Authors:
Markus Schneider (GKN Sinter Metals Engineering GmbH, Germany), Tina Schlingmann (EOS GmbH, Germany), Dirk Bettge (Bundesanstalt für Materialforschung und -prüfung, Germany), Kai Hilgenberg (Bundesanstalt für Materialforschung und -prüfung, Germany), Maximilian Binder (Fraunhofer-Institut für Gießerei-, Composite- und Verarbeitungstechnik, Germany), Burghardt Klöden (Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung, Germany)
Abstract:
When it comes to higher accuracies, new technologies and real applications in additive manufacturing, there is one topic which cannot be avoided: The material response on the chosen processing parameters and its agreement and correspondence with literature data of the wrought material grade counterpart. In industrial additive manufacturing standards in terms of printing parameters, protection gas atmospheres or powder handling instructions are not obligatory. Therefore, the question must be answered whether the additive manufacturing process is reproducible and reliable over different printing companies. This was the motivation to realize a round robin test between 8 European printing companies and academic partners. The consortium had printed and tested fatigue and tensile testing bars under plant-specific conditions. A commonly used cast aluminum alloy, AlSi10Mg, was chosen as test material for the PBF-LB|M process. Differences of the results between the partners and the scatter itself were discussed in detail.
DOI:
https://doi.org/10.59499/WP225377471
Authors:
Delvin Wuu (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Zheng Zhang (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Yinn Leng (Linus) Ang (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Verner Soh (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Te Ba (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Zhiqian Zhang (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Pei Wang (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore)
Abstract:
Advancements in space repair technology are essential for extending mission longevity. This research investigates lightweight robotic cold spray additive manufacturing (CSAM) for repairing freeform components of damaged orbital equipment, offering a versatile, resource-efficient solution for microgravity environments. Focusing on copper—a critical material for thermal and electrical conductivity in spacecraft—the study examines key process parameters such as nozzle standoff distance, gas pressure, and temperature. By systematically analysing their effects on pososity, this work aims to identify optimal conditions for reliable on-orbit repairs. The integration of CSAM not only enhances mission safety and reduces costs but also supports the principles of a circular economy in space exploration by minimizing waste and maximizing resource utilization. This research advances the capabilities of CSAM for sustainable space applications, contributing to the long-term success of space missions.
DOI:
https://doi.org/10.59499/EP256765855
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Authors:
Shandra Sainz (CEIT, Spain), Odei Ruiz (CEIT, Spain), Iñigo Iturriza (CEIT, Spain), Brian Kernan (Desktop Metal, USA), Ashley Morishige (Desktop Metal, USA), Steve Hudelson (Desktop Metal, USA), Francois Dary (Desktop Metal, USA)
Abstract:
Single Pass JettingTM technology was explored using the Desktop Metal’s Production SystemTM P-1 to develop a 440C stainless steel with Nb addition. A MIM powder grade was used as the raw material and the complete process towards its densification has been defined, from the selection of the appropriate powder conditioning and printing parameters to the identification of the sintering and heat-treating cycles considering metallurgical criteria. On those grounds, C and Nb content as well as the sintering atmosphere play a critical role. Chemical analysis and metallographic characterization were performed to analyse the evolution of the porosity and the microstructure. The steps of the heat treatment were selected based on retained austenite monitoring and a target hardness of 58±1 HRC. Testing samples were printed to evaluate the tensile and impact properties of the alloy against Standard MPIF35 .
DOI:
https://doi.org/10.59499/WP225372017
Authors:
Mikael Luoto (1), Dr. Enrico Daenicke (2), Ralf Müller (2), Dr. Thomas Hartwig (1)
1- Fraunhofer IFAM, Bremen
2- Rolls-Royce Deutschland Ltd. & Co.KG, Germany
Abstract:
Although Metal Injection Moulding (MIM) is a process for parts with complex designs, not all geometries are feasible. The goal of the project was to find a way to bond individually moulded parts before the sintering step and to assess the quality of the achieved sinter joining. Material Inconel 713 Low Carbon was selected for this study. The bonding of the parts was realized by applying adhesive pastes on the parts after solvent extraction. The mechanical properties of sinter joined parts were assessed by using tensile, fatigue (low cycle) and creep (stress rupture) tests. The tensile test showed that the proof stress and ultimate tensile strength were comparable to unjoined baseline material, but a drop in elongation was observed. The creep properties were similar to unjoined baseline material, but a decrease of fatigue properties was measured. A “housing” geometry that is not producible using the conventional MIM-process was manufactured as a demonstrator and it showed that it is plausible that sinter joining could be used for serial production.
DOI:
https://doi.org/10.59499/EP246278323
Authors:
Hosam ElRakayby, KiTae Kim
Abstract:
Hot isostatic pressing is a near-net-shape manufacturing process that usually uses a metal container to encapsulate powders then consolidate them to fully dense compacts. Metal containers induce the Mises stress to powder compacts due to the rigidity of the container walls. Thus, anisotropic deformation of powder compacts. This paper investigates the effect of glass container encapsulation on densification and deformation behaviors of 316L stainless steel powder during hot isostatic pressing. Finite element results were compared with measured deformed shape of powder compact after hot isostatic pressing to study the capabilities of glass containers to form near-netshape parts. Glass container showed more homogeneous densification and isotropic deformation of compacts than conventional metal containers.
DOI:
https://doi.org/10.59499/EPgfhgsd
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Authors:
Tobias Deckers (Linde GmbH, Germany), Thomas Ammann (Linde GmbH, Germany), Kai Zissel (Linde GmbH, Germany), Franz Wolf (Linde GmbH, Germany), Gerd Witt (University Duisburg-Essen, Germany)
Abstract:
This paper aims to investigate the influence of the process gas atmosphere during the Powder Bed Fusion of Metals using a Laser Beam (PBF-LB|M) of a Nickel-Chromium alloy on the melt pool geometries of single laser tracks and on the discoloration of process by-products. The trials were performed on an EOS M290, which was equipped with a photodiode-based melt pool monitoring system (MPM). First results indicated differences in the intensity levels of the MPM signal and in the penetration depths. Furthermore, a correlation between the discoloration of the sampled powder material and the intensity level of the MPM signal was detected.
DOI:
https://doi.org/10.59499/WP225372132
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Authors:
Juan Jiménez (1), Javier Hidalgo (1), Cristina Berges (1), Roberto Campana (2), Gemma Herranz (1)
1- DYPAM Research Group, INEI-ETSII, Universidad de Castilla-La Mancha (UCLM), ETSI Industriale
2- Centro Nacional del Hidrógeno, Prolongación Fernando el Santo s/n, Puertollano, 13500, Ciudad Real, Spain
Abstract:
This study explores innovative approaches to boost the Solid Oxide Fuel Cell (SOFC) interconnector industry, integrating intelligent master alloy design and powder injection molding (PIM). Current challenges in interconnector fabrication via powder metallurgy include the economic high-scale production of complex designs for improved SOFC performance and the restricted availability of commercial powders. To address these limitations, we propose the use of commercial high-Cr master alloys combined with ferrous powders, aiming for compositions equivalent to or surpassing standard Crofer 22. This strategy overcomes powder scarcity challenges and enables precise control over shrinkage and thermal expansion coefficient, crucial for producing ambitious large thin-walled interconnector geometries through PIM. A comprehensive comparative study, covering all PIM stages and properties characterization, is conducted, comparing Crofer 22 pre-alloyed powders with a modified Fe-Cr alloy incorporating additional elements for enhanced performance.
DOI:
https://doi.org/10.59499/EP246282995
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Authors:
Gabriel Caballero (Universidad Carlos III de Madrid, Spain) Lucia Garcia de la Cruz (Universidad Carlos III de Madrid, Spain) Paula Alvaredo (Universidad Carlos III de Madrid, Spain) Mónica Campos (Universidad Carlos III de Madrid, Spain)
Abstract:
Additive manufacturing (AM) encompasses various techniques, one of which is material extrusion (MEX). When the material used is in granular form, it is referred to as g-MEX, which stands out for its versatility and cost-effectiveness in fabricating complex metallic components. A comprehensive analysis was conducted across all stages—pre-printing, printing, and post-processing. Preliminary characterizations, such as metal powder granulometry, rheology, thermogravimetry, optimization of binder system components, as well as printing parameters and final stages like debinding and sintering were examined. The goal was to achieve fully dense metallic parts, monitoring quality parameters such as final density, dimensional shrinkage, mechanical properties, among others. This research aims to clarify how preliminary characterization is key to a successful printing stage, highlighting its predictive power and potential application when using other metallic materials depending on the required application.
DOI:
https://doi.org/10.59499/EP256764736
Authors:
Alessandra Martucci (1), Giulio Marchese (1,2), Alberta Aversa (1,2), Diego Manfredi (1,2), Sara Biamino (1,2), Daniele Ugues (1,2), Federica Bondioli (1,2), Massimo Messori (1,2), Mariangela Lombardi (1,2), Paolo Fino (1,2)
1- Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy
2- Consorzio Interuniversitario Nazionale per la Scienza e Tecnologia dei Materiali (INSTM), Via G. Giusti 9, 50121 Firenze, Italy
Abstract:
The Powder Bed Fusion-Laser Beam is a promising additive-manufacturing process that allows the production of complex-shaped functional components for many applications. However, the layer-by-layer scanning and high cooling rates result in a high thermal gradient (ΔT) and, thus, in thermally induced stresses that could lead to undesirable cracking and delamination phenomena in the final component. A strategy to reduce the ΔT and facilitate a correct heat flow is using support structures. However, the support geometry needs to be optimised, considering that the thermal resistance increases as the support-height increases and the contact cross-section decreases. Furthermore, it is essential to consider the anchoring function of the support structures. Based on these considerations, two geometric indices and a decision support matrix were developed in the present work for a quick and efficient setting of geometric parameters. The robustness of the developed approach was verified on two different alloys: AlSi10Mg and IN625.
DOI:
https://doi.org/10.59499/EP235725900
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Authors:
Dominic Peachey (1), Vivès Solange (2), Yining He (1), Pimin Zhang (1), John Clark (1), Zara Hussain (1), Thomas Wagstaff (1), André Nemeth (1), David Crudden (1)
1- Alloyed Ltd., Oxford, UK
2- Aubert & Duval, Paris, France
Abstract:
The evolution of additive manufacturing (AM) has sparked a growing interest in using nickel-based superalloys, particularly for high-temperature applications above 1000°C. Traditional alloys, intended for casting or wrought processes, face challenges in AM due to the rapid heating/cooling rates and multiple melt cycles, resulting in compromises to material performance or part design freedom. Here we introduce ABD®-1000AM, a novel high gamma prime nickel-based superalloy designed computationally using the Alloys-by-Design (ABD®) approach, tailored for high-temperature AM applications. ABD®-1000AM exhibits world leading performance in terms of both processing capability as-well-as high temperature mechanical and environmental performance at 1000°C. The study discusses the alloy design and development strategy, highlighting the trade-offs in key performance parameters and the intricate process-microstructure-performance optimization undertaken to achieve the alloy's exceptional creep resistance. Based on the insights gained the future direction of alloy development of superalloys for complex AM components is discussed.
DOI:
https://doi.org/10.59499/EP246283346
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Authors:
Leonhard Gertlowski (Institute of Applied Powder Metallurgy and Ceramics (IAPK), Germany) Oliver Schenk (Institute for Materials Applications in Mechanical Engineering (IWM), Germany) Stefan Müller (Chair Materials Technology, Germany) Santiago Benito (Chair Materials Technology, Germany) Sebastian Weber (Chair Materials Technology, Germany) Christoph Broeckmann (Institute for Materials Applications in Mechanical Engineering (IWM), Germany)
Abstract:
High-speed steels are commonly used for cutting tools that require a high impact toughness and fatigue resistance. Both properties are significantly enhanced by employing the powder metallurgical production (PM) route using hot isostatic pressing (HIP) as consolidation technique. The fatigue strength is conventionally assessed by Wöhler tests that imply a systematic variation of the stress amplitude in the vicinity of the presumed load limit, employing multiple specimens. However, the available test volume is limited by the size of the HIP capsule. Hence, an accelerated fatigue testing method is presented that can significantly reduce the use of material and time by determining the fatigue limit with a single specimen. This method involves the measurement of the temperature rise in a sample during a load increase test whose characteristic course indicates damage initiation. Its validity is demonstrated by the determination of the fatigue limit for HS6-5-3 employing both accelerated and conventional testing.
DOI:
https://doi.org/10.59499/EP256767866
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Authors:
W. Schoeffmann (1), C. Knollmayr (1), K. Mehrabi (1)
1- AVL List GmbH, Austria
Abstract:
The goal of zero carbon operation of powertrain systems requires compatibility for Ethanol, Methanol and in particular Hydrogen as future energy carriers for internal combustion engines (ICE) as well as Fuel Cell systems. Future AM applications will include complex components in combination with high grade materials, such as high temperature, alcohol and hydrogen resistant steel and nickel alloys, for low and medium volume production. Multi-material AM processes, combining multi-metal manufacturing, are subject of research programs and will support the mobility change by extending the applications to E-Motors, Fuel Cell systems and battery components. Focus of the paper is on the application of metal-AM for prototype and small series of appropriate powertrain components providing material compatibility for CO2 neutral fuels. The motivation for the conversion from conventional to additive manufacturing is discussed in regard of functional optimization with AM-process related production design, as well as economically to achieve higher profitability.
DOI:
https://doi.org/10.59499/EP246281384
