Euro PM2023 Proceedings

Authors:

Main Tomasz Choma (1,2), Bartosz Kalicki (1,2), Bartosz Morończyk (1,2), Iryna Smolina (3), Saumya Sadanand (4), Konrad Gruber (3), Maria Teresa Pérez-Prado (4), Isabella Gallino (5), Ralf Busch (5), Marcin Kasprowicz (3), Łukasz Żrodowski (1,2), Mateusz Ostrysz (1,2)

1- Warsaw University of Technology, Faculty of Materials Science and Engineering, Wołoska 141, 02-507 Warsaw, Poland

2- AMAZEMET Sp. z o. o. Al. Jana Pawła II 27, 00-867 Warsaw, Poland

3- Center for Advanced Manufacturing Technologies (CAMT-FPC), Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, 5 Łukasiewicza street, 50-371 Wroclaw, Poland

4- IMDEA Materials Institute, C/ Eric Kandel 2, 28906 Getafe, Madrid, Spain

5- Saarland University, Chair of Metallic Materials, Campus C6.3, 66123 Saarbrücken, Germany

Abstract:

Access to a wide range of alloy powders is necessary for the development of new materials for additive manufacturing. This is due to the lengthy and expensive validation process, as well as the high cost of powder production. Another important aspect is the method of producing powders, such as gas, plasma, centrifugal, or water atomization technologies that are used. Despite the biggest advantages of these processes, such as high production yield, some disadvantages of these processes are the high investment cost, the small number of materials that can be processed, the wide powder size distribution, or the minimal amount of material input for atomization. This paper shows a novel approach of ultrasonic atomization to manufacture small quantities of metallic powders for research scale, including Al 5754 and FINEMET alloys.

DOI:

https://doi.org/10.59499/EP235755976

Authors:

G. Herranz (1,2),J. Hidalgo (1,2), J. Naranjo (1,2), C. Berges (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), 13005. Ciudad Real, Spain

Abstract:

Cordierites exhibit high thermal stability and thermal shock resistance, which combined with their low price make them interesting in many industrial applications. However, they are limited by their relatively low mechanical properties compared to other technical ceramics and the simple geometries attainable by the current processing methods. Based on the literature on other ceramics, the reinforcement of cordierite with graphene will significantly improve their properties expanding their application range. Ceramic injection moulding (CIM) is an economic, jet unexplored, alternative for processing such composites in complex shapes. This work aims to set the basis of the use of CIM for the production of cordierite with reduced graphene oxide (rGO). Several rGO addition methods are scrutinized by determining the homogeneity of the resulting feedstocks and drawing conclusions on how it affects their rheological behaviour to combine adequate flow behaviour with the changes in mechanical and in target functional properties.

DOI:

https://doi.org/10.59499/EP235765299

Authors:

Jannik Schuppener (1), Santiago Benito (1), Songhuang Ye (1), Sebastian Weber (1)

1- Ruhr-University Bochum, Universitätsstraße 150, 44801 Bochum, Germany

Abstract:

Hot isostatic pressing of powder metallurgy tool steels results in high performance tools with outstanding properties. However, the successively deployed conventional heat treatments are not tailored for this manufacturing route, generating room for improvement. This work presents a simulation workflow targeting a twofold optimization of the heat treatment after the consolidation process. These two goals are (i) the improvement of the process stability regarding hardness and chemical variations resulting from the as-delivered condition; and (ii) the determination of the most efficient treatment to guarantee a minimum hardening. The workflow includes calculation of metastable states using Matcalc®, finite element analysis using AbaqusFEA®, and optimization routines written in Python and MATLAB®. To validate the models, a PM X153CrMoV12 ingot was treated in a laboratory furnace, with supporting dilatometry and hardness testing completing the experimental setup. Simulated and measured results agree well, proving the suitability of the workflow for industrial deployment.

DOI:

https://doi.org/10.59499/EP235755820

Authors:

Marc Serra (1), Fernando García-Marro (1,2), Nuria Cinca (3), Luis 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- Hyperion Materials & Technologies, 08107 Barcelona, Spain

Abstract:

Hardmetals are composite materials comprising carbides embedded in a ductile metallic binder. This combination, with different relative amounts and sizes of ceramic particles, allows obtaining a wide variety of microstructural qualities with excellent mechanical and tribological properties. However, many of the applications in which these materials are used involve cyclic stresses, which often lead to premature failure of components and tools. Therefore, studying the fatigue strength of hardmetals is a topic of great practical interest. A commonly used method to estimate the fatigue strength of structural materials is the "staircase method". Results obtained are usually analyzed by the Dixon and Mood approach. Trying to reduce time and resources, this work analyzes the use of a modified staircase method, to optimize the methodology to both evaluate the fatigue resistance by using a reduced number of samples and improve the acquisition of statistical information on the reliability of the fatigue life.

DOI:

https://doi.org/10.59499/EP235764267

Authors:

Felicioni Stefano (1), Padovano Elisa (1), Marchese Giulio (1), Quercio Michele (2), Canova Aldo (2), Biamino Sara (1), Bondioli Federica (1)

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

2- Department of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy

Abstract:

The CuCrZr alloys exhibit advantageous mechanical properties and high electrical conductivity which make them promising for many applications in the electrical and aerospace engineering industries, e.g. in the manufacture of vacuum electronics and fusion energy research. Unfortunately, these two advantageous properties are in opposition to each other, i.e., the increase of hardness, is associated to a decrease of electrical conductivity. Additive manufacturing technologies are good candidates to balance these two aspects to achieve high performance parts. Powder-Bed-Fusion (PBF) techniques, in fact, involve rapid heating and cooling rates which allow to obtain huge microstructural refinements, thereby improving the mechanical properties without any significant loss in electrical conductivity. This study concerns the process parameter optimization for CuCrZr alloys produced using Electron-Beam-PBF technology using a trial-and-error approach. Material was characterized by porosity analysis, tensile and electrical conductivity measurements. The effect of process parameters on microstructure and densification behavior was also investigated.

DOI:

https://doi.org/10.59499/EP235762626

Authors:

Dieter Sporer (1), Ludo Bautmans (1), Davide Beretta (2), Andreas Vogelpoth (3), Paolo Colombo (2), Valentina Zangheri (2)

1- Oerlikon Surface Solutions AG

2- GF Casting Solutions Novazzano SA

3- Fraunhofer Institute for Laser Technology ILT

Abstract:

Inconel 738LC is a high temperature alloy with a high content of gamma prime precipitates to improve its high temperature creep strength. This type of material is difficult to process in Additive Manufacturing by Laser Based Powder Based Fusion (LB-PBF), also referred to as Metal 3D Printing, due to its inherent tendency to form microcracks during the laser-based processing. This paper reviews a systematic approach to mitigate the crack formation in 738 type compositions for LB-PBF by varying the alloy chemistry, the processing conditions, and the necessary heat treatments. Hereby the heat treatments are not only used to perform a solution annealing and a precipitation treatment for the alloy but also to coarsen the grain structure which, in the as-3D-printed condition, is significantly finer compared to an as-cast material status.

DOI:

https://doi.org/10.59499/EP235765329

Authors:

Andoni Sanchez-Valverde (1), Marten Franz (1)

1- Outokumpu, Germany

Abstract:

Outokumpu, stainless steel producer, started producing spherical metal powders in a Vacuum Induction melting inert Gas Atomization (VIGA) plant in Krefeld Germany at the beginning of 2023. Using flat scrap arising from its own processes as raw material the company can produce gas atomized powders. The produced metal powders are high quality, customizable and sustainable raw materials for production in various Powder Metallurgy (PM) technologies. To showcase the importance of broadening the possibilities of material selection for PM engineers in the present article two examples of novel stainless steel powder materials barely used nowadays are introduced. The first one a stainless-steel alloy used for elevated temperatures 253MA (1.4835). This powder grade was developed at pilot scale in collaboration with Swerim Metal Research Institute. The second one a highly alloyed stainless-steel grade also known as a super austenitic stainless steel 904L (1.4539). This powder grade was developed at pilot scale in collaboration with RWTH Aachen University.

DOI:

https://doi.org/10.59499/EP235762851

Authors:

Elena Gordo (1); Gabriel Sánchez (1); Ángel Biedma (1); Juan Villemur (1); Claudio Bertalan (2); Ralph Useldinger (2); María de Nicolás (1),(4); Luis Llanes (3)

1 Universidad Carlos III de Madrid, Avda. de la Universidad 30, 28911, Leganés, Madrid, Spain

2 CERATIZIT Group Luxembourg S.à.r.l., 8232, Mamer, Luxembourg

3 Universitat Politécnica de Catalunya – BarcelonaTech, 08019 Barcelona, Spain

4 IMDEA Materiales, Tecnogetafe, Eric Kandel 2, 28906 Getafe, Madrid, Spain

Abstract:

This study shows the results of mechanical properties (hardness, toughness, TRS), oxidation behavior against high temperature and wear resistance of composite materials based on a ceramic phase –Ti(C,N) or WC– and a metal binder (Fe15Ni10Cr). These hard metals were produced through a powder metallurgy process that included mechanical milling, uniaxial pressing, and sinter-HIP. Standardized cylindrical specimens were used for TRS tests, and oxidation tests were conducted on broken specimens in static air at temperatures up to 1000 ºC. Wear behavior was analyzed through reciprocal sliding tests using WC-Co balls as counter material with loads up to 30 N and test times up to 150 min. This study recorded the friction coefficient during and after the tests, the mass variation, the width, and depth of the wear tracks analyzed by an optical profilometer.

DOI:

https://doi.org/10.59499/EP235762742

Authors:

Marie Luise Scheck (1), Michael Norda (3), Simone Herzog (2), Anke Kaletsch (1,2), Frank Petzoldt (3), Christoph Broeckmann (1,2)

1- Institute of Applied Powder Metallurgy and Ceramics (IAPK) at RWTH Aachen University e.V., Augustinerbach 4, 52064 Aachen, Germany

2- Institute for Materials Applications in Mechanical Engineering, RWTH Aachen University, Augustinerbach 4, 52064 Aachen, Germany

3- Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Wiener Straße 12, 28359 Bremen, Germany

Abstract:

Laser-based powder bed fusion (PBF-LB) is still rarely applied due to the limited range of available alloys. Powders of carbide containing tool steels have a low weldability and a high cracking tendency during processing. Additions of high-melting carbides to an easily processable steel in the powder feedstock enables a higher carbide content in the alloys without affecting the processability. In this study, AISI H13 base steel was modified by additions of 5 wt.-% edged TiC. TiC remain as partially unmolten particles within the steel matrix and enhance macro hardness and wear resistance of the alloy while enabling a stable processing of crack-free alloys. Supplementary in-depth microstructure analysis by EBSD and texture analysis were performed and a shift towards isotropic microstructures was observed. The TiC act as nucleation sites for equiaxed grain growth during solidification, which eliminates the typical epitaxial grains in building direction and potentially reduces the anisotropy of mechanical properties.

DOI:

https://doi.org/10.59499/EP235764739

Authors:

Volker Piotter (1), Alexander Klein (1), Klaus Plewa (1), Thi Tra My Nguyen (1), Heinz Walter (1)

1- Karlsruhe Institute of Technology (KIT), Institute for Applied Materials (IAM-WK)

Abstract:

Precise and reliable simulation of Powder Injection Molding (PIM) process steps requires particular determination of material parameters. Compared to pure or low-filled polymers, however, feedstocks often show significantly different flow behaviour. In this respect, recent investigations at KIT targeted the impact of Bagley pressure correction on simulation accuracy. Calculations were performed using corrected and non-corrected data followed by real injection molding experiments including pressure and temperature measurements during mold filling. As expected, precise simulation results could only be achieved if corrected pressure values were applied. In case of PIM feedstocks (40vol% filling of zirconia powder), however, simulation were correlated well to experimental results irrespectively whether the pressure data had been corrected or not. Conclusions on flow conditions during viscosity measurements will be proposed.

DOI:

https://doi.org/10.59499/EP235765208

Authors:

Carlos Botero (1); William Sjöström (1); Emilio Jimenez-Piqué (2); Aydın Şelte (3); Lars-Erik Rännar (1)

1- SportsTech Research Centre, Mid Sweden University, Akademigatan 1, SE-83125, Östersund, Sweden

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

3- Uddeholms AB 683 85, Uvedsvägen, Hagfors, Sweden

Abstract:

Most Powder Bed Fusion (PBF) methods for the Additive Manufacturing (AM) of metals are based on the melting of powder of one specific metallic material; either of pure-elemental or pre-alloyed composition. Although the potential to build components from different materials in AM has recently gained a lot of attention, it is still not feasible in the current metal PBF systems. In the specific case of Electron beam- based PBF (PBF-EB), it is possible to precisely control the beam parameters in each site of the build area, which opens great possibilities for adaptive processes that allows melting powders of different nature in the same build. In this investigation, different steel-based and Ti6Al4V alloy powders are used to create metal-metal assemblies. By steering the fetching of two powders loaded in different hoppers it was possible to build different metal-metal assemblies. The microstructure and mechanical properties of the final materials were evaluated.

DOI:

https://doi.org/10.59499/EP235735468

Authors:

Matti Lindroos (1), Tom Andersson (1), Abhishek Biswas (1), Pilar Rey Rodriquez (2), Sicong Ren (1), Tomi Suhonen (1), Juha Lagerbom (1), Tomi Lindroos (1), Anssi Laukkanen (1)

1- VTT Research Centre of Finland, Finland

2- AIMEN, Spain

Abstract:

Virtual design of additively manufactured AlCoNiFe alloys enables optimization of material performance required at elevated operational temperatures. Compositional tailoring of the material leads to a complex mixture of stable and metastable phase structures, which affect the engineering material properties. This focuses on the micromechanical modelling of AlCoNiFe alloy microstructures with crystal plasticity by utilizing preceding material design steps with Calphad analysis for the alloys suggested by neural network decision making. We evaluate key aspects of the material behavior, such as strength/strain hardening and fatigue responses.

DOI:

https://doi.org/10.59499/EP235765038