Euro PM2023 Proceedings

Authors:

Thomas Studnitzky (1), Chongliang Zhong (1), Thomas Weißgärber (1,2), Claus Aumund-Kopp (1)

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

2- Technische Universität Dresden, Faculty Mechanical Engineering, Institute of Materials Science, Chair Powder Metallurgy, 01062 Dresden, Germany

Abstract:

Laser powder bed fusion (LPBF) is dominating Additive Manufacturing of metals in equipment manufacturers, research and applications. Since LPBF has still limitations in terms of geometries and materials as well as in productivity, sinter-based additive manufacturing (SBAM) processes such as Metal Binder Jetting (MBJ) or Fused Filament Fabrication (FFF) are becoming increasingly important. Furthermore, new processes such as MoldJet (MJ) or Lithography-based Metal Manufacturing (LMM) continue to enter the market and attract widespread attention due to their promising properties. At the same time, it is becoming apparent that there is still a need for intensive development in accompanying processes such as heat treatment and sinter simulation. In this review, the status of the most important sinter-based processes is highlighted and compared with LPBF. In addition, this paper outlines future development trends and the market potential of the various SBAM processes.

DOI:

https://doi.org/10.59499/EP235765077

Authors:

Adriana Wrona (1), Anna Czech (1), Marcin Lis (1), Jacek Mazur (1), Krzysztof Pęcak (1), Adrian Kukofka (2)

1- Łukasiewicz Research Network- Institute of Non-Ferrous Metals, Poland

2- Progresja New Materials Sp. z o.o., Poland

Abstract:

One of the problems of the AM technology market is low availability of powder materials, particularly the high-melting ones. On the other hand, due to the characteristics of these materials, it is difficult to obtain printouts with optimal density and a small number of cracks. There are many ways to avoid these types of problems. One of them is input materials modification. The paper presents a solution using the phenomenon called "the rhenium effect", based on molybdenum powders modification with rhenium. Different processes of thermal reduction and plasma spheroidization were used. Physical properties, microstructure, homogeneity, chemical and phase composition of produced powders were investigated.

DOI:

https://doi.org/10.59499/EP235782977

Authors:

C.Chirico (1), A. Ferrandez (1), B. Ferrari (1), A.J. Sanchez-Herencia (1)

1- Instituto de Ceramica y Vidrio, ICV-CSIC, C/Kelsen 5, 28049, Madrid, Spain

Abstract:

3D printing technology is the solution to the free-mold fabrication challenge of light parts of Ti alloys with complex geometries. Fused Filament Fabrication (FFF) is one of the most competitive technologies for titanium processing. Main advantage of FFF is the design flexibility to produce complex geometries and light internal structures without supports. Biomass thermoplastics use turns printing eco-efficient, limiting debinding to a thermal step. Moreover, colloidal procedure allows the use of low particle size powders (D50 10 µm), achieving feedstocks with high-quality particles dispersion to enhance sintering and Ti-parts performance and lowering the diameter of the printing nozzle (0.4 mm) to improve surface finishing. In this study, printable PLA-based filaments of Ti6Al4V alloy (76-72 wt.%) were produced following the colloidal process patented by COLFEED4Print company. Dynamic oscillatory melting rheology was analyzed by varying temperature, deformation rate, and frequency parameters to adjust the printing window and control the flowability of melt. Printed and sintered samples were analyzed.

DOI:

https://doi.org/10.59499/EP235765598

Authors:

Tomás Resendes (1), Patrícia Rodrigues (1), Hélder Cordeiro (2), Francisco Cruz (1), Teresa Vieira (1)

1- Centre for Mechanical Engineering, Materials and Processes (CEMMPRE), University of Coimbra, Portugal

2- Moldes RP, Indústria de Moldes SA, Marinha Grande

Abstract:

The additive manufacturing (AM) process lets freedom to explore new ways to make several complex geometries of 3D objects. However, these can be critical to the mechanical behavior during the structural application. Maintaining the stress field inside the component within the safe values previously evaluated from the design is essential to prevent its premature failure. This study aims to promote a precise measurement of the deformation through a strain sensor integrated into the 3D object close to critical zones. The NiTi shape memory alloy could promote high-precision measurements of sensors. The superelasticity of this alloy enables a linear relationship between the deformation and the electrical resistivity. Therefore, this solution allows taking advantage of superelasticity to evaluate the deformation close to the critical zones of 3D objects with high precision during their lifetime. The present study highlights the role of inside strain sensors embedded during AM and compares them with conventional measurements.

DOI:

https://doi.org/10.59499/EP235764202

Authors:

G. Sarriegui (1,2), E. Urionabarrenetxea (1,2), P. Ortega (1,2), N. Burgos (1,2), J.M. Martín (1,2), I. Eguren (3), G. Ugalde (3)

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- Mondragon Unibertsitatea, Loramendi 4, 20500 Mondragon, Spain

Abstract:

In this work, it is presented a direct metallurgical route for the recycling of end-of-life (EoL) sintered NdFeB magnets to produce competitive bonded magnets. Three different grades of scrap, classified according to the total content of heavy rare earth elements, were converted into fresh recycled NdFeB powder by gas atomization. Several atomizations with helium (He) and argon (Ar) were conducted to produce isotropic spherical powders. The use of He as atomizing gas resulted in higher cooling rates and, thus, finer and almost fully amorphous particles. After proper annealing, the powder exhibited a greater improvement in magnetic properties. Laboratory specimens were produced by compression molding using an epoxy resin as bonding phase. The magnetic, mechanical and physical characterization of the bonded NdFeB recycled magnets confirm that gas atomization is a feasible process for recycling NdFeB scrap.

DOI:

https://doi.org/10.59499/EP235765357

Authors:

Yan Liu (1), Erik Adolfsson (2), Örjan Christoffersson (3), Seyed B. Hosseini (2,3), Zhenghua Yan (1)

1-Simtec Soft Sweden AB, Sweden

2-Research Institutes of Sweden AB (RISE AB), Sweden

3-TurnTime Technologies AB, Sweden

4-Chalmers University of Technology, Sweden

Abstract:

An innovative component used for the cargo handling systems of Boeing 737 aircraft is developed to improve loaders' working conditions and protect cargo spaces, passenger luggage, and goods from damage. Since the design of the component makes it difficult to manufacture using conventional techniques, metal Binder Jetting, an Additive Manufacturing technique both faster and more cost-effective compared to the conventional laser/electron beam techniques, is used. However, there is a risk of thermally induced distortion in connection with the post-processing, specifically the sintering step. To address this, a 3D computational fluid dynamics simulation model is developed and simulations are made to identify where and when unwanted distortions may occur during the sintering process. In the simulation, the sintering process follows about 15 hours full sintering cycle with all the heating, holding and cooling stages. The simulations are compared with experiments to validate the numerical results.

DOI:

https://doi.org/10.59499/EP235762437

Authors:

Kiranmayi Abburi Venkata (1), Siwen Gao (1)

1- Hexagon/Simufact, Manufacturing Intelligence Division, Tempowerkring 19, 21079, Hamburg, Germany

Abstract:

Sinter-based additive manufacturing (AM), especially Metal Binder Jetting (MBJ) is emerging as an economical AM technology for cheaper metal parts production. Although sinter-based manufacturing has been around for over half a century, the design freedom and specific process characteristics of MBJ necessitate reliable sintering simulation. A validated simulation tool provides greater understanding of the underlying material behaviour necessary for design optimisation, process control and standardisation. Using Simufact Additive MBJ module, the macroscopic shrinkage and deformation behaviour of the material during MBJ sintering are predicted accurately. The simulation predictions are used to automatically generate pre-compensated part geometry such that the part tolerances are within quality specification after sintering. Other quality control strategies such as live setters/supports can also be assessed to identify the best strategy for a given geometry, material and process parameter combination. The simulation framework as a virtual design tool is validated on industry relevant geometries with experimental investigation.

DOI:

https://doi.org/10.59499/EP235754938

Authors:

E. Carreño-Morelli (1), L. Meylan (1), M. Rodriguez-Arbaizar (1), X. Carthoblaz-Délèze (1), B. Sahli (2), R. Chandran (2), G. Balestra (2)

1- HES-SO Valais-Wallis, University of Applied Sciences and Arts Western Switzerland, CH-1950 Sion

2- iPrint, HEIA-FR, HES-SO University of Applied Sciences and Arts Western Switzerland, CH-1700 Fribourg

Abstract:

Soft ferromagnetic parts have been produced by two sinter-based additive manufacturing techniques: Solvent on Granules 3D Printing (SG-3DP) and Material Extrusion (MEX). Fe2.7Si and Fe6.5Si powders were mixed with multicomponent binders, then shaped to granules. Different formulations suitable for SG-3DP and MEX respectively were processed. Square section toroids for magnetic measurements, test cubes and a rotor/stator prototype were printed. The green parts were debound under nitrogen and sintered under hydrogen atmosphere, in a single thermal cycle, using a retort furnace. The sintered parts were characterized by measurements of B‐H hysteresis cycles. The impurity contents of carbon and oxygen were measured by melt extraction. The performance of parts processed by both SG-3DP and MEX methods, was compared with literature values obtained from conventional powder metallurgy processes.

DOI:

https://doi.org/10.59499/EP235762510

Authors:

Greg Kalfayan (1), Florian Bussiere (1), Sophie Le Gallet (1), Mostapha Ariane (1,2), Frédéric Bernard (1)

1- ICB, UMR 6303 CNRS/Université de Bourgogne - 9 Avenue A. Savary - BP 47 870, 21078 DIJON.

2- SINTERMAT SAS, 9 rue l’Oze, 21150 Venarey Les Laumes, France

Abstract:

Titanium (Ti)-nanodiamond (ND) composite discs were sintered using spark plasma sintering (SPS). Several parameters were studied such as the mixing technique, the heating rate and the applied pressure. The effect of these parameters on the densification of Ti + ND composites was shown. The mixing techniques and the applied pressure have a great influence on the densification of Ti + ND composites. The heating rate also has an influence, but less so for the mixing technique and applied pressure parameters. This study determines the optimized sintering parameters for the Ti + ND composites. Density, hardness and electrical conductivity were measured. The higher the ND content in the Ti + ND powder, the more the TiC solid phase forms in the composite which increases the hardness and reduces the electrical conductivity. At a given temperature, the density decreases with increasing ND content.

DOI:

https://doi.org/10.59499/EP235765190

Authors:

José Luis Aguilar (1), Eduardo Tabares Lorenzo (1), Elisa M. Ruiz-Navas (1), Antonia Jimenez-Morales (1,2)

1- Powder Technology Group (GTP), Materials Science and Engineering Department, IAAB, Universidad Carlos III de Madrid, Avda. Universidad 30, 28911, Leganés, Madrid, Spain

2- CIBER de Enfermedades Infecciosas, Instituto de Salud Carlos III, Madrid, Spain

Abstract:

This work studies the sintering process of the 2024 aluminium alloy after 3D printing by Composite Extrusion Modelling (CEM) from sustainable pellet feedstocks, as an alternative route to process aluminium alloys. For the design of the sustainable feedstock of aluminium, powders were combined with water-soluble and low CO2 emissions polymers, PEG and CAB respectively. The powder injection moulding (PIM) technique was used as a first approach to produce good quality samples, thanks to previous studies by the research group. The sintering study was carried out by adding different percentages of traces of alloying elements in the aluminium-based feedstock to improve the sinterability of the material and designing an optimal experimental setup for this critical final stage. A microstructural characterisation of the parts with tin addition was carried out in order to obtain the optimum sintering parameters.

DOI:

https://doi.org/10.59499/EP235766295

Authors:

B. L. Checa Fernández (1,2), J.M. Martín (1,2), G. Sarriegui (1,2), N. Burgos (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

Abstract:

This work presents a detailed study of grain growth annealing of gas-atomized Nd-Fe-B powders with different Nd contents, ranging from 27.5 to 31.5 wt.%. The influence of Nb or Nb-Ga additions have also been investigated. First, the microstructure of the as-atomized powders was studied and the initial grain size was measured. Grain growth annealing has been carried out at 1150 ºC for 5 hours. The addition of Nb resulted in a decrease of the final grain size due to the refining effect of Nb-Fe rich compounds and the reduced amount of free Nd to form a liquid phase. Moreover, it has been determined by Thermo-Calc simulations that Nb content in the liquid increases when the Nd content decreases, further enhancing the refining effect. In contrast, Ga addition increased the liquid formation and enhanced the grain growth kinetics, particularly in the samples with the lower Nd content.

DOI:

https://doi.org/10.59499/EP235754756

Authors:

Uilame Umbelino Gomes (1), Kívia Fabiana Galvão de Araújo (1), Maria José Santos Lima (1), Vitor Manoel Silva Fernandes De Souza (1), Cléber da Silva Lourenço (1), Rafael Alexandre Raimundo (2)

1- Materials Science and Engineering Postgraduate Program, Federal University of Rio Grande do Norte, 59078-970, Natal, Brazil

2- Department of Physics, Federal University of Paraíba, 58051-900, João Pessoa, Brazil

Abstract:

Copper niobate (CuNb2O6) has been studied for technological and environmental applications, such as in solar cells and photocatalysts, for example. And to make the application of CuNb2O6 even more feasible, in this study, therefore, high-energy milling was applied in its synthesis process with variation in the milling time, from the precursor powders Nb2O5 and CuO. The calcination occurred in a muffle with temperatures in the range of 500 °C to 1000 °C, for 3 h and heating rate of 5 °/min. Then, the powders were characterized by XRD, SEM, EDS and Raman. The powders showed crystallite sizes smaller than 80 nm, good homogeneity and high purity. The particle morphologies and the Raman spectrum are coherent with the literature. It was also verified that the increase in milling time reduced the initial formation temperature of the monoclinic phase and the calcination time for the complete formation of the orthorhombic phase.

DOI:

https://doi.org/10.59499/EP235765398