, Spain
2- PALBIT SA P.O. Box 4, 3854-908 Branca, Portugal
Abstract:
Additive manufacturing of hard metals is gaining attention due to the possibility of fabricating complex shaped parts and new functional designs. Among all of them, Binder Jetting (BJ) appears to be one of the most promising technology due to its low-cost, fast manufacturing process that produces stress and crack-free parts with isotropic properties. In the present work, the feasibility of using hard metal thermal spray powders (WC-12%Co) for binder jetting technology has been studied. Properties of two different agglomerated and sintered powders (AMPERIT 519.059 from Höganäs and WOKA 3111FC from Oerlikon Metco) have been analysed and compared. In addition, physical, mechanical and microstructural properties (density, hardness) of the printed parts sintered in a sinter-hip-furnace at 1455°C and 30bars have been evaluated and compared. The obtained results demonstrated the feasibility of using this type of powders for binder jetting, obtaining near full density parts (>99%) with hardness values around 1320 HV and homogeneous fine-medium microstructure.
DOI:
https://doi.org/10.59499/EP235763986
