Euro PM2024 Proceedings

Authors:

Vignesh Mohan (1), Christian Gierl-Mayer (1), Elisabeth Rauchenwald (2), Christoph Vogler (2)

1- Insitute for Chemical Technology and Analysis, Technische Universität Wien, Vienna, Austria

1- HUAWEI TECHNOLOGIES AUSTRIA GmbH, Vienna, Austria

Abstract:

Soft Magnetic Composites (SMCs) are a class of ferromagnetic materials used for various applications. At high frequencies, they face significant eddy current losses. To limit these losses, their electrical resistivity must be increased. An effective way is to use pre-alloyed powders and insulated coatings (e.g. oxidation). However, pre-alloyed powders are more difficult to oxidize. In this paper, a successful approach is described. The responses of three Fe-based SMC powders to this approach are discussed using oxygen measurement (Leco) and SEM (Scanning Electron Microscopy) imaging. Oxygen measurements reveal different oxygen contents among the materials. This was expected, yet the oxidation time seems to make no difference to oxygen content. In SEM images, oxide layers are seen in the powders. Since this study aims to better understand the feasibility of oxidation as a coating mechanism, further analysis of the powders is limited.

DOI:

https://doi.org/10.59499/EP246284004

Authors:

Satya Chaitanya Vaddamanu (1), Hugo Wärner (2), Ulrika Fager (2), Eduard Hryha (1)

1- Department of Industrial and Material Science, Chalmers University of Technology, Gothenburg, Sweden

2- SSAB Special Steels, Oxelösund, Sweden

Abstract:

With the advent of additive manufacturing (AM), there is a need for new materials in the field of structural materials. The primary challenge hindering the widespread use of traditional ferrous materials for this purpose is the high carbon content (>0.1%), making the processing difficult. This study aims to explore the processability window and consequent microstructure and properties of a novel low-alloyed steel powder processed using Powder Bed Fusion - Laser Beam (PBF-LB). Process parameters were developed for two different layer thicknesses of 30 and 60 µm to obtain fully dense (~99.9%) and crack free specimens. An in-depth process map was created by characterizing the dimensions and regularity of melt pools using optical microscopy, and further microstructural analysis was carried out using Scanning Electron Microscopy (SEM) revealing the features of a martensitic microstructure. Subsequently, the optimized parameter sets were used to produce tensile and impact testing specimens used to evaluate the mechanical performance of the alloy.

DOI:

https://doi.org/10.59499/EP246281555

Authors:

RWN Nilen (1), I Konyashin (2), RS Balmer (1), T Nicolaides (1), B Ries (2), M Walsh (1)

1-Element Six (UK) Ltd., Global Innovation Centre, Harwell Campus, United Kingdom

2-Element Six GmbH, Burghaun, Germany

Abstract:

The excellent abrasion resistance and impact resistance of polycrystalline diamond (PCD) make it the material of choice for certain rock cutting applications. For example, a PCD table bonded to a WC/Co substrate forms a cutter suitable for oil and gas drilling. However, the presence of binder in the PCD – infiltrated from the substrate during high pressure, high temperature (HPHT) sintering – severely shortens tool life through thermal degradation mechanisms. Acid leaching this binder from the cutting surface significantly improves its thermal stability, but the use of alternative, more thermally stable binders is also an option. In this work, a novel Co-Re binder was evaluated for thermally stable PCD. Hot-stage XRD confirmed a 200°C delay to the onset of graphitisation in the PCD compared to standard Co binder-based PCD and post-heat treatment crack analysis demonstrated the suitability of this material for thermally demanding drilling applications.

DOI:

https://doi.org/10.59499/EP246277058

Authors:

C. Kukla (1), V. Momeni (2), S. Schuschnigg (2), C. Holzer (2)

1- Montanuniversitaet Leoben, Research and Innovation Service, Leoben, Austria

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

Abstract:

The backbone plays a significant role in the binder system for FFF of metals. Since the backbone is degraded thermally, the temperature for this debinding step should be below the sintering temperature of the involved metal. Thus, the low degradation temperature makes PLA a proper candidate for the backbone in feedstocks for aluminium with a relatively low sintering temperature starting at about 550 °C. However, processing of PLA is challenging due to high shear and temperature sensitivity. Therefore, the printability at different nozzle temperatures (230, 250, 270 °C) was investigated for various formulations with PLA content ranging from 25 to 40 vol.% in the binder system. Solvent debinding for printed samples was conducted at room temperature and different immersion times. The results indicated the substantial impact of printing temperature on enhancing shape retention and preventing interlayer cracking during the solvent debinding process. The main binder was removed successfully without any defects during solvent debinding.

DOI:

https://doi.org/10.59499/EP246281505

Authors:

Andrea Cogotti (1), Dr. Sebastian Boris Hein (1), Lea Reineke (1)

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

Abstract:

Metal Binder Jetting has become an established manufacturing process for serial production in recent years. Therefore, it is crucial to ensure the repeatability and qualification of the process for different materials. An infrared lamp is used to warm the powder bed during the process, causing the solvent in the binder to evaporate. The temperature of the lamp is controlled by an infrared sensor. To accurately measure the temperature of a powder bed, and thus being able to ensure proper process control, it is necessary to know the emissivity value of the metal powder. This study determined the emissivity value for various powders and compared the properties of green parts, printed with the correct emissivity to those printed without prior determination.

DOI:

https://doi.org/10.59499/EP246281695

Authors:

Giorgia Lupi (1), Federico Gobber (2), Giovanni Carlucci (1), Marco Actis Grande (2), Riccardo Casati (1)

1- Department of Mechanical Engineering, Politecnico di Milano, Italy

2- Department of Applied Science and Technology, Politecnico di Torino, Italy

Abstract:

The Powder Bed Fusion- Laser Beam (PBF-LB) of pure Cu pose significant challenges due to the high laser-reflectivity and thermal-conductivity of this metal. Near-IR lasers are widely considered not suitable for processing Cu, unless high power is employed, limiting the accessibility to Cu. In this work, we investigate a disruptive approach to improve Cu processability by using a low-power (200 W) near-IR PBF-LB/M system, which is based on the Ag-coating of Cu particles that were heat-treated at 500°C/600°C to promote diffusion at the coating interface. Pure Cu and coated powder were processed by PBF-LB/M to produce bulk samples. Microstructure analysis was performed by SEM, EDX, and XRD. It was observed that the Ag layer has a positive effect on the laser processability of Cu. Almost fully dense materials (>98%) were achieved due to the formation of a Cu-Ag eutectic network able to heal pores and defects during solidification.

DOI:

https://doi.org/10.59499/EP246278649

Authors:

Aurelien Neveu (1), Filip Francqui (1)

1- Granutools,Awans, Belgium

Abstract:

A good powder spreadability is essential in powder bed-based processes to ensure the production of smooth and homogeneous layers during recoating. However, the evaluation of the spreadability inside the printer requires a sufficiently large batch to fill the machine and is a very time-consuming process, especially the cleaning of the machine. Therefore, having a simple way to predict the spreadability beforehand should drastically reduce the cost at the powder selection stage. In this study, we show that a good correlation is found between the Cohesive Index metric evaluated in a rotating drum and the quality of the layer deposited in a SLM printer (SLM280, SLM Solutions). A wide range of metal powders of different materials and particle sizes have been characterized in the rotating drum. In addition, layers have been produced in the printer and analyzed with an image processing algorithm to obtain a measure of the spreadability.

DOI:

https://doi.org/10.59499/EP246283045

Authors:

Mahmoud Naim (1, 2), Mahdi Chemkhi (1, 2), Delphine Auzene (3), Elies Benammar (3), Valentin Maillet (2)

1- UR-LASMIS, University of Technology of Troyes, France

2- EPF School of Engineering, Rosières-Prés-Troyes, France

3- CRITT MDTS, Charleville-Mézières, France

Abstract:

Additive Manufacturing (AM) sinter-based technologies, particularly filament-based material extrusion (MEX) is gaining popularity for its simplicity and cost-effectiveness, mainly for the shaping by 3D printing, making metal additive manufacturing more accessible for industrial production. Even though this technique offers flexibility in material choices and great potential for fabricating high-quality parts, there is still a lack of research on the mechanical and surface properties of the MEX-ed H13 tool steel and the influence of the printing setup on them. In the present work, this literature gap will be filled by analyzing the surface roughness, density and tensile behavior of H13 tool steel parts that were constructed horizontally and on edge.

DOI:

https://doi.org/10.59499/EP246290825

Authors:

Frederik Tegeder (1), Sandra Wieland (2), Julius Eckel (2), Lea Reineke (2), Christoph Broeckmann (1)

1- Institute for Materials Applications in Mechanical Engineering (IWM), Aachen

2- Fraunhofer Institute for Manufacturing Technology and Applied Materials Research (IFAM), Bremen

Abstract:

Additive manufacturing offers numerous possibilities for toolmaking, such as the integration of internal cooling structures. Another important aspect is minimizing the necessary post-processing steps through near-net shape manufacturing, which allows for significant cost savings, particularly with hard-to-machine carbide-rich tool steels. Previous research projects have examined processing using laser-based methods (PBF-LB/M). Due to locally high cooling rates and associated residual stresses, cracks often occur in high-strength tool steels. In this study, the cold work steel AISI A11 X245VCrMo10-5-1 was successfully fabricated using Metal Binder Jetting (MBJ) and sintered under two different conditions. The resulting microstructure was examined to determine a correlation between the sintering conditions and mechanical properties. The mechanical properties are compared with those from the conventional manufacturing route. The study demonstrates that the production of tools from high-strength tool steels using MBJ represents a promising alternative to the conventional manufacturing route.

DOI:

https://doi.org/10.59499/EP246281685

Authors:

Gulcagri Sahin (1), Ilven Mutlu (1)

1- Istanbul University-Cerrahpasa, Metallurgical and Materials Engineering Department, Istanbul, Turkey

Abstract:

In this study, nickel-based superalloys (Ni-Cr-Mo-Nb-Fe-Ti) with varied Ti contents have been produced by using mechanical alloying-powder metallurgy method for turbine blade material. Effect of Ti addition was investigated. Superalloy powders were prepared by mechanical alloying by using 6 mm zirconia balls for 20 hours at 400 rpm. Then, the powder mixtures were compacted at 400 MPa in a hydraulic press, and the green specimens were sintered at 1200 °C for 1 hour. Properties of the superalloys were studied by non-destructive eddy current test and ultrasonic test. Elastic modulus was characterized by destructive compression and non-destructive ultrasonic tests. Effect of alloying elements on the elastic modulus was determined. Microstructure and electrical conductivity properties were studied by eddy current tests. Effect of alloying elements on the conductivity was determined. Electrochemical corrosion behaviour of the superalloys was studied in NaCl solution. Effect of alloying elements on the corrosion behaviour was studied.

DOI:

https://doi.org/10.59499/EP246280887

Authors:

Cihan Temiz (1), Ilven Mutlu (1)

1- Istanbul University-Cerrahpasa, Metallurgical and Materials Engineering Department, Istanbul, Turkey

Abstract:

In this study, novel Ti-Mo-Sn alloys for biomedical applications was produced and investigated. Precipitation hardenable beta-titanium and metastable-beta titanium alloys, having lower elastic modulus, were produced by the powder metallurgy method. Properties of the Ti alloys were studied by non-destructive eddy current test and ultrasonic test. The effect of the alloying elements on the elastic modulus and corrosion behaviours of the specimens were studied. Microstructure and electrical conductivity properties of the sintered alloys were studied by eddy current tests. The effect of alloying elements on the electrical conductivity was determined. The electrochemical corrosion behaviour of the specimens was studied in a simulated body fluid solution.

DOI:

https://doi.org/10.59499/EP246280888

Authors:

Cihan Temiz (1), Gulcagri Sahin (1), Ilven Mutlu (1)

1-Istanbul University-Cerrahpasa, Metallurgical and Materials Engineering Department, Istanbul, Turkey

Abstract:

In this study, novel high entropy alloys have been produced by using mechanical alloying-powder metallurgy method. The high entropy alloys were produced for military applications. Initially, metal powders were prepared by mechanical alloying in a ball mill by using 6 mm zirconia balls for 15-20 hours at 400 rpm. Then, the high entropy alloy powder mixtures were compacted at about 400 MPa pressure in a hydraulic press, and then the green specimens were sintered in a vacuum environment at a temperature of 1250 °C for 1 hour in a horizontal tube furnace. Properties of the high entropy alloys were studied by non-destructive eddy current test and ultrasonic test. Elastic modulus of the sintered high entropy alloys was characterized by destructive compression tests and non-destructive ultrasonic tests comparatively.

DOI:

https://doi.org/10.59499/EP246281002