Authors:
Tobias Edtmaier (TU Wien, Austria) Sivagnana Venkatesh Kumaran (ArcerlorMittal, Spain) José Manuel Torralba (IMDEA Materials Institute, Spain) Alberto Meza (IMDEA Materials Institute, Spain)
Abstract:
High-entropy alloys (HEAs) have attracted significant attention in recent years due to their unique microstructures and exceptional mechanical properties. Among these, biphasic HEAs (FCC+BCC phases) offer a promising balance of strength and ductility, especially when their phases are precisely tailored. In this study, Laser Powder Bed Fusion (LPBF) is employed to fabricate two Al-containing biphasic HEAs from commodity powders, followed by post-processing heat treatments involving solution treatment and aging. These treatments are designed to finely disperse the BCC phase as precipitates within the FCC matrix, thereby enhancing mechanical strength and hardness. Microstructural characterization was performed by SEM, EDS, EBSD, and TEM explorations, while the mechanical performance was assessed by hardness measurements, profilometry-based indentation plastometry (PIP), and micro-compression tests at room and high temperatures.
DOI:
https://doi.org/10.59499/EP256767921
Authors:
Rafael Cury (Plansee Tungsten Alloys, France), Pascal Mahot (Plansee Tungsten Alloys, France), Heinrich Kestler (Plansee, Austria)
Abstract:
Amour Piercing fin-stabilized discarding sabot is a type of a non-explosive kinetic energy penetrator ammunition used on anti-tank weapons. It requires material showing remarkable characteristics such as high density, high mechanical and impact resistance in order to provide the best penetration possible against targets. Tungsten Heavy Alloys are commonly used for this type of penetrators. Recently, with the increasing interest on Tungsten Heavy Alloy additive manufactured parts, it became mandatory to investigate the influence of this process on material properties. Thus, additive manufacturing was used to obtain bars, which were submitted to solid-liquid sintering under hydrogen and processed under vacuum to avoid embrittlement. These alloys were fully characterized with respect to their microstructure and mechanical characteristics. Results shown that additive manufacturing is a viable process for this type of alloys.
DOI:
https://doi.org/10.59499/WP225371922
Authors:
Ramin Rahmani (1,2), Javad Karimi (3), Farideh Davoodi (4), João C.C. Abrantes (2), Pedro R. Resende (2), Sérgio I. Lopes (1)
1- CiTin—Centro de Interface Tecnológico Industrial, 4970-786 Arcos de Valdevez, Portugal
2- proMetheus—Instituto Politécnico de Viana do Castelo (IPVC), 4900-347 Viana do Castelo, Portugal
3- BIAS—Bremer Institut für Angewandte Strahltechnik GmbH, Klagenfurter Straße 5, 28359 Bremen, Germany
4- DMMM—Department of Mechanics, Mathematics and Management, Politecnico di Bari, V.Ie Japigia 182, 70126 Bari, Italy
Abstract:
The industry 5.0 revolution prioritizes digital transformation and automation, while also focusing on improving human-machine interface (HMI), improving production and reducing work-related injuries. On the other hand, to tackle the challenge of designing lightweight and complicated structures, new high-tech materials have been developed using combined additive manufacturing (AM) and powder metallurgy (PM) techniques. The futuristic subsections of additive manufacturing (AM) produce composite materials that incorporate both metallic and ceramic components, suitable for a range of applications from art to industrial use. This brief overview examines the key features of the fifth industrial revolution, with particular attention to the selective laser melting (SLM) process. Two specific areas of study include the exploration of an antiviral metal-ceramic composite and also reflective metal fabrication using integrated AM-PM technologies.
DOI:
https://doi.org/10.59499/EP235742275
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Authors:
Sebastian Riecker (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Germany), Robert Teuber (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Germany), Anne Mannschatz (Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Germany), Bernhard Müller (Fraunhofer Institute for Machine Tools and Forming Technology, Germany)
Abstract:
Pseudoelastic behavior with elastic strains of up to 8 % and the shape memory effect are well-known features of nickel-titanium alloys (Nitinol). These properties are highly interesting for the fabrication of e.g. functional auxetic and programmable structures as well as for solid state joints and compliant mechanisms. To extend the current range of available geometries and to enable near-term fabrication of customized complex devices, sinter-based additive manufacturing (AM) of NiTi components via Fused Filament Fabrication (FFF) has been investigated. For this purpose, a highly filled thermoplastic filament (63 vol.-% powder) has been developed which could be printed to complex geometries using standard FFF printers. The AM post-processing steps of debinding and sintering were aiming for extraction of O, C and N to achieve the desired properties. Green state machining experiments resulted in high part quality and low surface roughness of Ra <5 µm.
DOI:
https://doi.org/10.59499/WP225371432
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Authors:
Saeed Khademzadeh (Chalmers University of technology, Sweden), Yijun Zhou (Uppsala University, Sweden)
Abstract:
Additive Manufacturing of non-assembly metallic mechanisms is highly desirable because of their potentially higher performance and low costs due to enhanced structural features and the reduced need for labour-intensive procedures. However, fabrication of such mechanisms using metal AM techniques faces many challenges. For instance, down-skin inclined surfaces suffer from an insufficient quality due to the staircase effect and partially melted attached powder particles that may deteriorate the function of the mechanism since residuary stuck material can block the clearance space. In this work, a novel scanning strategy was employed for the fabrication of non-assembly functional micromechanisms. A threshold angle was defined for activation of a new set of process parameters for down-skin surfaces. Non-assembly ball joints were additively manufactured using laser powder bed fusion technology. The effects of threshold angle, overlap between in-skin and down-skin surfaces, and input energy on the functionality of non-assembly joints was investigated using micro-computed tomography
DOI:
https://doi.org/10.59499/WP225371467
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Authors:
Kay Reuter (Fraunhofer IFAM Dresden, Germany), Inge Lindemann-Geipel (Fraunhofer IFAM Dresden, Germany), Thomas Studnitzky (Fraunhofer IFAM Dresden, Germany), Olaf Andersen (Fraunhofer IFAM Dresden, Germany), Thomas Weißgärber (Fraunhofer IFAM Dresden, Germany), Raphael Koch (Ford Werke GmbH, Germany)
Abstract:
Energy-efficient electric motors are crucial for the progress of electromobility. Soft magnetic materials with a high silicon content, such as Fe6.5Si, offer the possibility of high electrical resistance, high saturation magnetization and comparatively low power losses. However, due to the brittleness of Fe6.5Si, this material cannot be processed using conventional manufacturing methods (such as stamping). By means of 3D screen printing process, this material can be processed through a powder metallurgical processing route. Thus, electric steel sheets with low thickness, high alloying content and high productivity can be realized. We present results of printed and sintered Fe6,5Si electric steel sheets with thicknesses between 100 and 350 µm. The power loss can be reduced below 35 W kg-1 at 1000 Hz and 1 T. The magnetic properties of the sheets will be discussed in dependence on the sintering parameters and the powder properties.
DOI:
https://doi.org/10.59499/WP225371624
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Authors:
Didier Fonta (Pollen AM, France), Thibaud Deshons (Pollen AM, France)
Abstract:
Characterization of metal 3D printed parts produced by direct MIM feedstock extrusion.
DOI:
https://doi.org/10.59499/WP225371995
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Authors:
Esma Mese (1), Haneen Daoud (1), Wolfgang Hofmann (2), Peter Würtele (2), Uwe Glatzel (1)
1- Neue Materialien Bayreuth, Germany
2- Peter Würtele GmbH, Germany
Abstract:
The nickel-based superalloy (MAR-M247) is a non-weldable alloy with attractive high-temperature properties. However, it has not been possible to print components using classic additive manufacturing processes. Sinter-based processes enable the production of difficult and non-weldable alloys. But cracking and porosity in printed components is high. Therefore, in this study, highly filled metal filaments of MAR-M247 were used to print specimens using fused filament fabrication (FFF). The microstructure and weight change were analyzed after printing, debinding and sintering by optical and scanning electron microscopy and EDX. The high temperature tensile tests for sintered samples are presented.
DOI:
https://doi.org/10.59499/EP235735787
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Authors:
T. Lindroos (1), J. Pippuri-Mäkeläinen (1), T. Kinos (1), A. Antikainen (1), T. Riipinen (1), S. Metsä-Kortelainen (1), A. Manninen (1), A. Bertinetti (2), J. O. Odden (3)
1- VTT Technical Research Centre of Finland Ltd., P.O. Box 1000, FI-02044 VTT, Finland
2- Gemmate Technologies s.r.l. - CCIAA Torino REA TO-1189884, Italy
3- Elkem Silicon Product Development AS, Norway
Abstract:
Green electrification is vital for the society’s decarbonization. This sets a strong pressure on manufacturers of electric machines to produce items of higher efficiency and, simultaneously, prepare oneself for forecasted supply risks of raw materials. Additive Manufacturing (AM) is seen as enabler to produce components for novel electric machine architectures with designs and performance unattainable with conventional manufacturing. In this study, a permanent magnet (PM) assisted synchronous reluctance motor based on laser powder bed fusion (L-PBF) AM is introduced. Production of soft magnetic powder tailored for L-PBF and optimization of process parameters and further post treatments to achieve good magnetic properties are shown. Characterized magnetic properties are used as input values for motor design where both performance and possibilities of L-PBF are used as design criteria. Permanent Magnet electric motor of the e-scoot is used as reference. The results show that optimized architectures provide high performance with lower PM content.
DOI:
https://doi.org/10.59499/EP235763996
Authors:
Canto Estany Diana (1), Saula Miquel (1), Sole Macia (1), Puigardeu Aramendia Sergi (1)
1-HP Printing & Computing Solutions, Spain
Abstract:
Ensure test reproducibility and device process repeatability is a must when optimizing or performing a design of experiments on a manufacturing operation. 3D printing additive manufacturing low level subsystem information can be collected and used to trigger investigations on printed parts properties or understand which are the main contributors for a specific one. On 3D HP Binder Jetting printing devices this information is published and can be accessed through an application programming interface (API) or using the HP digital production suite.
DOI:
https://doi.org/10.59499/EP246280947
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Authors:
Ahad Mohammadzdeh (1, 2), Alessandro De Nardi (1, 3), Faraz Omidbakhsh (4), Amir Mostafaei (5), Jose Manuel Torralba (1, 3)
1- Imdea Materials Institute, Calle Eric Kandel, 2, 28906, Getafe, Madrid, Spain
2- Department of Materials Engineering, Faculty of Engineering, University of Maragheh, Maragheh, P.O. Box 83111-55181, Iran
3- Universidad Carlos III de Madrid, Av. De la Universidad 30, 28911, Leganés, Spain
4- Department of Mechanical Engineering, College of Engineering, Islamic Azad University, Tabriz Branch, Tabriz, Iran
5- Department of Mechanical, Materials and Aerospace Engineering, Illinois Institute of Technology, 10 W 32nd Street, Chicago, IL, 60616, USA
Abstract:
A novel CoNi-based high entropy superalloy has been developed for fusion-based additive manufacturing processes based on configurational entropy and high entropy alloy principles. A multi-component compound with the chemical composition of Co-35Ni-8Al-4Ti-4V-2W-2Ta-9Cr was prepared via gas atomization. A comprehensive study was conducted to establish a process-structure relationship in laser powder bed fusion processed CoNi superalloy powder. The effect of processing parameters, including laser power and scan speed, on part characteristics was studied using the Design of Experiment approach based on the response surface methodology. Numerical models validated by experimentation were used to develop a process window to attain parts with a relative density of >99.9%. Advanced electron microscopy incorporated with phase analysis was used to observe grain structure and defects (i.e., pores, microcracks) and phase evolution. It was concluded that thermodynamic predictions were in good agreement with microstructure analysis to attain a single-phase fcc solid solution in the powder and as-built coupons.
DOI:
https://doi.org/10.59499/EP235764983
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Authors:
D. A. Sandoval (1), L. Larrimbe (1), O. Lavigne (1), V. Girman (2,3), R. Sedlak (2), V. Luzin (4), M. Serra (5), M. T. Méndez (6)
1- Hyperion Materials & Technologies, Spain
2- Institute of Materials Research, Slovak Academy of Sciences, Slovak Republic
3- Institute of Physics, P.J. Safarik University, Slovak Republic
4- Australian Nuclear Science & Technology Organisation, Australia
5- Politecnical University of Catalunya, Spain
6- BRC Global Rolls Ltd., Singapore
Abstract:
Cemented carbide samples with 12 wt.% of binder content and fine and coarse WC grain size are sintered in two different cycles (SC1 and SC2). After assessing the mechanical properties, it is found that sintering conditions affect the hardness-toughness trade-off relationship found in hardmetals. To understand the effect of temperature, materials are deeply characterized by neutron diffraction and transmission electron microscopy (TEM). No substantial difference is observed in the average stress state between fine-grained samples sintered in both conditions. TEM observations reveal same dislocation density for finer specimens, independently on sintering temperature. Nevertheless, further investigation in coarser material discloses that intrinsic plasticity changes when sintering at higher temperatures, showing a greater dislocation density and the presence of stacking faults within WC grains.
DOI:
https://doi.org/10.59499/EP246277229
