Euro PM2025 Proceedings

Authors:

Markus Schneider (GKN Powder Metallurgy GmbH, Germany) Virgil Savu (GKN Powder Metallurgy, USA) Ian Donaldson (GKN Powder Metallurgy, USA) Alessandro DeNicolo (GKN Powder Metallurgy, Italy) Omar Franceschi (GKN Powder Metallurgy, Italy) Tom Fonville (GKN Powder Metallurgy, USA)

Abstract:

The usage of heat sinks and heat exchangers to dissipate or to distribute heat is mandatory when designing devices in the field of power electronics. In the case of complex geometries, it is possible to increase the heat-transferring surface by using rips, pins and fins. These complex geometries can be realized with various PM shaping technologies, e.g. P&S, MIM or AM. However, this also changes the flow conditions, i.e. the pressure drop due to the drag effect of the pins must be kept as low as possible. This optimisation task and a proper pin design in general can be done by using numerical CFD calculations. The achievable thermal conductivity of the used PM Cu or PM Al material limits the height of the pins. This paper presents a large CFD study on a variety of pin structures which can be made by PM.

DOI:

https://doi.org/10.59499/EP256782426

Authors:

Fabrice Lion (IPC, France) Aurélien Etiemble (ECAM Lassale, France) Stéphane Garadebian (IPC, France) Xavier Boulnat (INSA Lyon, France) Claire Rigollet (ECAM Lassale, France) Laura Delcuse-Robert (IPC, France) Thomas Joffre (IPC, France) Jean-Yves Buffiere (INSA Lyon, France)

Abstract:

The performance of steel parts produced by additive manufacturing (AM) is still inadequate for some industrial applications, particularly in the fields of production and tooling, which require increased durability specifications. They demand high hardness (HRC>60), while maintaining other mechanical performances such as fatigue, toughness and thermal conductivity. The key challenges of printing hard steels occur during the fusion process, due to high carbon contents cracks are likely to occur during the manufacturing process. In this work, laser powder bed fusion (LPBF) and fused pellet fabrication (FPF) are used to print M2 steel parts.Both technologies generate unique microstructures. Here, the microstructure is thoroughly investigated (Optical, XRD, SEM, Leco…) to understand the influence of these technologies on microstructural features such as grains, carbides, porosity and consequences on hardness.

DOI:

https://doi.org/10.59499/EP256779113

Authors:

Mathieu Vandecasteele (Ghent University, Belgium) Samuel Searle (KULeuven, Belgium) Domenico Iuso (University of Antwerp, Belgium) Mohsen Nourazar (Ghent University, Belgium) Ayyoub Ahar (Flanders Make, Belgium) Milad Hamidi Nasab (KULeuven, Belgium) Bey Vrancken (KULeuven, Belgium) Brian Booth (Ghent University, Belgium)

Abstract:

Porosity and deformation defects remain critical challenges to consistent, high-quality production of metallic parts using powder bed fusion (PBF). Existing state-of-the-art monitoring systems typically lack the speed required for real-time adjustments and often target only single defect types. To address these limitations, we present a high-speed, multi-modal in-situ monitoring system operating at up to 20 kHz. The system integrates dynamic region-of-interest cameras in both the visible and short-wave infrared ranges with a GPU-optimized, machine learning-based image processing pipeline. By incorporating local print context, the system accurately identifies porosity and deformation defects, enabling rapid corrective actions. Validation on 316L stainless steel samples, deliberately engineered to exhibit these defects, demonstrates Pearson correlation coefficients of 0.9493 for porosity prediction and normalized mean absolute errors of 17% for deformation detection. The results show promise for the system to be effectively used for high-speed, intra-layer closed-loop control, significantly improving the PBF process.

DOI:

https://doi.org/10.59499/EP256766760

Authors:

Delvin Wuu (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Zheng Zhang (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Yinn Leng (Linus) Ang (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Verner Soh (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore) Te Ba (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Zhiqian Zhang (Institute of High Performance Computing (IHPC), A*STAR, Singapore) Pei Wang (Institute of Materials Research and Engineering (IMRE), A*STAR, Singapore)

Abstract:

Advancements in space repair technology are essential for extending mission longevity. This research investigates lightweight robotic cold spray additive manufacturing (CSAM) for repairing freeform components of damaged orbital equipment, offering a versatile, resource-efficient solution for microgravity environments. Focusing on copper—a critical material for thermal and electrical conductivity in spacecraft—the study examines key process parameters such as nozzle standoff distance, gas pressure, and temperature. By systematically analysing their effects on pososity, this work aims to identify optimal conditions for reliable on-orbit repairs. The integration of CSAM not only enhances mission safety and reduces costs but also supports the principles of a circular economy in space exploration by minimizing waste and maximizing resource utilization. This research advances the capabilities of CSAM for sustainable space applications, contributing to the long-term success of space missions.

DOI:

https://doi.org/10.59499/EP256765855

Authors:

Gabriel Caballero (Universidad Carlos III de Madrid, Spain) Lucia Garcia de la Cruz (Universidad Carlos III de Madrid, Spain) Paula Alvaredo (Universidad Carlos III de Madrid, Spain) Mónica Campos (Universidad Carlos III de Madrid, Spain)

Abstract:

Additive manufacturing (AM) encompasses various techniques, one of which is material extrusion (MEX). When the material used is in granular form, it is referred to as g-MEX, which stands out for its versatility and cost-effectiveness in fabricating complex metallic components. A comprehensive analysis was conducted across all stages—pre-printing, printing, and post-processing. Preliminary characterizations, such as metal powder granulometry, rheology, thermogravimetry, optimization of binder system components, as well as printing parameters and final stages like debinding and sintering were examined. The goal was to achieve fully dense metallic parts, monitoring quality parameters such as final density, dimensional shrinkage, mechanical properties, among others. This research aims to clarify how preliminary characterization is key to a successful printing stage, highlighting its predictive power and potential application when using other metallic materials depending on the required application.

DOI:

https://doi.org/10.59499/EP256764736

Authors:

Leonhard Gertlowski (Institute of Applied Powder Metallurgy and Ceramics (IAPK), Germany) Oliver Schenk (Institute for Materials Applications in Mechanical Engineering (IWM), Germany) Stefan Müller (Chair Materials Technology, Germany) Santiago Benito (Chair Materials Technology, Germany) Sebastian Weber (Chair Materials Technology, Germany) Christoph Broeckmann (Institute for Materials Applications in Mechanical Engineering (IWM), Germany)

Abstract:

High-speed steels are commonly used for cutting tools that require a high impact toughness and fatigue resistance. Both properties are significantly enhanced by employing the powder metallurgical production (PM) route using hot isostatic pressing (HIP) as consolidation technique. The fatigue strength is conventionally assessed by Wöhler tests that imply a systematic variation of the stress amplitude in the vicinity of the presumed load limit, employing multiple specimens. However, the available test volume is limited by the size of the HIP capsule. Hence, an accelerated fatigue testing method is presented that can significantly reduce the use of material and time by determining the fatigue limit with a single specimen. This method involves the measurement of the temperature rise in a sample during a load increase test whose characteristic course indicates damage initiation. Its validity is demonstrated by the determination of the fatigue limit for HS6-5-3 employing both accelerated and conventional testing.

DOI:

https://doi.org/10.59499/EP256767866

Authors:

Tobias Edtmaier (TU Wien, Austria) Sivagnana Venkatesh Kumaran (ArcerlorMittal, Spain) José Manuel Torralba (IMDEA Materials Institute, Spain) Alberto Meza (IMDEA Materials Institute, Spain)

Abstract:

High-entropy alloys (HEAs) have attracted significant attention in recent years due to their unique microstructures and exceptional mechanical properties. Among these, biphasic HEAs (FCC+BCC phases) offer a promising balance of strength and ductility, especially when their phases are precisely tailored. In this study, Laser Powder Bed Fusion (LPBF) is employed to fabricate two Al-containing biphasic HEAs from commodity powders, followed by post-processing heat treatments involving solution treatment and aging. These treatments are designed to finely disperse the BCC phase as precipitates within the FCC matrix, thereby enhancing mechanical strength and hardness. Microstructural characterization was performed by SEM, EDS, EBSD, and TEM explorations, while the mechanical performance was assessed by hardness measurements, profilometry-based indentation plastometry (PIP), and micro-compression tests at room and high temperatures.

DOI:

https://doi.org/10.59499/EP256767921

Authors:

Benjamin Delignon (Gränges Powder Metallurgy, France) Hans-Wolfgang Seeliger (Gränges Powder Metallurgy, Germany) Thomas Dickmann (Gränges Powder Metallurgy, Germany) Robert Plesa (Gränges Powder Metallurgy, France)

Abstract:

AlSi alloys are used for lightweight applications requiring high stiffness and low CTE, sometimes in combination with high mechanical properties or wear resistance. Even though these applications are becoming more and more common in the semiconductor and automotive industries, AlSi alloys are crack prone materials, which limits their wider democratisation. In this work we developed three different processing solutions for the production of several AlSi alloys:The production of large size components of AlSi40 by HIP process.The development of LPBF printing parameters for AlSi35 and AlSi25Cu4Mg, targeting mid-size components.The process optimisation to achieve high mechanical properties by combination of sprayforming, extrusion and heat treatment of AlSi25Fe4Ni3CuMgMnCrTi.Various microstructural analyses, mechanical tests, and powder controls were performed in order to define the process parameters enabling industrial and cost-efficient production of these alloys.

DOI:

https://doi.org/10.59499/EP256764899

Authors:

Liviu Brabie (Swerim AB, Sweden) Sofia Kazi (Chalmers University of Technology, Sweden) Annika Strondl (Swerim AB, Sweden) Tatiana Fedina (Swerim AB, Sweden) Pelle Mellin (Swerim AB, Sweden) Eduard Hryha (Chalmers University of Technology, Sweden) Fredrik Mikaelsson (Alfa Laval Technologies AB, Sweden)

Abstract:

This study explores the sustainable production of 316L stainless steel powders using atomization with argon (Ar) and nitrogen (N2) gases. The powders were produced at SWERIM’s state-of-the-art VIGA unit, utilizing feedstock from additive manufacturing (AM) residual materials, including defective parts and support structures. By repurposing rest materials, the research aims to minimize the use of virgin raw materials and reduce the carbon footprint associated with powder production. The produced powders were characterized to evaluate their surface properties, including total oxygen content and surface chemistry, powder rheological properties and powder surface chemistry using XPS and HR SEM+EDX. The study examines the influence of atomization gases on powder quality and assesses their potential for reuse in AM processes. The results demonstrate the feasibility of producing high-quality powders from recycled materials, promoting circular economy principles and supporting the development of more sustainable manufacturing practices in the AM industry.

DOI:

https://doi.org/10.59499/EP256766881

Authors:

Rasmus Björk (Quintus Technologies AB, Sweden) James Shipley (Quintus Technologies AB, Sweden) Anders Magnusson (Quintus Technologies AB, Sweden)

Abstract:

Hot isostatic pressing (HIP) has been used to consolidate powder for various industries for many years. It is a well-established production method globally, but newly discussed investments involve larger units than currently in operation. Certain factors are key in developing large HIP systems: enhanced safety, reduced weight and footprint, and safe material handling. This paper will present design considerations of large HIP systems for the powder metallurgy industry. It will also discuss how near-net-shape manufacturing of large components via HIP aids key local industries in sustaining supply chains.

DOI:

https://doi.org/10.59499/EP256766682

Authors:

Giorgio Valsecchi (TAV VACUUM FURNACES, Italy)

Abstract:

High-temperature solution nitriding (HTSN) is a thermochemical treatment that exposes stainless steel to nitrogen gas at specific pressures (below or above atmospheric) and high temperatures (1000°C–1200°C). This process introduces nitrogen into the surface of austenitic, ferritic, and martensitic stainless steels, enhancing their hardness, wear resistance, and corrosion resistance. The HTSN process is followed by a rapid cooling to room temperature, necessary to retain the nitrogen in solid solution without forming chromium nitrides; for that reason, vacuum furnaces dedicated to HTSN need to be specifically designed for such process. A variation of HTSN is also used for Ni-free austenitic stainless steel, such as X15 CrMnMoN17-11-3, which requires a precise amount of nitrogen in solid solution to stabilize the austenitic microstructure at room temperature.This article examines HTSN’s applications for powder metallurgy stainless steel components, detailing process parameters and specialized vacuum furnace designs.

DOI:

https://doi.org/10.59499/EP256767090

Authors:

Marco Zago (University of Trento, Italy) Giacomo Segata (University of Trento, Italy) Sabrina Veronesi (University of Trento, Italy) Matteo Perina (Mimest, Italy) Ilaria Cristofolini (University of Trento, Italy)

Abstract:

Metal Binder Jetting (MBJ) is an additive manufacturing (AM) technology increasingly gaining interest due to its capability of producing complex products in medium-large batches, cost-effectively compared to other AM technologies. Nevertheless, dimensional accuracy is still challenging, considering the significantly anisotropic shrinkage on sintering. The influence of printing parameters on the anisotropic shrinkage of two different geometries is studied in this work. Using fractional factorial Design of Experiments (DOE), four factors at three levels were considered (printhead speed, binder saturation, rake speed, and shell thickness). 30 cubes with squared through-hole, and 30 cylinders with circular through-hole were produced for each experiment using 316L; the shrinkage along different printing directions was derived from the dimensions measured at green and sintered state by Coordinate Measuring Machine. The optimal combination of printing parameters for the different geometries was identified using ANOVA. The effect of printing parameters on the two geometries was highlighted and discussed.

DOI:

https://doi.org/10.59499/EP256767057