Euro PM2024 Proceedings

Authors:

Barbara Rivolta (1), Riccardo Gerosa (1), Davide Panzeri (1), Paolo Veronesi (2)

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

2- Università degli Studi di Modena e Reggio Emilia, Dipartimento di Ingegneria “Enzo Ferrari”, Modena, Italy

Abstract:

Additive manufacturing is nowadays increasingly adopted to produce a large variety of components, especially with complex geometries. A deep investigation and optimization of the mechanical and corrosion performance of the selective laser melted Alloy 625 is extremely useful to support designers in the transition from the conventional to the additive manufacturing technology. Even though the selective laser melting technique is still associated with too high production costs and low productivity to enable a broader expansion, it permits to obtain excellent mechanical and corrosion properties compared to those of the conventionally manufactured alloy. Despite the additively produced material shows outstanding performance already in the as-built condition, aging treatments permit further strength improvement enabling possibility of reducing thicknesses, mass, resources consumption and environmental emissions. However, the balance between the mechanical and corrosion properties is critical and it requires a careful tuning of the heat treatment parameters.

DOI:

https://doi.org/10.59499/EP246281709

Authors:

Hans-Wolfgang Seeliger (1), Tillmann R. Neu (2), Paul H. Kamm (2), Francisco García-Moreno(2)

1- Gränges Powder Metallurgy GmbH, Germany

2- Institute for Applied Materials, Helmholtz Zentrum Berlin for Materials and Energy, Germany

Abstract:

For the purpose of the application for an on-tank valve, various Al alloy series were produced and tested, to which different contents of up to 0.3 wt% Sc and Zr were added. The hardening curves were plotted for different temperatures and correlated with the corresponding mechanical tests. The alloys were characterized by hardness measurements, tensile tests. By characterizing the materials, transferring them to simulation models and developing design guidelines, the foundations are laid for technology transfer to other applications of these materials. In order to produce these new materials, the Spray Forming process was used on the systems of the Gränges Powder Metallurgy company. This has the advantage that both the metal powder and the solid material for the forged part can be produced in one manufacturing step.

DOI:

https://doi.org/10.59499/EP246278515

Authors:

Federico Simone Gobber (1), Antonio Pennacchio (1), Marco Actis Grande (1), Paolo Priarone (2)

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

2- Department of Management and Production Engineering, Politecnico di Torino, Torino, Italy

Abstract:

Sustainability in production processes is a crucial topic that ensures the responsible use of resources, minimizes environmental impact, fosters long-term viability, and aligns economic success with ecological and social well-being. Regarding powder production via gas-atomization, powder quality and powder yield represent the main aspects to be maximized in order to achieve a robust process. However, gas-atomization energy consumption varies depending on gas-atomization pressure, heating time, power, and consumable reuse. This study proposes a methodology to optimize gas-atomized powder production by reducing the equivalent carbon generated per kilogram of powder. The methodology incorporates particle size distribution, morphology, and environmental impact considerations. The article reports a comprehensive case study for super-duplex steel powders produced by a lab-scale inert gas atomizer. The purpose of the study is to present a general methodology to evaluate the sustainability of gas – atomized powder.

DOI:

https://doi.org/10.59499/EP246282648

Authors:

Louis Becker (1), Felix Radtke (2), Jonathan Lentz (1), Simone Herzog (2), Christoph Broeckmann (2), Sebastian Weber (1)

1- Chair of Materials Technology (LWT), Bochum, Germany

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

Abstract:

Laser Powder Bed Fusion/Metal (PBF-LB/M) shows great promise for industrial applications, but its extended production time remains a challenge. To address this, innovative methods such as the shell-core approach have been developed. In this procedure, a component is created with a dense outer shell surrounding a core of either unexposed or minimally exposed powder, drastically reducing processing time. Full densification and specific property adjustment are achieved by subsequent hot isostatic pressing (HIP). This study demonstrates the use of shell-core specimens made from a powder blend of austenitic stainless steel and Si3N4 to produce high-nitrogen steel components that are otherwise difficult to produce due to limited nitrogen solubility in the steel melt. During HIP, Si3N4 dissolves into the austenitic matrix, enriching it with nitrogen and circumventing solubility issues. This results in a material with increased strength and potentially improved corrosion resistance due to the beneficial impact of nitrogen on steel properties.

DOI:

https://doi.org/10.59499/EP246252913

Authors:

Merlin Thamm (1), Inge Lindemann-Geipel (1), Christoph Höhnel (1,2), Thomas Hutsch (1), Shufan Wang (3), Yuanbin Deng (3,4), Christoph Broeckmann (3,4), Thomas Wentzlik (5), Tobias Trupp (5), Thomas Weißgärber (1,2)

1- Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Germany

2- TUD Dresden University of Technology, Faculty Mechanical Engineering, Institute of Materials Science, Chair Powder Metallurgy, Germany

3- Institute of Applied Powder Metallurgy and Ceramics at RWTH Aachen e.V. (IAPK), Germany

4- Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen University, Germany

5- Magnetec GmbH, Germany

Abstract:

Within the public founded project “NanoKompakt”, the powder of initial amorphous soft magnetic alloy Vitroperm (Fe73.6Si15.5B6.9Cu1.0Nb3.0) is compacted to nanocrystalline components by FAST/SPS. The aim is to manufacture industrially relevant components such as E-cores that cannot be produced from wounded ribbon. The increased mechanical stability allows for omitting a polymer case, which increases the possible application temperature. Firstly, small toroidal cores were compacted. A high permeability of 20 000 and a low coercivity of 3 A/m are achieved. Based on the thermal and electrical properties of the compacted toroidal cores, a larger pressing tool is also designed and optimized by simulation. The simulation is necessary because the temperature range for compaction is only a few Kelvin wide and the precipitation of hard magnetic phases must be prevented. In the second step, E-cores are cut from compacted slices and analyzed.

DOI:

https://doi.org/10.59499/EP246279398

Authors:

T. Mossop (1), DJ Browne (1), M. Celikin (1)

1- School of Mechanical and Materials Engineering, University College Dublin, Dublin, Ireland

Abstract:

Processing β-titanium (Ti) alloys via metal additive manufacturing (AM) has high potential to be used for biomedical applications, hence understanding their solidification behaviour under rapid cooling is critical. The solidification structures of Ti-niobium-tantalum (Ti-Nb-Ta) based alloys were investigated under various cooling rates (c. 2,000-20,000 K/s) using rapid solidification suction casting. An anti-solute trapping effect was determined for a ternary Ti-Nb-Ta alloy. In relatively slower-cooled samples, the microsegregation was in line with Scheil-Gulliver theory, however under more rapid cooling, the microsegregation increased significantly. This anomalous microsegregation had the effect of stabilizing additional α/α’- and β-phase content of the as-solidified ternary alloy – reducing the otherwise favoured martensitic α’’ content and resulting in a dual-phase structure where the dendrites are primarily β-phase and the interdendritic regions are α’’ martensite.

DOI:

https://doi.org/10.59499/EP246281565

Authors:

Martin Bram (1), Monica Keszler (1), Felix Großwendt (2), Sebastian Weber (2)

1- Forschungszentrum Jülich GmbH, Germany

2- Ruhr-Universität Bochum, Germany

Abstract:

The grinding of steel tools to the final shape generates sludge containing metallic swarf considered undesirable for direct recycling. After cleaning and separation of this steel swarf, its morphology often leaves it inappropriate for standard powder metallurgical uses. However, the possibility exists of utilizing field assisted sintering techniques to densify this swarf directly into new parts, thereby avoiding the need for remelting. This technique also allows for the generation of new metal matrix composites through its quick sintering time. The application of field assisted sintering as a recycling tool is realized through the densification of two different steels, PM T15 and D2, exploring the influence of varied parameter sets and tool setups on their sintering. For proof of concept, a cutting disc made of D2 swarf has been produced, which will be tested in the near future.

DOI:

https://doi.org/10.59499/EP246280685

Authors:

Paria Karimi (1), Esmaeil Sadeghi (1)

1- OptiFab Technologies, Ontario, Canada

Abstract:

This study investigates the influence of novel scan patterns on the microstructure and hardness of γ-TiAl base alloy manufactured using the electron beam-powder bed fusion process. Different scan patterns were explored for their effects on thermal history and heat transfer, resulting in diverse microstructures from fully lamellar to duplex structures. As-built samples with varied scan patterns underwent hardness testing, elucidating differences in hardness qualities. The formation mechanisms of desired microstructures for each scan pattern were extensively examined. The findings provide a valuable framework for tailoring materials with specific microstructures and performance attributes by adjusting scan patterns during electron beam-powder bed fusion, with significant implications for future applications.

DOI:

https://doi.org/10.59499/EP246282019

Authors:

Pelle Mellin (1), Johannes Gårdstam (2), Stefan Heino (1), James Shipley (2), Anders Magnusson (2), Fredrik Forsberg (3), Björn Forsgren (4), Per Waernqvist (4)

1- Swerim AB, Kista, Sweden

2- Quintus Technologies AB, Västerås, Sweden

3- Luleå University of Technology, Luleå, Sweden

4- Ringhals AB, Väröbacka, Sweden

Abstract:

Pores in cast, compacted or AM built material that shrink during HIP, can regrow if they are filled with argon and are subjected to high temperature. To better understand this, we present a study on a set of capsules that contain a huge 2 cm3 cavity. These cavities were filled with argon by sealing them under 1 atm of 100% argon. Using HIP (equipped with URQ) these cavities shrink to an approximate size of 0.006 cm3 resulting in a room temperature pressure of ~340 bars. Upon stepwise reheating the pressure increases, and for IN718 the cavity expands above 900 °C (pressure is here ~1400 bar), while for 316L the cavity expands above 1000 °C (pressure is here ~1450 bar). The temperature at which expansion occurs are not far from typical HIP conditions, which makes sense. The pressure inside a pore appears to be a good indicator for if expansion will occur.

DOI:

https://doi.org/10.59499/EP246280783

Authors:

M. Bemani (1,2,4), W. Sjöström (5), Roos. S (5), Parareda (1), M. Mares (1), A. Mateo (2), R. Das (4),A. Molotnikov (4), C. Botero (5), D. Casellas (1,3)

1-Eurecat, Centre Tecnològic de Catalunya, Metal Digital Manufacturing JRU, Spain

2-CIEFMA – Department of Materials Science and Engineering, EEBE, Universitat Politècnica de Catalunya, Spain

3-Luleå University of Technology, Division of Mechanics of Solid Materials, Sweden

4-Centre for Additive Manufacturing, School of Engineering, RMIT University, Australia

5-Department of Quality Technology and Mechanical Engineering, Sports Tech Research Centre, Mid Sweden University, Sweden

Abstract:

Surface roughness of the additively manufactured (AM) parts can reduce the service life, especially under dynamic loadings, due to promoting fatigue by providing initiation sites for fatigue cracks. Therefore, improving the surface condition of AM specimens can be a solution to increase the fatigue strength. The stiffness method is a rapid fatigue test method that allows to obtain reliable fatigue limit values in a cheaper and easier way than traditional methods. Consequently, this work aims to investigate the effect of surface roughness on the fatigue behavior of stainless steel AISI 316L specimens using the stiffness method. These specimens were printed with laser and electron beam powder bed fusion techniques. Different contour parameters were utilized to obtain different surface roughness values. The competitional effect of the internal defects, which become surface defects after machining, and the surface roughness of the as-built specimens, is also addressed by the stiffness method results.

DOI:

https://doi.org/10.59499/EP246276182

Authors:

Henrik Karlsson (1), Rasha Alkiasee (1), Rasmus Kristensen (1), Peter Harlin (2), William Hearn (3), Eduard Hryha (3)

1- Volvo AB, Sweden

2- Sandvik AB, Sweden

3- Chalmers University of Technology, Sweden

Abstract:

Additive manufacturing (AM) has developed and expanded into new segments the recent years. Nonetheless, the automotive industry has so far not implemented AM to any larger extent, one reason being that the availability of materials for AM has been limited. However, recently several low-alloyed carbon-containing steels suited for the automotive segments have been developed for AM. This paper addressed the heat treatment of AISI 4140 (42CrMo4) and its effect on microstructure and residual stresses. Tests have been carried out on an engine component manufactured by Powder Bed Fusion-Laser Beam process (PBF-LB) and varying subsequent heat treatments. It was found that in a regular quench and temper cycle the parts achieved a similar residual stress state as conventionally manufactured AISI 4140. Samples exposed to a direct temper cycle (tempering only after PBF-LB), showed promising results in terms of residual stresses and metallographic aspects. From the results it is concluded that the current investigation can serve as a basis to further optimization of heat treatment cycles to better utilize PBF-LB/AISI 4140 steels in the automotive sector.

DOI:

https://doi.org/10.59499/EP246278564

Authors:

Erika Tuneskog (1), Lars Nyborg (1), Karl-Johan Nogenmyr (2)

1- Chalmers University of Technology, Sweden

2- CSiemens Energy AB, Sweden

Abstract:

Metal additive manufacturing (AM) enables intricate designs, particularly beneficial for complex fluid applications in gas turbines. Despite its advantages, AM introduces higher surface roughness compared to conventional technologies. In the powder bed fusion–laser beam (PBF-LB) process, surface roughness elements can create blockages in small channels, leading to increased friction. Understanding how features like adhering powder particles, spatter, and melt tracks interact with fluid flow is essential for modeling friction in channel flows. This study statistically characterizes surface roughness variation, considering printing parameters and orientation, utilizing optical profilometers and microscopy. Test samples in stainless steel 316L include flat surfaces and channels oriented from 0° to 90° with 20° intervals. Adhering powder particles are primary inducers of channel roughness, exhibiting positive skewness and high slopes. The density of powder particles on flat surfaces is significantly lower. Therefore, other variables including melt tracks, printing direction, and power input, influence surface characteristics more.

DOI:

https://doi.org/10.59499/EP246281948