Euro PM2023 Proceedings

Authors:

Jazmina Navarrete-Cuadrado (1,2), Tomás Soria-Biurrun (1,2), Lorena Lozada-Cabezas (1,2), Federico Ibarreta-López (3), Roberto Martínez-Pampliega (3), Jose M. Sánchez-Moreno (1,2)

1- CEIT-Basque Research and Technology Alliance (BRTA), Manuel Lardizabal 15, 20018 Donostia / San Sebastián, Spain.

2- Universidad de Navarra, Tecnun, Manuel Lardizabal 13, 20018 Donostia / San Sebastián, Spain.

3- FMD CARBIDE, Fabricación Metales Duros, S.A.L., Gudarien etorbidea 18, 48970 Basauri, Spain.

Abstract:

The limited availability of materials like tungsten, cobalt or nickel is a risk for the hardmetal industry. TiC based cermets are potential candidates for replacement of hardmetals in certain hot wear applications. In this work, TiC-Fe-Cr-Mo cermets have been produced by vacuum sintering under different vacuum conditions. Molybdenum was added either as Mo2C or as Mo metallic powder along with Fe and Cr3C2. The vacuum level is critical for promoting the carbothermal reduction of oxides and porosity removal during the sintering cycle. Introduction of 1.2 bars of argon overpressure at 1300 ºC is key for avoiding binder evaporation. However, due to an open porosity state at this temperature, part of the injected argon gets entrapped, leaving some porosity in sintered specimens of TiC-Fe-Cr-Mo. Mo2C powders induce higher densification than those based on metallic Mo. This is likely related to its finer particle size distribution and its contribution to the carbothermal reduction of oxides during the sintering cycle.

DOI:

https://doi.org/10.59499/EP235763635

Authors:

Serena Lerda (1); Giulio Marchese (1); Emilio Bassini (1); Mariangela Lombardi (1); Daniele Ugues (1); Paolo Fino (1); Sara Biamino (1)

1- Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy

Abstract:

Inconel 625 (IN625) is a Ni-based superalloy characterized by good mechanical performance and excellent oxidation resistance up to 1000°C. In order to enhance the mechanical performances of the IN625, ceramic particles can be added to the alloy. In the current work, the IN625 powder was mixed with submicrometric TiC particles and then processed by the laser powder bed fusion (LPBF) process. The microstructure of the as-built and heat-treated composite was compared to the base alloy in order to investigate the variations in terms of microstructure. The as-built condition of the IN625 and composite exhibited columnar grains with very fine dendritic structure along the building direction. Differently, a high-temperature solution annealing involved recrystallization of the IN625 samples while the composite still presented columnar grains, thus showing higher microstructure stability at elevated temperatures.

DOI:

https://doi.org/10.59499/EP235765271

Authors:

Alberto Ruiz (1), Xavier Plantà Torralba (1), Ricardo Hernández Rossi (1), Montserrat Vilaseca Llosada (1)

1- Eurecat, Centre Tecnológic de Catalunya, Avda. Universitat Autónoma 23, 08290 Cerdanyola del Vallés, Spain.

Abstract:

The use of microwaves is one of the techniques utilised in industrial environments which allow time and energy reductions. One of the most interesting aspects is the production or treatment of materials, either as raw material or as residue, using a microwave-induced plasma (MIP) torch. In particular, this technology allows the modification of the particles' shape with origin in waste or rejections, either as scrap or powder, reintroducing them effectively in the powder industry. We can mention other advantages such as cost reduction in powder generation or cost reduction in transportation because it is possible to use a waste powder "in situ". The scaling and power of the equipment allow their ubication near the production place, optimizing processing times. This article is a fast overview of several works realised to recover some waste production with tungsten carbide as central axis.

DOI:

https://doi.org/10.59499/EP235765286

Authors:

Mari Carmen Monterde Gascón (1), Lucile Bernadet (2), Jose Antonio Calero Martinez (1), Emilio Jimenez-Piqué (3), Albert Tarancón (2,4), Marc Torrrell Faro (2)

1- AMES PM Tech, Pol. Ind. Les Fallulles, Camí de Can Ubach, 8, 08620 Sant Vicenç dels Horts, Barcelona (Spain)

2- IREC, Catalonia Institute for Energy Research, Dept. Advanced Materials for Energy Jardins de les Dones de Negre 1, 2ª pl. 08930 Sant Adrià de Besòs Barcelona (Spain)

3- Universitat Politécnica de Catalunya, department of Material Science and Engineering., C/Eduard Maristany 16, 08019 Barcelona (Spain)

4- ICREA, Passeig Lluís Companys 23, 08010 Barcelona, Spain

Abstract:

Manganese cobalt oxide spinel ink applied by roll painting on SUS445 steel interconnects are the state-of-the-art coating materials as protective layer to volatile chromium species. MnCo coatings are often sintered in two stages, involving reducing and oxidizing atmospheres, to ensure the desired density. This work shows the design, development and optimization of a functional metal interconnect fabricated by conventional powder metallurgy for solid oxide fuel cell and electrolysers systems (SOFC and SOEL). The efficiency of the final interconnects is evaluated by the electrochemical test of single repeating unit and completed by a microstructural characterisation. The polarization I-V curve obtained in solid oxide cell mode at 800°C shows a current density around 0.9 A/cm2. The degradation results below 1%/Kh after 750h at 800°C under 10A working in solid oxide electrolysis mode show an efficient barrier layer coating to volatile chromium species. The obtained results show the efficiency of the coating process and the functionality of the designed interconnector.

DOI:

https://doi.org/10.59499/EP235783264

Authors:

Michael Andersson (1)

1- Höganäs AB, Sweden

Abstract:

Astaloy CrS is a water atomized iron powder alloyed with 0.85%Cr and 0.15%Mo, recently developed to meet coming demands for sustainability. For many applications fatigue strength is a limiting factor, and reliable fatigue models and data are key to using any material to the best potential, not least for sustainability reasons. This paper focuses on the fatigue strength of Astaloy CrS, where the strength of this new material is compared to more traditional alloying systems, such as FeCuC. In parallel, a fracture mechanics model fatigue is developed to predict the strength of the material. With this model it’s possible to include both the effect of density as well as stress concentrations to estimate component strength under different conditions.

DOI:

https://doi.org/10.59499/EP235756038

Authors:

Petr Mamykin (1), Jean-Philippe Chateau-Cornu (1), Frederic Bernard (1)

1- Institut Marey - Maison de la Métallurgie, France

Abstract:

This study examines the possibility of simulating the rearrangement stage of 316L steel powder using a modified cam-clay model. The oedometric compression tests were carried out at up to 900°C using an SPS device. Unlike clay soils, the virgin consolidation line is non-linear, with a slope dependent on volumetric deformation. The dependency of the slope is characterized at different temperatures and a consolidation law under isostatic pressure is proposed. The initial pressure at which the virgin powder starts to densify plastically was successfully adjusted. This adjustment was made using density measurements obtained after HIP interrupted tests performed on the same powder encapsulated in a spherical container. The complete consolidation law can be implemented in FEM simulations to take into account the rearrangement stage in the densification of industrial parts. The second part aims at determining the optimal simulation parameters for oedometric cold pressing of the powder powder using the discrete element method. The simulation uses the Hertz-Mindlin contact model and the Spherical Johnson-Kendall-Roberts model to account for powder particle adhesion. Simulation parameters have been optimised through iterative refinement. The particle size distribution is measured experimentally by sieving. For this size distribution, the values determined for the simulation parameters were 5 nanoseconds for the minimum time step, 0.002 for the friction coefficient and 0.36 for the adhesion coefficient. These parameters ensure accurate representation of the powder behaviour in monotonic compression but the simulation lacks of efficiency when unloading-reloading stages are applied.

DOI:

https://doi.org/10.59499/EP235751775

Authors:

Li, Xiaoshuang (1); Gianfolcaro, Nicolas (1); Chaoqun Zhang (2,3,4); Malik Shadab (4)

1- Aerosint SA, Rue d’Abhooz 31, B-4040 Herstal, Belgium

2- School of Materials, Sun Yat-sen University, Shenzhen 518107, China

3- Innovation Group of Marine Engineering Materials and Corrosion Control, Southern Marine Science and Engineering Guangdong Laboratory (Zhuhai), Zhuhai 519082, China

4- School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

Abstract:

The emerging multi-material additive manufacturing technology enables the production of components with region specific properties via a single-step manufacturing process. One of various advantages is to combine high performance and high-cost materials with low performance and low-cost materials. In the present study, the selected Inconel 625 superalloy and common 316L steel were additively manufactured by laser-based powder bed fusion. Regardless of the presence of material boundary, a continuous scanning strategy was used to optimize processing parameters for both materials with the assistance of artificial intelligence. It turned out that it is feasible to make fully dense parts with a single set of parameters. Intensive material mixing at the interface shown in the SEM results indicates sound metallurgical bonding. In addition to great manufacturability, the manufacturing speed was greatly improved up to two times by employing large hatch spacing coupled with proper laser powder, scanning speed and layer thickness.

DOI:

https://doi.org/10.59499/EP235741167

Authors:

O. Schenk (1), Y.Deng (1), A. Kaletsch (1), A. Şelte (2), C. Broeckmann (1)

1- RWTH Aachen University, Institute for Materials Applications in Mechanical Engineering (IWM), Augustinerbach 4, 52062 Aachen, Germany

2- Uddeholms AB, SE-683 85 Hagfors, Sweden

Abstract:

Powder compaction is an essential part of the powder metallurgical (PM) process chain, being mainly responsible for the shape and distribution of the inherent porosity of a sintered component. While the significant effects of the porosity and the pore morphology on the fatigue behavior of PM components have been widely investigated, their numerical prediction during PM process has rarely been performed. In this work, a multiscale model of powder compaction of Astaloy 85Mo is presented, which provides information on both density distribution and pore morphology. A modified Drucker-Prager model and a friction model were experimentally derived to simulate the compaction process for different tool steels on macroscale, providing information on the density distribution. Using machine learning, artificial microstructural images of the powder compact were generated depending on local density. Both models were combined and applied to the compaction of a gear, which delivered promising results that agree well with experiments.

DOI:

https://doi.org/10.59499/EP235763805

Authors:

J.A. Naranjo (1,2), G. Perez, C. Berges (1,2), J. Hidalgo (1,2), G. Herranz (1,2)

1- Escuela Técnica Superior de Ingeniería Industrial (ETSII), Av. Camilo José Cela s/n, 13071, Ciudad Real, Spain.

2- Instituto de Investigaciones Energéticas y Aplicaciones Industriales (INEI), Camino de Moledores 33, 13005. Ciudad Real, Spain.

Abstract:

The development of materials using master alloys has many advantages over pre-alloyed powders, such as better preservation of the shape of the parts at a more competitive cost. This type of alloy is commonly used for Metal Injection Moulding (MIM), which makes its use in 3D printing very interesting. However, its use for sinter based additive manufacturing technologies is not obvious, as it requires a detailed analysis of its flowability to accomplish a unique feedstock processable by MIM and Fused Filament/Pellets Fabrication (FFF/FPF) technologies (hybrid feedstock). Rheological and experimental criteria are used in which suitable flow characteristics are pursued. The measured parameters allow the selection of the optimum metal content of the feedstock to achieve a balance between MIM, FFF and FPF requirements, guaranteeing the industrial viability of the feedstock. After green shaping, debinding and sintering, the results concerning the final density, microhardness, tensile strength, shrinkage and dimensional accuracy are discussed.

DOI:

https://doi.org/10.59499/EP235765138

Authors:

I. Lindemann-Geipel (1), T. Mix (1), M. Thamm (1), K. Reuter (1), A. Kirchner (1), T. Hutsch (1), T. Weißgärber (1,2)

1- Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Winterbergstrasse 28, 01277 Dresden (Germany)

2- Technische Universität Dresden, Faculty of Mechanical Engineering, Institute of Materials Science, Helmholtzstrasse 7, 01062 Dresden (Germany)

Abstract:

Excellent soft magnetic properties of Fe-6.5Si are well known since a very long time. But its usage was hindered by the difficulty of processing by conventional methods. Until now, most innovative fabrication methods are limited to the lab scale. In this study, different powder metallurgical methods are demonstrated for the fabrication of soft magnetic Fe-6.5Si parts. The magnetic properties as well as geometric limitations of the process will be compared for a sinter-based method (screen printing) with an electron beam powder bed-based process (E-PBF) and a more conventional pressing process (FAST/SPS) for manufacturing soft magnetic components from Fe-6.5Si. The magnetic properties will be correlated with the structural properties. Most important aspects like different powder properties as well as fabrication constraints and conditions will be discussed.

DOI:

https://doi.org/10.59499/EP235763601

Authors:

Bram Neirinck (1); Shuigen Huang (2) ; Jozef Vleugels (2); Xiaoshuang Li (1)

1- Aerosint SA, Belgium

2- KU Leuven, Department of Materials Engineering, Belgium

Abstract:

Co-fired devices were developed in the late 50’s as a robust option for high power / high temperature electronics. As the name suggest, they were obtained by simultaneously sintering different materials, often an insulating ceramic substrate with a conductive metal on top. Since these devices were first conceived there have been significant developments in processing and sintering technologies. This paper addresses a potential alternative approach to create High temperature Co-fired Ceramics (HTCC’s). Commercially pure nickel and yttria-stabilized zirconia powder layers with a controlled thickness were deposited in graphite dies using Selective Powder Deposition (SPD). These layers were subsequently pre-compacted in the die and consolidated using FAST/SPS sintering. The results show that crack-free laminates of fully dense metal and ceramic layers can be obtained. The metal sections are electrically insulated from one another, demonstrating the possibility to generate conductive tracks/circuits, while using a relatively uncomplicated deposition process and high-speed sintering.

DOI:

https://doi.org/10.59499/EP235752352

Authors:

Tomi Lindroos (1); Tuomas Jokiaho (1); Atte Antikainen (1); Juha Lagerbom (1)

1- VTT Technical Research Centre of Finland Ltd., Finland

Abstract:

Nitrogen alloyed austenitic nickel-free stainless steel (ANFSS) is one of the most promising group of materials for consumer and health care products. They can be used to substitute not only conventional AISI 316L, but also titanium and Co-Cr alloys. Previously the utilization of nitrogen alloyed materials has been limited due to high work hardening rate. Recent developments in powder metallurgy, e.g., additive manufacturing (AM), are offering economically feasible net shape manufacturing routes to go around machining related problems. In the present study a viable processing route for ANFSS powder is introduced. It includes gas atomization and AM of test specimens by laser- and sinter-based methods. Special attention is paid on controlling the nitrogen content in different processing steps. The results show that by proper selection of processing parameters, the nitrogen content can be kept in desired level, thereby controlling the mechanical properties of ANFSS alloys.

DOI:

https://doi.org/10.59499/EP235764029