Euro PM2024 Proceedings

Authors:

Simone Maffia (1), Ondrej Kovarik (2), Jaroslav Cech (2),Tobias Stittgen (1)

1- Ponticon GmbH, Germany

2- Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Czech Republic

Abstract:

Conventional powder Laser-Based Directed Energy Deposition (DED-LB) has revolutionized Additive Manufacturing (AM) by enabling the fabrication of large, support-free geometries and minimizing material waste through targeted deposition. Despite these advantages, conventional DED-LB faces challenges in microstructure control, primarily due to high heat inputs, limiting fine adjustments and compromising material integrity. In this work, the transformative potential of Ponticon’s 3D Extreme High-Speed Laser Metal Deposition (EHLA) for large-scale applications is investigated, highlighting its capabilities in both, deposition performance and microstructural control. 3D-EHLA's high feed rates, reaching up to 200 m/min, not only significantly enhance deposition performance but also enable precise control over microstructures, thanks to a two-order-of-magnitude increase in cooling rates. As a result, tailored microstructures enable local modification of mechanical properties through process parameter adoption. This innovation addresses the limitations of conventional DED-LB, providing a viable solution for high-end large-scale AM components.

DOI:

https://doi.org/10.59499/EP246283203

Authors:

Daniel Rommel (1), Christopher Schunk (1), Christoph Wielenberg (2), Frank Palm (3)

1- Colibrium Additive – a GE Aerospace company, Germany

2- Premium AEROTEC, Germany

3- Airbus, Germany

Abstract:

A next generation Al-Sc-alloy (Scancromal® (Al-Cr-Sc-Zr)) was printed using L-PBF technology. Compared to the more familiar Scalmalloy® (Al-Mg-Sc-Zr-Mn) the new material concept Scancromal® offers several advantages regarding process stability. Focus of the investigation was to explore the potential of such tailored alloy regarding maximum productivity utilizing increased layer thickness and laser power. Processing windows for two build layer thicknesses: 50 and 100 µm and two laser powers: 370 and 740 W were explored in order to identify parameter combinations to create dense (high strength & ductile) material and at the same time achieving highest build rates. The most promising combinations were down selected to print additional samples for microstructural and mechanical characterization. Samples were analyzed in “as printed” and heat-treated states to enable conclusions regarding processing parameters and resulting microstructure in addition to mechanical properties. Therefore, tensile properties were evaluated at room and elevated temperature.

DOI:

https://doi.org/10.59499/EP246278426

Authors:

Zhanfang Wu (1), Lida Che (1), Kai Wang (1), Zhoujin Lv (1), Xiangyang Li (1)

1- CISRI HIPEX TECHNOLOGY CO., LTD., Beijin, China

Abstract:

As one of the important technologies in powder metallurgy, Hot Isostatic Pressing Near Net Shape (HIP-NNS) technology has been widely used in the aerospace field in recent years due to its ability to prepare high-performance products with complex structures. The Duplex stainless steel (DSS) material has attracted the attention of marine engineering, shipbuilding, nuclear power, petrochemical and other industries for its excellent mechanical properties and corrosion resistance. This paper uses HIP-NNS technology, Shima yield model and MSC.Marc finite element software completed the densification of DSS powder and the prediction of package size deformation, and analyzed the changes in powder relative density and equivalent stress. The results showed that the simulation model achieved high prediction accuracy, with a maximum size error of no more than 3%. The numerical simulation method was used to accurately predict the shrinkage of the package and the powder densification process, greatly improving powder utilization and production efficiency, reducing processing costs, and providing a new process approach for achieving integrated forming of complex DSS products.

DOI:

https://doi.org/10.59499/EP246299296

Authors:

Philipp Kindermann (1), Martin Wunderer (1), Maximilian Straßer (1), Maja Lehmann (1), Ismail Ünsal (1), Georg Schlick (1), Christian Seidel (2), Wolfram Volk (1,3)

1- Fraunhofer Institute for Casting, Composite and Processing Technology (IGCV), Germany

2- Munich University of Applied Sciences, Germany

3- Technical University of Munich, Germany

Abstract:

Cold spray is comparatively novel thermal spray process with high potential for the additive manufacturing of metallic materials. It has several unique characteristics – most notably, the process does not require any melting or fusion of the processed materials and the substrate. The powder is accelerated by a gas flow and forms dense layers on impact due to the high kinetic energy. The chamber temperature is the most known parameter in cold spray alongside the pressure of the process gas. The set chamber temperature has a crucial effect on the gas flow and its velocity and, thus, the build quality. However, in addition to the chamber temperature, other parameters, such as the nozzle material and the powder gas flow rate, also influence the parameters of the gas flow. The cause-effect relationships are not yet fully understood. This paper describes the influence of the nozzle material on the outlet gas temperature and its effect on the particle velocity.

DOI:

https://doi.org/10.59499/EP246282622

Authors:

Thomas Kairet (1), Godet Stéphane (2), Malet Loïc (2), Erin Kuci

1- Sirris, Seraing, Belgium

2- ULB, Brussels, Belgium

Abstract:

The printing of Fe-6.5wt%Si by LB-PBF is a complex process due to the formation of brittle phases during processing, which can lead to sensitivity to internal stresses. The paper shall show the issues encountered during processing and the resulting material, based on optical microscopy, defect analysis and classification. The manufacturing of thin walls has yielded better results than thick bulk material, and various laser melting strategies will be presented to demonstrate the trend between single and multiple meltpool thicknesses. The internal grain texture of the wall is obtained by means of EBSD. Furthermore, the magnetic hysteresis cycle of the printed material is measured using a vibrating magnetometer.

DOI:

https://doi.org/10.59499/EP246275409

Authors:

Thomas Kairet (1), Godet Stéphane (2), Malet LoÏc (2), Hemberg Alex (3)

1- Sirris, Seraing, Belgium

2- ULB, Brussels, Belgium

3- Materia Nova Innovation Center, Mons, Belgium

Abstract:

The titanium coated powder has shown promising results for in-situ microalloying. Hot cracking of the 7075 alloy was completely inhibited and grain refinement is massive. This effect is visible with and without preheating of the build plate. Mapping of the alloying elements has shown that precipitation at the grain boundaries is important, hence these elements require solution treatment to be available for precipitation hardening. The best yield strength achieved in this work was 376MPa.

DOI:

https://doi.org/10.59499/EP246274677

Authors:

Faraz Deirmina (1), Eleonora Bettini (1), Jonathan Hann (2), Sasan Amirabdollahian (3), Zhao Zhao (4), Sylvain Dossin (5), Giorgia Lupi (6), Riccardo Casati (6), Massimo Pellizzari (4), Arne Röttger (2)

1- Sandvik Additive Manufacturing, Sweden

2- Bergische Universität Wuppertal, Germany

3- Prom facilities, Italy

4- Trento University, Italy

5- Hydro AS, Norway

6- Politechnic of Milan, Italy

Abstract:

To address the challenges in processing medium-carbon hot work tool steels by laser-based additive manufacturing (AM), a recently developed hot work tool steel with improved processability was processed by both laser powder bed fusion (L-PBF) and laser-directed energy deposition (L-DED). Microstructure and phases in as-built (AB) and quenched (Q) states were compared for both processing routes. Hardness, Charpy V notch impact toughness, tempering- and thermomechanical softening- resistance, after direct double tempering from AB condition (DT) and quenching and tempering (QT) were measured and assessed. Properties were then compared with those of AM-, as well as wrought- AISI H13 hot work tool steel. The results suggest that the new steel exhibits comparable mechanical and thermomechanical properties to steel H13. Finally, practical case studies of repairing tools made from H13, using the new tool steel (L-DED), and producing relatively large molds with complex geometries (L-PBF) were demonstrated.

DOI:

https://doi.org/10.59499/EP246282485

Authors:

Aurore Leclercq (1), Thibault Mouret (1), Vladimir Brailovski (1)

1- École de Technologie Supérieure, Montréal, Canada

Abstract:

Molybdenum (Mo) is one of the target materials for laser powder bed fusion additive manufacturing processes. Using the following set of printing parameters: E=179 W; v=133 mm/s; h=60 µm and t=30 µm, crack-free Mo specimens were printed, subjected to hot isostatic pressing (1300°C & 150 MPa for 3 hours), and characterized in terms of their density, structure, and compression behavior at room and elevated temperatures. The results obtained with as-built specimens with a printed density of ~97% and an ultimate compression stress of 486, 242, 264 and 145 MPa at 20, 600, 800 and 1000°C respectively, are comparable to those shown by their counterparts produced by conventional powder metallurgy processes. The selected HIP conditions resulted in a ~1% increase in the part density, but simultaneous porosity evolution and grain coarsening led to a concurrent ~10% decrease in the room and elevated-temperature mechanical properties of printed parts.

DOI:

https://doi.org/10.59499/EP246281988

Authors:

A. Luaces (1), A. Aourdou (1), G. García (1), J.M. Amado (1), M.J. Tobar (1), A.Yáñez (1)

1- Campus Industrial. CITENI. Universidade da Coruña 15403 Ferrol, Spain

Abstract:

This study investigates the laser direct energy deposition (DED) of WC-steel metal matrix composites to create functionally graded coatings with varying carbide content. Using a Nd-YAG laser and a powder distribution system, coatings were deposited with controlled gradients of WC within the A316L stainless steel matrix. Microstructural analysis revealed uniform carbide distribution and effective bonding with the metallic matrix. Hardness measurements demonstrated a significant increase in matrix hardness with increasing WC content, confirming successful carbide incorporation. Tribological tests indicated varying wear resistance capabilities across different zones of the coatings, correlating with the carbide gradient.

DOI:

https://doi.org/10.59499/EP246282865

Authors:

A. Luaces (1), A. Aourdou (1), G. García (1), J.M. Amado (1), M.J. Tobar (1), A.Yáñez (1)

1- Campus Industrial. CITENI. Universidade da Coruña, Ferrol, Spain.

Abstract:

This study investigates the laser directed energy deposition (DED) of WC-steel metal matrix composites to create functionally graded coatings with varying carbide content. Using a Nd-YAG laser and a powder distribution system, coatings were deposited with controlled gradients of WC within the AISI316L stainless steel matrix. Microstructural analysis revealed uniform carbide distribution and effective bonding with the metallic matrix. Hardness measurements demonstrated a significant increase in matrix hardness with increasing WC content, confirming successful carbide incorporation. Tribological tests indicated varying wear resistance capabilities across different zones of the coatings, correlating with the carbide gradient.

DOI:

https://doi.org/10.59499/EP246283184

Authors:

José Brant de Campos (1), Kellen Venancio dos Santos (1), Camila Pelicarto Alves da Silva Botão (1), Eustáquio de Souza Baêta Júnior (1), Letícia dos Santos Aguilera (2), Fernando Massa Fernandes (3), Suzana Bottega Peripolli (1)

1- Rio de Janeiro State University, Postgraduate Program in Mechanical Engineering – PPG-EM, Rio de Janeiro, Brazil

2- Rio de Janeiro State University, Postgraduate Program in Materials, Rio de Janeiro, Brazil

3- Institute of Condensed Matter and Nanosciences (IMCN) of the Catholic University of Louvain, Belgium.

Abstract:

PbS semiconductor nanoparticles have been shown to be promising in applications such as microelectronics, optoelectronics and optics and it can be also useful in electroluminescent devices such as light-emitting diodes. In this system, when PbS crystal sizes are smaller than the Bohr radius, excitons become confined in all three spatial directions, a phenomenon called the quantum confinement. This effect is an interesting aspect to be studied, since optical and electronic properties of materials are size dependent of the particles. The use of an aqueous synthesis in 2-mercaptoethanol is an alternative to standard synthesis, which uses Oleic Acid (OA). In this work, the synthesis route for the production of PbS nanoparticles was evaluated through characterization by Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) to investigate the distribution, morphology and size of the nanoparticles, as well as X-ray Diffraction (XRD) to confirm that the phase formed is galena (PbS).

DOI:

https://doi.org/10.59499/EP246280486

Authors:

T. Lindroos (1),T. Kinos (1), A. Antikainen (1), T. Riipinen (1), A. Manninen (1), A. Bertinetti (2), J. O. Odden (3), J. Pippuri-Mäkeläinen (1)

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

2- Gemmate Technologies s.r.l., Italy

3- Elkem Silicon Product Development AS, Norway

Abstract:

Clean and smart electrification is at the core of the European Green Deal since it is definitively a key option for society’s decarbonization and for tackling climate change. The electrification transformation of processes and mobility is creating an unparalleled demand for components like electric machines. This, concurrently, is causing a huge push towards higher efficiencies and power densities, lighter weights, and customized solutions for electric machines, meaning that innovation in the field is required to fulfil future demands. Additive Manufacturing (AM) is seen as an enabler in producing components for novel electric machine architectures with designs and performance unattainable with conventional manufacturing. In this study we summarize development of Laser Powder Bed Fusion route for soft magnetic electric motor components starting from tailoring of soft magnetic material for L-PBF process and ending to demonstration of electric motor stator and rotor components. The paper highlights our findings and challenges to tackle. The effect of alloying elements, L-PBF parameters, and post-processing routines on magnetic performance are discussed.

DOI:

https://doi.org/10.59499/EP246277219