Euro PM2023 Proceedings

Authors:

Deekshitha Kancharla (1), Moritz Greifzu (1,2), Axel Marquardt (1,2), Joanna Eckardt (1)

1- Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS, Germany

2- Institut für Werkstoffwissenschaft, TU Dresden, Germany

Abstract:

Metal Binder jetting (BJ) is an additive manufacturing technology that requires a series of post-processing steps to obtain the final product, with sintering being one of the important steps. Multiple coupled phenomena such as densification, coarsening, grain growth, and evolution of microstructure, influence sintering. Grain growth during sintering impacts the final mechanical properties and the densification of a material. The most common method to evaluate the grain growth behaviour is conducting interrupted-sintering analysis followed by microscopy which is a time-consuming process. This work intends to estimate the grain growth during sintering from the shrinkage data obtained from dilatometry. The concept of integrating a master sintering curve (MSC) into the Skorohod-Olevsky-based model is explored to predict grain growth and sintering behaviour. The main aim is to evaluate the adaptability of this approach to BJ.

DOI:

https://doi.org/10.59499/EP235763105

Authors:

Julian Henrichs (1,2), Jimmy Hilbert (1), Ronald Rosenberg (2), Pierre Forêt (2), Marcus Giglmaier (1), Nikolaus A. Adams (1)

1- Technical University of Munich; TUM School of Engineering and Design, Chair of Aerodynamics and Fluid Mechanics, Boltzmannstr. 15, D-85748 Garching, Germany

2- Linde GmbH, Linde Technology - Additive Manufacturing, Carl-von-Linde-Straße 25, D-85716 Unterschleißheim, Germany Abstract

Abstract:

One of the current major barriers to the industrialization of metal additive manufacturing (AM) is the cost-effective production of a high-quality metal powder, usually in the range of 1-150 μm, making investigations of the atomization process essential. Numerical investigations usually reach their limits due to the massive multiscale problem, whereas experimental investigations are either performed on a laboratory scale with limited transferability or on industrial equipment with limited accessibility for measurement techniques. To face this challenge a new atomization test bench (ATB) is developed which was tailored for detailed experimental investigation on the fundamentals of atomization in an industrial scale set-up. All input parameters can be set individually and are measured continuously and precisely. At the same time, the good optical accessibility allows a temporally and spatially highly resolved visualization of the gas flow as well as a detailed investigation of the mechanisms of decomposition during primary and secondary atomization.

DOI:

https://doi.org/10.59499/EP235768771

Authors:

Fernanda Signor (1), Maria José Silva Carvalho (1), Augusto Botton Pozzebon (1), William Bevilaqua (2), Inacio Limberger (1), Natália de Freitas Daudt (1,3)

1- Grupo de Tecnologia e Mecânica dos Materiais (GMAT), Departamento de Engenharia Mecânica, Universidade Federal de Santa Maria, Brazil

2- Colégio Técnico Industrial de Santa Maria (CTISM), Universidade Federal de Santa Maria, Brazil

3- Mechanical Engineering Post-Graduate Program (PGMEC), Departamento de Engenharia Mecânica, Universidade Federal de Santa Maria, Brazil

Abstract:

The fabrication of copper parts by 3D-extrusion of highly viscous paste was studied. This technology is classified as sinter-based AM technology. Extrusion-based 3D printing have been often reported in literature for production of ceramics components, however there are still few studies on metal components. 3D-extrusion allows printing of metallic components with a low anisotropy index, by deposition of layers of a paste composed of polymeric solution loaded with metal powder. In the present study, we evaluated the effect of paste composition on the microstructure and compressive strength behavior of copper parts. For that three different composition of water based polymeric pastes loaded with copper particles were prepared. Green parts were printed by paste extrusion at room temperature. Afterwards the parts were debinded and sintered. Extrusion-based 3D printing of metals pastes is an attractive route for cost effective production of small batches of complex shaped parts.

DOI:

https://doi.org/10.59499/EP235764456

Authors:

G. Miranda (1), L. Basílio (2,3), B. Guimarães (2,3), O. Carvalho (2,3), C. M. Fernandes (4), D. Figueiredo (4), F. S. Silva (2,3)

1- CICECO - Aveiro Institute of Materials, Department of Materials and Ceramic Engineering, University of Aveiro, 3810-193 Aveiro, Portugal

2- Center for MicroElectroMechanical Systems (CMEMS-UMinho), University of Minho, Campus de Azurém, 4800-058 Guimarães, Portugal

3- LABBELS – Associate Laboratory, Braga/Guimarães, Portugal

4- Palbit S.A., P.O. Box 4, 3854-908 Branca, Portugal

Abstract:

Laser surface texturing has a high potential for the development of innovative solutions for the cutting tool industry, by allowing the fabrication of high-precision micro-scale geometries. In this study, different cross-hatched micro patterns were explored, by using an Nd:YAG laser to texture WC-10wt% Co green compacts. After dewaxing and sintering, a complete characterization was performed to evaluate topography, roughness, and dimensions of the fabricated textures. This study allowed to conclude on the better scanning strategy and laser parameters for obtaining a given texture geometry with defined dimensions on a reproducible manner. Besides allowing to modify a selected surface area, targeting to higher wettability or increased contact area, this approach has shown not to compromise the integrity and mechanical strength of the compact, allowing to preserve the tool conventional functionality.

DOI:

https://doi.org/10.59499/EP235765405

Authors:

N. Azurmendi (1), A. Lores (1), I. Agote (1), C.M. Fernandes (2), D. Figueiredo (2)

1- TECNALIA, Basque Research and Technology Alliance (BRTA), Mikeletegi Pasealekua 2, 20009 Donostia-San Sebastián, Spain

2- PALBIT SA P.O. Box 4, 3854-908 Branca, Portugal

Abstract:

Additive manufacturing of hard metals is gaining attention due to the possibility of fabricating complex shaped parts and new functional designs. Among all of them, Binder Jetting (BJ) appears to be one of the most promising technology due to its low-cost, fast manufacturing process that produces stress and crack-free parts with isotropic properties. In the present work, the feasibility of using hard metal thermal spray powders (WC-12%Co) for binder jetting technology has been studied. Properties of two different agglomerated and sintered powders (AMPERIT 519.059 from Höganäs and WOKA 3111FC from Oerlikon Metco) have been analysed and compared. In addition, physical, mechanical and microstructural properties (density, hardness) of the printed parts sintered in a sinter-hip-furnace at 1455°C and 30bars have been evaluated and compared. The obtained results demonstrated the feasibility of using this type of powders for binder jetting, obtaining near full density parts (>99%) with hardness values around 1320 HV and homogeneous fine-medium microstructure.

DOI:

https://doi.org/10.59499/EP235763986

Authors:

Mohammad Momeni (1), Lluis Gimeno-Fabra (1), Herbert Danninger (2), Christian Gierl-Mayer (2)

1- European Patent Office, Patentlaan 2, 2288 EE Rijswijk, Netherlands

2- Institute of Chemical Technologies and Analytics, Technische Universität Wien, Getreidemarkt 9/164-03, A-1060 Wien/Vienna, Austria

Abstract:

Patents provide a solid legal framework for inventors to fairly benefit from their contribution to technology. The social deal around patents, requires a clear and sufficient disclosure of novel and inventive subject-matter. This means that patents contain valuable information on the most advanced state of innovation worldwide. Consequently, providing an overview of the granted patents seems to be crucial to know the industrial trends. In this presentation, the public data is decoded and presented in selected granted patents at European Patent Office (EPO) from 2015 to 2020 (for which the opposition periods have expired) to sketch this evolution and show the major industrial trends. The scope of the presentation is revealing some latest industrial developments and growing technology developments in manufacturing of ferrous powders & sintered steels.

DOI:

https://doi.org/10.59499/EP235762617

Authors:

C. Kukla (1); V. Momeni (2); G. Poehle (3); S. Riecker (3); S. Schuschnigg (2)

1- Montanuniversitaet Leoben, Industrial Liaison Department, Leoben, Austria

2- Montanuniversitaet Leoben, Department of Polymer Engineering and Science, Institute of Polymer Processing, Leoben, Austria

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

Abstract:

Material Extrusion with filaments, Fused Filament Fabrication – FFF, is the most widespread additive manufacturing technology. This counts mainly for polymers, since the use of this technology for metal and ceramic powders is still in its early days. For several metals, filaments can be bought in the market. Aluminium has a low sintering temperature already in the range of the temperatures for thermal debinding of many feedstocks and needs special sintering regimes. To meet these special requirements, a feedstock for the production of highly filled aluminium filaments was developed. The printed parts are debinded by solvents. Here, the following results are presented: 1) rheological behaviour of the feedstock, 2) debinding behaviour with emphasis on the selection of solvents and 3) printing performance.

DOI:

https://doi.org/10.59499/EP235763812

Authors:

Martin Bram (1), Fernando Maccari (2), Monica Keszler (1), Tarini Prasad Mishra (1)

1- Forschungszentrum Jülich GmbH, Institut für Energie- und Klimaforschung, 52425 Jülich, Germany

2- Technical University of Darmstadt, Institute for Materials Science, Functional Materials, 64287 Darmstadt, Germany

Abstract:

Flash spark plasma sintering (Flash SPS) is an attractive alternative method for the processing of Nd-Fe-B magnets with anisotropic magnetic properties. Therefore, a load is applied on a pre-compacted sample. Then, a well-defined power pulse is applied followed by deformation and densification of the sample in seconds. Compared to established processing of anisotropic magnets via hot pressing with subsequent die-upsetting, Flash SPS introduces the possibility of electroplasticity as an additional deformation mechanism. This mechanism has the potential to improve the magnetic properties through the fine-tuning of the microstructure. Our results reveal that suitable pre-heating of the sample before applying the power pulse plays a crucial role for tailoring grain size and grain aspect ratio, both being the key for well-pronounced anisotropic magnetic properties. For better understanding of the relationship between Flash SPS parameters, microstructure and resulting magnetic properties, a systematic parameter study has been done in the present work.

DOI:

https://doi.org/10.59499/EP235762561

Authors:

Giorgia Lupi (1); João Teixeira Oliveira de Menezes (1); Filippo Belelli (1); Francesco Bruzzo (2); Joerg Volpp (3); Enrique Mariano Castrodeza (1); Riccardo Casati (1)

1- Department of Mechanical Engineering, Politecnico di Milano, Via G. La Masa 34, 20156 Milano (MI), Italy

2- Fraunhofer, Institut für Werkstoff- und Strahltechnik, Winterbergstraße 28, 01277 Dresden, Germany

3- Luleå University of Technology, Department of Engineering Sciences and Mathematics, SE-971 87 Luleå, Sweden

Abstract:

In this work, a mechanical characterization of AlSi10Mg alloy processed by Direct Energy Deposition with Laser Beam of Metals (DED-LB/M) in atmospheric conditions was performed. SE(B) and ESE(T) specimens, for fracture and fatigue tests were printed and machined having the cracks in three different crack plane orientations. Microstructural and fractographic analyses were performed by FE-SEM and LOM, and it was observed that the fracture response is strongly affected by the crack plane orientation and porosity distribution. Moreover, the ESE(T) specimens were analyzed using the EBSD technique and the results shed light on the effect of melt pool boundaries, grain boundaries and crystallographic orientation of grains on the crack path for the different crack plane orientations.

DOI:

https://doi.org/10.59499/EP235765625

Authors:

Matteo Zanon (1); Armin Müller (1); Darek Kossakowski (1); Aljoscha Roch (2); Joseph R. Croteau (3); Tom Pelletiers (3)

1- Kymera International / Ecka Granules Germany, Germany

2- AM Extrusion GmbH, Germany

3- Kymera International / SCM Metal Products, USA

Abstract:

Among the sinter-based technologies, Fused Filament Fabrication (FFF) is proving itself as a low capital investment, small series approach to 3D printing. Firmly established for plastics, it can be extended to metals by composite filaments with around 60% metal loading by volume. The large quantity of binder, necessary for the filament compounding and extrusion, poses special challenges to the debinding process. This becomes especially true with reactive materials such as aluminium, but also when targeting high electrical conductivity in copper, which is extremely sensitive to residual impurities. Metal powder and binder expertise must then be brought together to enable this technology to compete in the 3D printing market.

The current joint work presents results with both aforementioned classes of non-ferrous powders, highlighting the impact of debinding procedure and powder characteristics on the final sintered and microstructural properties. Effect of heat treatment is also investigated.

DOI:

https://doi.org/10.59499/EP235761372

Authors:

Vanzetti Matteo (1), Pavel Michael (2), Perez Andrade Lorena (2), Padovano Elisa (1), Aversa Alberta (1), Weaver Mark (2), Brewer Luke (2), Bondioli Federica (1)

1- Politecnico di Torino, Torino, Italy

2- University of Alabama, Tuscaloosa, USA

Abstract:

Metallic powders are one of the most common feedstock materials for metal additive manufacturing (MAM). Nowadays, only few alloys can be processed by these technologies and most of them are casting alloys. This work is focused on the characterization of a novel aluminum alloy produced by a close coupled gas atomizer (CCGA) with composition AlSi10Mg + X Cu (X= 4, 8, 20 wt%). These compositions are very attractive because copper is a well-known strengthener for aluminum alloys. The produced powders were characterized in terms of morphology, flowability, particle size distribution (PSD) and density. Furthermore, the powders microstructures were analyzed to evaluate the composition and the morphology of the phases generated by the rapid solidification that characterized the gas-atomization process.

DOI:

https://doi.org/10.59499/EP235763134