Authors:
Peter Nahringbauer (1), Alexander Holzer (1), Elisabeth Rauchenwald (2), Christoph Vogler (2), Christian Gierl-Mayer (1)
1- TU Wien, Austria
2- Huawei Technologies Austria GmbH
Abstract:
Soft magnetic materials are crucial for efficient energy conversion and transfer in various electrical devices and power systems. For ideal soft magnetic properties such as a high saturation magnetisation, high permeability and minimal losses, precise control over the material properties is necessary. In this work, the ultrasonic atomization of Fe-based alloys is described as a new method to obtain powders with tailored compositions, particle size and morphology. Various production parameters were used to gain insight into their impact on the powder properties, focusing particularly on particle size. Additionally, this research also concentrates on phase formation and the chemical composition of the powders to study the underlying mechanisms during the atomization process. It was found that the ultrasonic atomization can provide highly spherical powders with a narrow particle size distribution while maintaining raw material composition. Therefore, it is suitable for small-batch production of novel soft magnetic powders for research purposes.
DOI:
https://doi.org/10.59499/EP246282701
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Authors:
Shahrzad Sajjadivand (1), Mark Hartnett (2), Mert Celikin (1)
1- School of Mechanical and Materials Engineering, UCD, Belfield, Dublin, Ireland
2- Irish Manufacturing Research, National Science Park, Mullingar, Westmeath, Ireland
Abstract:
This study aims to optimise post-processing heat treatment methodology of 18Ni (300) maraging steel manufactured via Laser-based Powder Bed Fusion (PBF-LB). This is achieved by understanding the effect of post-processing heat treatment on the microstructural evolution and mechanical behaviour of PBF-LB 18Ni (300) maraging steel in comparison to conventionally manufactured 18Ni (300) maraging steel. In-depth materials characterisation was carried out using X-ray diffraction (XRD), scanning electron microscopy (SEM). The analysis reveals microstructural variation in PBF-LB 18Ni (300) maraging steel in as-built condition with noticeable hardness changes. However, solutionising at 850 °C, 950 °C, and 1050 °C lead to a more homogenized microstructure and reduced variation in hardness. A comparison of PBF-LB and conventionally manufactured samples reveals similar hardness levels upon post-processing heat treatment.
DOI:
https://doi.org/10.59499/EP246281376
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Authors:
Damian Karpowicz (1), Katarzyna Jach (1), Marcin Rosinski (1)
1- GeniCore Sp. z o.o., Poland
Abstract:
Field assisted sintering called also spark plasma sintering allows to produce exceptional quality materials which found a niche in applications where the quality is a most important factor or making the product with other methods is impossible. Here, we present a new type of HYBRID FAST system which combines FAST type DC power supply with induction heating provided by AC power supply where novelty is oriented on assuring the high heating rates up to 500℃/min even for big volume samples. This solution ensures that the main advantage of FAST technology, which is the reduction of grain growth, will affect the quality of the big volume samples, which is a challenge for DC alone systems.
DOI:
https://doi.org/10.59499/EP246202215
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Authors:
Damian Karpowicz (1), Katarzyna Jach (1), Marcin Rosinski (1)
1- GeniCore Sp. z o.o., Poland
Abstract:
Field assisted sintering called also spark plasma sintering allows to produce exceptional quality materials which found a niche in applications where the quality is a most important factor or making the product with other methods is impossible. Here, we present a new type of HYBRID FAST system which combines FAST type DC power supply with induction heating provided by AC power supply where novelty is oriented on assuring the high heating rates up to 500℃/min even for big volume samples. This solution ensures that the main advantage of FAST technology, which is the reduction of grain growth, will affect the quality of the big volume samples, which is a challenge for DC alone systems.
DOI:
https://doi.org/10.59499/EP246268565
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Authors:
John Power (1), Owen Humphreys (1), Mark Hartnet (2), and Denis Dowling (1)
1-Form Centre, School of Mechanical and Materials Engineering, University College Dublin, Belfield, Ireland
2-Irish Manufacturing Research, Dublin, Ireland
Abstract:
The evolution of laser powder bed fusion (L-PBF) has provided increased design flexibility in the fabrication of a range of parts, including aerospace components and medical devices. The presence of overhangs in metal alloy print structures, however, can give rise to enhanced levels of print defects such as porosity. This is associated with overheating of the alloy meltpool in the region around the overhang structures. This study demonstrated the effectiveness of in-situ meltpool process monitoring as a route to assist laser parameter optimisation for printed Ti-6Al-4V alloy parts. Informed by the observations from the process monitoring of the laser meltpool, the laser parameters are controlled to prevent overheating in the area around the overhang, yielding a more homogeneous printed part's microstructure. In addition to microstructure optimisation, the enhanced control of the L-PBF process yielded an 88% reduction in overhang roughness (Ra) and a 75% reduction in porosity.
DOI:
https://doi.org/10.59499/EP246277046
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Authors:
B. Guimarães (1,2), F. Marques (1), C. M. Fernandes (1), D. Figueiredo (1), F. S. Silva (2), G. Miranda (3)
1- Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Bremen, Germany
2- Center for MicroElectroMechanical Systems (CMEMS-UMinho), University of Minho, Campus de Azurém, 4800-058 Guimarães, Portugal
3- CICECO, Aveiro Institute of Materials, Department of Materials and Ceramic Engineering, University of Aveiro, 3810-193 Aveiro, Portugal
Abstract:
In the scope of Industry 5.0 applied to the cutting tools industry, the advent of smart cutting tools consisting in the integration of sensors in cutting tools to monitor, and thus help control and adjust in real time different aspects of a machining process, arises as a unique opportunity to achieve unprecedent levels of operational efficiency and productivity. Therefore, this work focuses on the incorporation of temperature sensors in WC-Co cutting tools for measuring cutting temperature, through the fabrication of 3D printed K-type embedded thermocouples by multi-material laser powder bed fusion. The thermocouples powder composition was prepared through high-energy ball milling and properly characterized to guarantee the characteristics for laser powder bed fusion. Validation in an industrial environment during turning of different alloys revealed that the developed 3D printed embedded thermocouples can measure precisely and accurately cutting temperature in real time, as well as withstand the demanding turning process.
DOI:
https://doi.org/10.59499/EP246281702
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Authors:
Anna Larsson (1), Johannes Gårdstam (2), James Shipley (2)
1- Höganäs AB, Sweden
2- Quintus Technology AB, Sweden
Abstract:
Additive manufacturing is gaining interest for manufacturing of critical components within sectors like aerospace, industrial gas turbine and other applications within the energy sector where the demand for high temperature resistant alloys is needed. Ni based super alloys are used for their high strength at elevated temperatures, the corrosion resistance and creep resistance. The powder bed fusion-laser beam (PBF-LB) technique makes it possible for advanced design with tailored features like internal cooling channels not possible to manufacture with traditional technique. The PBF-LB process needs to be optimized for the specific alloy and to the component design but still print defects like gas pores, voids and cracks could occur. To increase the robustness and confidence of the produced parts, a hot isostatic pressing (HIP) step could be added to eliminate or minimize these defects. In this study the properties of LB-PBF manufactured nickel base super alloys are examined. The influence of the print process, as well as post processes like heat treatment, HIP and the combination of the last two on the mechanical properties and on the microstructure was examined.
DOI:
https://doi.org/10.59499/EP246281597
