Euro PM2024 Proceedings

Authors:

Ariadna Marin (1), Rocío Muñoz Moreno (1), María Teresa Pérez-Prado (2), Sergi Bafaluy Ojea (2), Federico Sket (2)

1- HP Printing and Computing Solutions S.L., Spain

2- IMDEA Materials Institute, Eric Kandel, Spain

Abstract:

3D Metal Binder Jetting is currently disrupting manufacturing and accelerating mass production of 3D-printed parts. Its excellent balance between part quality and productivity rates is founded on powerful R&D investigations and metrics development to support applications for industrial cases. In this study, the technical physics description of the binder jet fundamentals and its role on parts consolidation will be explained. In particular, the focus will be on describing novel metrics of green parts microstructure obtained by scanning electron microscope (SEM) and X-ray computed tomography (XCT) as binder and porosity local fractions and their spatial distributions. These unique metrics will be evaluated for different powders and R&D print modes. The use of this set of metrics to support print mode development and materials integration, as a predictive and more sustainable method will be discussed.

DOI:

https://doi.org/10.59499/EP246280667

Authors:

Aditya Gopaluni (1), Pasi Puukko (1), Atte Antikainen (1), Hepo-oja Lotta (1), Joni Reijonen (1)

1- VTT Technical Research Centre of Finland, Finland 02044

Abstract:

Additive Manufacturing (AM) is considered as one of the most suitable methods for building parts with complex designs. AM is described as an efficient and sustainable manufacturing method, when compared to the traditional manufacturing methods. To understand the credibility of AM as a sustainable process, a study of the life cycle assessment (LCA) was conducted for PBF-LB, BJT-M and CNC machining for manufacturing of an impeller. The LCA calculations were made for different scenarios with respect to feedstock. It was observed that BJT-M had the largest CO2 footprint compared to PBF-LB, followed by CNC machining. It was concluded that the BJT footprint is highest owing to the extra steps involved in making the part user ready, mainly sintering. This study has been conducted as natural extension of a previous study conducted on LCI of PBF-LB and CNC processes and approaches the LCA from the point of view of raw material.

DOI:

https://doi.org/10.59499/EP246275974

Authors:

S. Sauceda (1,2), S. Lascano (3), C. Arévalo (2), I. Montealegre (2), E.M. Pérez-Soriano (2), P. Pedrosa (2), A. Machuca (3), R. Chavez (3), N. Araya (1)

1- Departamento de Ingeniería de Materiales, Universidad de Concepción, Chile.

2- Departamento de Ingeniería y Ciencia de los Materiales y del Transporte, Escuela Politécnica Superior, Universidad de Sevilla, Spain.

3- Departamento de Ingeniería Mecánica, Universidad Técnica Federico Santa María, Chile.

Abstract:

Applications such as high-power contacts or nuclear fusion reactors frequently rely on W-Cu composites when demanding exceptional electrical and thermal conductivity under extreme conditions. Powder metallurgy serves to create this type of material with different melting points. However, there is a discussion in the literature about the most suitable powder metallurgy techniques. Spark Plasma Sintering (SPS) and Rapid Sintering Process (RSP) make it possible to produce materials within minutes and at lower temperatures on an industrial scale. This study undertakes a comparative analysis of two different sintering techniques at 600°C while varying the pressure and sintering time for W-Cu samples containing 25% and 75%wt. of W. Results show that it is possible to sinter composite W-Cu at 600°C. The material's density, hardness, and microstructure are significantly affected by sintering time. Furthermore, RSP tends to generate higher densities, hardness and Young's modulus.

DOI:

https://doi.org/10.59499/EP246280921

Authors:

Felix Radtke (1), Markus Mirz (2), Klaus Dollmeier (3), Simone Herzog (1,2), Christoph Broeckmann (1,2)

1- Institute of Applied Powder Metallurgy and Ceramics (IAPK), Aachen, Germany

2- Institute for Materials Engineering in Mechanical Engineering, Aachen, Germany

3- Georgsmarienhütte Holding GmbH, Georgsmarienhütte, Germany

Abstract:

Austenitic high nitrogen steels (HNS) are the material of choice in the aerospace, medical, and electronics industry due to their unique combination of high strength, ductility and corrosion resistance. The standard manufacturing route of HNS parts comprises of pressure electroslag remelting and machining by turning or milling. In this study, the Powder Bed Fusion – Laser Beam Metal (PBF-LB/M) process was developed for the austenitic HNS grade X13CrMnMoN18-14-3. Analysis of key factors, such as porosity and manganese content, led to an optimized process window. Solution annealing ensured a fully austenitic transformation of an unintended duplex structure on cost of the fine as-built microstructure. Metallurgical analysis allowed the discussion of the effects of nitrogen content and microstructure on strength, hardness and toughness. The study achieved the desired material properties and contributes to the development of improved materials for the PBF-LB/M process.

DOI:

https://doi.org/10.59499/EP246278588

Authors:

Volker Piotter (1), Alexander Klein (1), Klaus Plewa (1), Heinz Walter (1)

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

Abstract:

Although key words like digital twin, digitalization, big data etc. are dominating our ideas for the future world of manufacturing there is still the demand for particular determination of real material parameters. Simulation of Powder Injection Moulding (PIM) makes no exception, however, due to the high degree of particle filling even marginal changes of the initial values may lead to thorough differences of the results. It could be demonstrated that accidently irrelevant improvements in pvt-data determination resulted in significantly higher accurate predictions. The influence of Bagley-correction as usually applied for polymer material characterization does not lead to better simulation reliability in case of highly filled PIM feedstocks.

DOI:

https://doi.org/10.59499/EP246281624

Authors:

Mikael Luoto (1), Dr. Enrico Daenicke (2), Ralf Müller (2), Dr. Thomas Hartwig (1)

1- Fraunhofer IFAM, Bremen

2- Rolls-Royce Deutschland Ltd. & Co.KG, Germany

Abstract:

Although Metal Injection Moulding (MIM) is a process for parts with complex designs, not all geometries are feasible. The goal of the project was to find a way to bond individually moulded parts before the sintering step and to assess the quality of the achieved sinter joining. Material Inconel 713 Low Carbon was selected for this study. The bonding of the parts was realized by applying adhesive pastes on the parts after solvent extraction. The mechanical properties of sinter joined parts were assessed by using tensile, fatigue (low cycle) and creep (stress rupture) tests. The tensile test showed that the proof stress and ultimate tensile strength were comparable to unjoined baseline material, but a drop in elongation was observed. The creep properties were similar to unjoined baseline material, but a decrease of fatigue properties was measured. A “housing” geometry that is not producible using the conventional MIM-process was manufactured as a demonstrator and it showed that it is plausible that sinter joining could be used for serial production.

DOI:

https://doi.org/10.59499/EP246278323

Authors:

Juan Jiménez (1), Javier Hidalgo (1), Cristina Berges (1), Roberto Campana (2), Gemma Herranz (1)

1- DYPAM Research Group, INEI-ETSII, Universidad de Castilla-La Mancha (UCLM), ETSI Industriale

2- Centro Nacional del Hidrógeno, Prolongación Fernando el Santo s/n, Puertollano, 13500, Ciudad Real, Spain

Abstract:

This study explores innovative approaches to boost the Solid Oxide Fuel Cell (SOFC) interconnector industry, integrating intelligent master alloy design and powder injection molding (PIM). Current challenges in interconnector fabrication via powder metallurgy include the economic high-scale production of complex designs for improved SOFC performance and the restricted availability of commercial powders. To address these limitations, we propose the use of commercial high-Cr master alloys combined with ferrous powders, aiming for compositions equivalent to or surpassing standard Crofer 22. This strategy overcomes powder scarcity challenges and enables precise control over shrinkage and thermal expansion coefficient, crucial for producing ambitious large thin-walled interconnector geometries through PIM. A comprehensive comparative study, covering all PIM stages and properties characterization, is conducted, comparing Crofer 22 pre-alloyed powders with a modified Fe-Cr alloy incorporating additional elements for enhanced performance.

DOI:

https://doi.org/10.59499/EP246282995

Authors:

Dominic Peachey (1), Vivès Solange (2), Yining He (1), Pimin Zhang (1), John Clark (1), Zara Hussain (1), Thomas Wagstaff (1), André Nemeth (1), David Crudden (1)

1- Alloyed Ltd., Oxford, UK

2- Aubert & Duval, Paris, France

Abstract:

The evolution of additive manufacturing (AM) has sparked a growing interest in using nickel-based superalloys, particularly for high-temperature applications above 1000°C. Traditional alloys, intended for casting or wrought processes, face challenges in AM due to the rapid heating/cooling rates and multiple melt cycles, resulting in compromises to material performance or part design freedom. Here we introduce ABD®-1000AM, a novel high gamma prime nickel-based superalloy designed computationally using the Alloys-by-Design (ABD®) approach, tailored for high-temperature AM applications. ABD®-1000AM exhibits world leading performance in terms of both processing capability as-well-as high temperature mechanical and environmental performance at 1000°C. The study discusses the alloy design and development strategy, highlighting the trade-offs in key performance parameters and the intricate process-microstructure-performance optimization undertaken to achieve the alloy's exceptional creep resistance. Based on the insights gained the future direction of alloy development of superalloys for complex AM components is discussed.

DOI:

https://doi.org/10.59499/EP246283346

Authors:

W. Schoeffmann (1), C. Knollmayr (1), K. Mehrabi (1)

1- AVL List GmbH, Austria

Abstract:

The goal of zero carbon operation of powertrain systems requires compatibility for Ethanol, Methanol and in particular Hydrogen as future energy carriers for internal combustion engines (ICE) as well as Fuel Cell systems. Future AM applications will include complex components in combination with high grade materials, such as high temperature, alcohol and hydrogen resistant steel and nickel alloys, for low and medium volume production. Multi-material AM processes, combining multi-metal manufacturing, are subject of research programs and will support the mobility change by extending the applications to E-Motors, Fuel Cell systems and battery components. Focus of the paper is on the application of metal-AM for prototype and small series of appropriate powertrain components providing material compatibility for CO2 neutral fuels. The motivation for the conversion from conventional to additive manufacturing is discussed in regard of functional optimization with AM-process related production design, as well as economically to achieve higher profitability.

DOI:

https://doi.org/10.59499/EP246281384

Authors:

Canto Estany Diana (1), Saula Miquel (1), Sole Macia (1), Puigardeu Aramendia Sergi (1)

1-HP Printing & Computing Solutions, Spain

Abstract:

Ensure test reproducibility and device process repeatability is a must when optimizing or performing a design of experiments on a manufacturing operation. 3D printing additive manufacturing low level subsystem information can be collected and used to trigger investigations on printed parts properties or understand which are the main contributors for a specific one. On 3D HP Binder Jetting printing devices this information is published and can be accessed through an application programming interface (API) or using the HP digital production suite.

DOI:

https://doi.org/10.59499/EP246280947

Authors:

D. A. Sandoval (1), L. Larrimbe (1), O. Lavigne (1), V. Girman (2,3), R. Sedlak (2), V. Luzin (4), M. Serra (5), M. T. Méndez (6)

1- Hyperion Materials & Technologies, Spain

2- Institute of Materials Research, Slovak Academy of Sciences, Slovak Republic

3- Institute of Physics, P.J. Safarik University, Slovak Republic

4- Australian Nuclear Science & Technology Organisation, Australia

5- Politecnical University of Catalunya, Spain

6- BRC Global Rolls Ltd., Singapore

Abstract:

Cemented carbide samples with 12 wt.% of binder content and fine and coarse WC grain size are sintered in two different cycles (SC1 and SC2). After assessing the mechanical properties, it is found that sintering conditions affect the hardness-toughness trade-off relationship found in hardmetals. To understand the effect of temperature, materials are deeply characterized by neutron diffraction and transmission electron microscopy (TEM). No substantial difference is observed in the average stress state between fine-grained samples sintered in both conditions. TEM observations reveal same dislocation density for finer specimens, independently on sintering temperature. Nevertheless, further investigation in coarser material discloses that intrinsic plasticity changes when sintering at higher temperatures, showing a greater dislocation density and the presence of stacking faults within WC grains.

DOI:

https://doi.org/10.59499/EP246277229

Authors:

Francisco Canillas (1), Nerea Ordas (2), Ernesto Urionabarrenetxea (2), Marcelo Roldan (1), Evelin Cardozo (2), Carlos Bloem (3), Edgar Leon-Gutierrez

1- Ciemat, National Fusion Laboratory, Madrid, Spain

2- Ceit-BRTA and Tecnun (Universidad de Navarra), Donostia-San Sebastián, Spain

3- AIDIMME, Paterna, Spain

Abstract:

CuCrZr is a precipitation-hardenable Cu alloy that combines high thermal conductivity and mechanical strength, along with thermal stability up to 350 °C. In this work we demonstrate the feasibility to obtain dense Cu-(0.6-0.9)Cr-(0.07-0.15)Zr (in wt.%) with densities of 99.5%, high thermal conductivity (>80-85% IACS) and enhanced mechanical strength compared to pure Cu, already in the as-built condition, using Powder Bed Fusion Electron Beam (PBF-EB). Further densification was achieved after HIP. Mechanical characterization showed outstanding results, similar or even superior to those reported in the literature for conventional wrought CuCrZr. Microstructural analysis by SEM, EBSD and TEM revealed a multi-scale hierarchical microstructure of ultra-fine Cr-rich precipitates as well as grain and subgrain boundaries, contributing to the excellent mechanical properties achieved. The microstructural stability of the CuCrZr alloy was evaluated by heat treatments in the range of 350 – 550 °C for up to 1080 hours.

DOI:

https://doi.org/10.59499/EP246300683