Euro PM2023 Proceedings

Authors:

Vladimir Ivannikov (1), Peter Munch (2), Martin Kronbichler, Thomas Ebel (1)

1- Helmholtz-Zentrum Hereon, Geesthacht, Germany

2- University of Augsburg, Augsburg, Germany

Abstract:

In order to perform plausible predictive numerical simulations of solid-state sintering, it is essential to capture accurately both shrinkage and microstructure evolutions of a given material. Moreover, for the results to be meaningful and statistically relevant, one has to analyze packings containing hundreds and thousands of particles. In the current work we present a highly efficient phase-field based numerical model that is able to handle large-scale three-dimensional cases at the early and later stages of sintering. The approach is based on the classical phase-field model of Wang. Multiple novel algorithms are developed for its efficient numerical FEM implementation: fully distributed tracking of individual grains, graph colorization for minimization of the number of order parameters, problem specific preconditioners and Jacobian-free formalism. We demonstrate how the proposed model can be applied for convenient microstructure analysis by providing quantities that can be used for subsequent comparison with experiments.

DOI:

https://doi.org/10.59499/EP235764034

Authors:

Nerea Ordas (1), Maria Florencia Schiopetto (1), Josu Lopez-Lopez (1), Iñigo Perez-Casero (1), Miren Aristizabal (1), Angela Veiga (1), Sergio Ausejo (1)

1- Ceit-BRTA and Tecnun (Universidad de Navarra), 20018, Donostia-San Sebastián, España

Abstract:

Laser-Directed Energy Deposition offers the possibility to combine traditional and additive manufacturing processes, boosting the flexibility during repairing damaged parts and manufacturing of complex-shaped components. This work demonstrates the potential of powder L-DED as an effective tool in hybrid processes. Two use cases are presented. The first one is a mounting lug built with a Ni-base superalloy, Astroloy, on a turbine case of the same material, previously produced by PM-HIP (Hot Isostatic Press of encapsulated powder), for aero-engines. The second one refers to repairing of a railway nose crossing of a high Mn steel. Gas atomized powders are used in all cases, being the chemical composition for railway specifically designed for this application. L-DED parameters were selected to avoid defects like pores or cracks. Microstructural and mechanical characterization were performed to verify that the AM parts meet the required specifications.

DOI:

https://doi.org/10.59499/EP235782991

Authors:

Rodolfo L. Batalha (1), André Carvalho (1,2), Piter Gargarella (3), Ana Cabral (1), Paulo Morais (1), Guiomar Evans (2)

1- ISQ - Instituto de Soldadura e Qualidade, Avenida Professor Dr. Cavaco Silva 33 Taguspark, 2740-120 Porto Salvo, Portugal

2- University of Lisbon, Campo Grande 016, 1749-016 Lisboa, Portugal

3- Federal University of São Carlos, Rod. Washington Luiz km 235, 13.565‑905 São Carlos, Brazil

Abstract:

The focus of this work is to process new biocompatible Ti alloys solely constituted of non-toxic elements by laser-powder bed fusion (L-PBF), a metal additive manufacturing (AM) technology. The main L-PBF processing parameters such as laser power and scanning speed were defined to obtain highly dense samples. The effects of the addition of ceramic particles and the influence of the scanning strategy on the microstructure of the Ti-based alloys were investigated, showing the possibility for in-situ tailoring the material properties in the L-PBF process. Finally, some prototypes were manufactured proving the feasibility of manufacturing parts of Ti-based biocompatible alloys with complex geometry by L-PBF.

DOI:

https://doi.org/10.59499/EP235765159

Authors:

Ciuffini Andrea Francesco (1)

1- European Synchrotron Radiation Facility - 71, avenue des Martyrs, CS 40220, 38043 Grenoble Cedex 9, France

Abstract:

In 2021 was completed the upgrade of the European Synchrotron Radiation Facility ESRF – EBS (Extremely Brilliant Source), becoming the first new generation of high-energy synchrotron, increasing brilliance and coherence of X-ray beams by a factor of 100 compared to present-day light sources. The highlights of the research activities in powder metallurgy made in these 2 years would be presented: the measurement of stress relief given by heat treatment on the residual stresses of an additive manufactured AISI 316L stainless steel arch structure (part of EU-funded EASI-STRESS project); a synchrotron μ-tomographic morphological description of additively manufactured open porous structures made by Laser-based Powder Bed Fusion (L-PBF), to characterize attached spherical particles on the surface of functional structures; a study about the solidification of a new Al-4Mn-3Ni-2Cu-1Zr alloy, designed for L-PBF, developing a new strategy for alloy design in high-strength aluminum alloys for powder metallurgy.

DOI:

https://doi.org/10.59499/EP235763648

Authors:

Johannes Gårdstam (1), Chad Beamer (2), Anders Magnusson (1), James Shipley (1)

1- Quintus Technologies AB, Sweden

2- Quintus Technologies LLC, US

Abstract:

Stabilizing and improving product quality, manufacturing lead time, cost, and overall energy efficiency, calls for continuous reviewing of current state of the art technologies in each field of interest. The past year has seen a new set of capabilities presented for controlling the processing atmosphere in Hot Isostatic Pressing. This reduces discoloration and oxidation of part surfaces after HIP/HPHT processing, improving mechanical strength and chemical consistency of difficult to machine surfaces and visual appearance of surfaces not to be machined. As the HIP process continuously is developed to present new, and improved tools in the engineer’s toolbox, this presentation aims to summarize the capabilities of current state-of-the-art, high pressure heat treatment, HPHTTM, for HIP equipment and reference recent work showing how this functionality is and can be used to further improve components as produced by current PM (Powder Metallurgy) manufacturing processes.

DOI:

https://doi.org/10.59499/EP235763750

Authors:

Jakob Scheibler (1), Dr. Thomas Studnitzky (1), Prof. Dr. Thomas Weißgärber (1,2)

1- Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, 01277 Dresden Germany

2- TUD Dresden University of Technology, Faculty Mechanical Engineering, Institute of Materials Science, Chair Powder Metallurgy, 01062 Dresden, Germany

Abstract:

Dispersion strengthening of copper enables the combination of high strength and high conductivity. However, production of dispersion strengthened materials is complex and only yields semi-finished products. The following work presents a new approach based on cuprous oxide as matrix with dispersed alumina. Powder mixtures are printed into a near net shape part via Lithography-based Metal Manufacturing. After debinding, cuprous oxide is reduced to copper in a hydrogen sintering atmosphere. Furthermore, the influence of milling the powder mixtures is investigated with samples produced by film drawing. Characterization includes scanning electron microscopy, Vickers hardness, and electrical conductivity measurements. Electrical conductivity reaches values of up to 78 % IACS. Vickers hardness surpasses pure copper, however, falls short of comparative values from the literature for dispersion-strengthened materials. Reasons for that are insufficient densification and suboptimal dispersoid distribution.

DOI:

https://doi.org/10.59499/EP235765269

Authors:

Isabel Montealegre-Melendez (1), Cristina Arévalo (1), Enrique Ariza (2), Michael Kitzmantel (2), Erich Neubauer (2), Eva M. Pérez-Soriano (1)

1- Department of Engineering and Materials Science and Transportation, School of Engineering, Escuela Politécnica Superior, Universidad de Sevilla, 41011 Seville, Spain

2- RHP-Technology, GmbH, Forschungs- und Technologiezentrum, 2444 Seibersdorf, Austria

Abstract:

Manufacturing of Hastelloy C-22 specimens via Plasma Metal Deposition (PMD) to determine the influence of the processing parameters on the final properties was investigated. The starting material was powder manufactured via Plasma Atomization Process and the composition of this powder was the standard Hastelloy C-22. The employed device was a PMD device. The argon atmosphere was constant in the manufacturing cycles. In previous studies, this material has been processed via PMD varying the granulometry of powders, however, the parameters remained constant. Therefore, it seeks to provide an answer to the optimal manufacturing parameters depending on the fixed demands. This work aims to investigate the effect of the processing parameters of specimens made from Hastelloy C-22 powder fabricated via PMD, thereby enhancing the understanding of this material regarding composition and microstructure related with the goodness of this additive technique. The obtained results confirmed the influence of the parameters on the final properties.

DOI:

https://doi.org/10.59499/EP235765321

Authors:

Günther Anne (1), Stelzer Sebastian (2), Mannschatz Anne (1), Dudeck Anna (2), Moritz Tassilo (1)

1- Fraunhofer IKTS, Dresden, Germany

2- Fraunhofer IWU, Dresden, Germany

Abstract:

The research aims not only at the hybridisation of metal and ceramic structures via an innovative textile interface, but also at the hybridisation of conventional and additive powder technologies. In this way, multifunctional components with a geometric complexity are producible. One focus is on powder injection moulding in combination with in-mould labelling and Laser Powder Bed Fusion (LPBF). Composite components are bonded to each other by means of a metallic textile nonwoven. Due to the inherent properties of the nonwoven, like non-directional structure of thin fibres and isotropic compressibility, it can partially embedded in the ceramic substrate and sintered without damaging the composite due to the different coefficients of thermal expansion (CTE) and shrinkage behaviour of ceramics and metals. For applications in implantology, in this case zirconia is bonded with titanium via LPBF by using a steel nonwoven to create the bond between the two materials and at the same time act damage tolerant.

DOI:

https://doi.org/10.59499/EP235753753

Authors:

B. Alves (1), D. Gatões (1), P. Soares (1), L. Rodrigues (2), M.T. Vieira (1)

1- Centro de Engenharia Mecânica, Materiais e Processos (CEMMPRE), University of Coimbra, Portugal

2- SOCEM INPACT, Portugal

Abstract:

Indirect additive manufacturing techniques like Material Extrusion (MEX) are rising in industrial application due to the freedom of design usually attributed to additive processing, as well as accessibility and a real contribution to sustainability. This study highlights the role of µ-tomography as a core of non-destructive techniques to optimize shaping and sintering parameters. Moreover, brings forth the possibility of continuous improvement and quality control without disposable specimens. Therefore, this study aims to optimize the manufacture of metallic specimens (AISI 316L), for similar feedstock (binder/additive), by using µ-tomography to analyse the filament, the strand, and the 3Dobject (green and sintered). Optimization the different MEX steps relies on setting key process variables and understanding their impact on defects using µ-tomography. This methodology allows the evaluation of 3Dobjects quality by non-destructive techniques.

DOI:

https://doi.org/10.59499/EP235765455

Authors:

Marvin Just (1,2), Alexander Medina Peschiutta (1,2), Ralph Useldinger (1), Jörg Baller (2)

1- CERATIZIT Luxembourg S.à r.l., 101 Route de Holzem, L-8232, Grand Duchy of Luxembourg

2- Department of Physics and Materials Science, University of Luxembourg, 162A Avenue de la Faiencerie, L-1511 Luxembourg, Grand Duchy of Luxembourg

Abstract:

The mass flow of granular matter through orifices can be described by the well-known Beverloo law. It depends on particle and orifice sizes, interparticle and particle/container interaction forces, particles’ surfaces - to name a few influences on the mass flow rate. We present an experimental study of the flow of a set of ready-to-press (RTP) hard metal powders through orifices of varying diameter. The obtained parameters of the Beverloo law are compared with angle of repose measurements. The interplay between attractive interparticle forces and gravitational forces are discussed for both types of experimental measurements and related to the difference between particle and orifice size.

DOI:

https://doi.org/10.59499/EP235765170

Authors:

L. Cabezas (1,2), A. Vornberger (3), E. Jiménez-Piqué (1,2), J. Pötschke (3), L. Llanes (1,2)

1- CIEFMA – Department of Materials Science and Engineering, EEBE – Campus Diagonal Besòs, Universitat Politècnica de Catalunya - BarcelonaTech, 08019 Barcelona, Spain

2- Barcelona Research Center in Multiscale Science and Engineering, Campus Diagonal Besòs, Universitat Politècnica de Catalunya - BarcelonaTech, 08019 Barcelona, Spain

3- Fraunhofer Institute for Ceramic Technologies and Systems IKTS, 01277 Dresden, Germany

Abstract:

High Entropy Alloys (HEA) are materials consisting of a mixture of five or more elements in equal or relatively large proportions. They are a promising alternative material due to their desirable properties such as good wettability, high toughness, wear resistance, and temperature stability. Recently, the concept of HEAs has been extended to include high entropy carbides (HECs), which have garnered attention in the scientific community. In this study, the microstructure and micromechanical properties of two different binders, Ni and Co, were characterized for HECs composed of Ti, Ta, Nb, V, and W. A high-speed nanoindentation mapping technique was used to obtain hardness (H) and elastic modulus (E) cartography maps. It allowed for the assessment of the intrinsic mechanical properties of the HECs, binders, and interphases, as well as those of the global microstructural assemblage. A total of 40,000 imprints were performed in each grade, and the resulting data sets were statistically analysed using 1D and 2D Gaussian approaches. It is found that cartographical maps permit to satisfactorily relate microstructural features and mechanical properties of the constitutive phases through 1D deconvolution statistical analysis.

DOI:

https://doi.org/10.59499/EP235765461

Authors:

Pelle Mellin (1), Oskar Karlsson (1), Hanna Nilsson Åhman (1), Ulrika Danielsson (2), Henrik Lidman (3), Kim Färnlund (4)

1- Swerim AB, Kista, Sweden

2- Siemens Energy AB, Finspång, Sweden

3- Befesa Scandust AB, Landskrona, Sweden

4- Amexci AB, Karlskoga, Sweden

Abstract:

Here, a Zefon Bio-Pump Plus from Cole-Parmer was used to capture airborne metal powder and dust particles on a sticky surface. The sticky surface coats a glass slide, which is enclosed in a single-use cassette called Air-O-Cell. The method is normally used for capturing fungal spores. However, we show here that metal powder and dust particles can be captured as well. SEM-EDS enable identification of the alloy that constitutes the captured particles. Using said method, airborne powder particles were captured in three separate workshops processing large quantities of PBF-LB powder (15-45 μm). Regardless of workshop, the diameter of captured powder particles ranged from 0.8-10 μm. Air classification removes most of these particles from PBF-LB powder, but some remain, and we show here that these particles become airborne. Post-processing generated much more dust and large particles appear to travel farther, probably since the post processed alloys were lightweight (Al and Ti-base).

DOI:

https://doi.org/10.59499/EP235765510