Euro PM2025 Proceedings

Authors:

Eshwara Nidadavolu (Helmholtz-Zentrum Hereon, Germany) Martin Mikulics (ERC-2, Forschungszentrum Jülich, Germany) Martin Wolff (Helmholtz-Zentrum Hereon, Germany) Thomas Ebel (Helmholtz-Zentrum Hereon, Germany) Regine Willumeit-Römer (Helmholtz-Zentrum Hereon, Germany) Berit Zeller-Plumhoff (Helmholtz-Zentrum Hereon, Germany) Joachim Mayer (ERC-2, Forschungszentrum Jülich, Germany) Hilde Helen Hardtdegen (ERC-2, Forschungszentrum Jülich, Germany)

Abstract:

Carbon (C) residuals at specific microstructural features are detected in a correlative way in the metal injection molded (MIM) Mg-0.6Ca material. Micro Raman mappings revealed Raman modes at nearly 1370 cm-1 and 1560 cm-1 that can be ascribed to elemental C, and C-C stretching at 1865 cm-1. The MIM Mg feedstock contained PPcoPE based backbone polymer that dissociates during thermal debinding (380 °C - 550 °C) prior to argon atmosphere sintering (644 °C). The decomposition of MgC2 and Mg2C3 carbides at 450 °C and 600 °C respectively, releases free C that can be trapped in the Mg matrix. The presence of calcium (Ca) leads to the formation of CaC2 phases during sintering that retains in the microstructure. Energy dispersive x-ray (EDX) analysis revealed the SiO2 impurities adjacent to the C, Ca and oxide detections. These findings can provide insights about the cell adhesion characteristics of PM Mg materials.

DOI:

https://doi.org/10.59499/EP256763349

Authors:

Zhenghua Yan (Simtec Soft Sweden AB, Sweden) Yan Liu (Simtec Soft Sweden AB, Sweden)

Abstract:

Metal Binder Jetting is a versatile 3D printing technology requiring post-processing to enhance green parts' mechanical properties, with debinding being a critical yet complex stage. This study employs Computational Fluid Dynamics (CFD) simulations to address debinding challenges, focusing on chemical reactions, gas flow, and heat transfer within porous samples.A robust model simulates debinding using polyvinyl alcohol as the organic binder. The reaction produces CO2, H2O, and C2H6O, accounting for transient temperature variations, moisture content, and heat transfer through conduction, convection, and radiation. Results demonstrate how debinding progresses from the outer layer to the core, influencing bulk density and binder removal. Detailed distributions of gas species, velocity, and pressure provide valuable insights into optimizing debinding cycles, preventing defects, and understanding atmospheric conditions.This comprehensive CFD approach demonstrates its capability to handle coupled multi-physics processes, paving the way for enhanced efficiency and product quality in MBJ post-processing for complex porous structures.

DOI:

https://doi.org/10.59499/EP256717663

Authors:

Sebastian Riecker (Fraunhofer IFAM, Dresden Branch, Germany) Jonas Bonk (Fraunhofer IFAM, Dresden Branch, Germany) Caroline Wierling (Fraunhofer IFAM, Dresden Branch, Germany) Thomas Studnitzky (Fraunhofer IFAM, Dresden Branch, Germany) Robert Teuber (Fraunhofer IFAM, Dresden Branch, Germany) Thomas Weißgärber (Fraunhofer IFAM, Dresden Branch, Germany)

Abstract:

There is an increasing interest in the additive manufacturing (AM) production of light metal alloys such as titanium or aluminum alloys. Due to their good mechanical performance combined with low density, these alloys are in high demand in various industries, such as in the mobility sector. Compared to powder bed AM processes, slurry-based processes have the advantage that no dry, potentially flammable powder has to be handled. Furthermore, even irregular powder with poor flowability can be processed into homogeneously packed green parts. However, challenges arise in connection with reactive powders that are oxygen-affine: Potential reactions between the powder and the suspension medium, as well as the complete removal of the organic components during thermal debinding, pose challenges. This paper evaluates the production of Ti-6Al-4V and Al6061 sinter parts using the gel casting process and presents results regarding the material properties achieved and the current state of development.

DOI:

https://doi.org/10.59499/EP256767411

Authors:

Elsa Sequeiros (FEUP, Portugal) Ana Figueiredo (FEUP, Portugal) Regina Coelho (FEUP, Portugal) Rui Ribeiro (FEUP, Portugal) Jose Costa (FEUP, Portugal)

Abstract:

This study aimed to characterize a 316L stainless steel powder and a component produced from the same powder batch using the Laser Powder Bed Fusion (LPBF) process. SEM and EDS analyses, apparent density, tapped density, and pycnometric tests were conducted, alongside DSC and XRD analyses. The powders exhibited predominantly spherical morphology, with some variation in particle size and surface oxidation due to recycling and improper storage. Particle size distribution analysis using a Mastersizer 3000 revealed a fine powder fraction, with a median particle size (Dv50) of approximately 2?µm, significantly below the typical LPBF range. The crystalline structure of the powder was predominantly austenitic, with minor peaks that could correspond to ferrite or martensite. The component exhibited hardness values between 230 and 260 HV0.1, with a homogeneous distribution along both build and transverse directions. These results highlight the critical importance of powder condition monitoring for maintaining LPBF component quality.

DOI:

https://doi.org/10.59499/EP256768115

Authors:

Gian Pietro De Gaudenzi (OMCD Tek Hub SpA, Italy) Mattia Garabelli (OMCD Tek Hub SpA, Italy) Fransisca Pirone (OMCD Tek Hub SpA, Italy) Sandra Tedeschi (OMCD Tek Hub SpA, Italy)

Abstract:

In the pursuit of developing alternative hardmetal systems to replace WC-Co grades for wear applications, ?-carbides and Functionally Graded HardMetals have garnered significant attention. This study focuses on characterizing a specific type of Functionally Graded HardMetals, more accurately defined as Functionally Layered HardMetals. The investigation examines the effects of coupling layers composed of different carbides and binder compositions. Two ?-carbides, niobium carbide and titanium carbide, were studied both in combination with each other and with tungsten carbide. Microstructural analyses of stacked samples revealed the formation of mixed carbide layers at the interfaces and the mutual migration of small amounts of refractory carbides. The study evaluates the impact of these compositional gradients on mechanical properties and the interaction of the coupled systems with oxidizing environments at room and elevated temperatures. These findings provide valuable insights for the development of layered hardmetal systems composed of various carbides, tailored to achieve functional objectives.

DOI:

https://doi.org/10.59499/EP256768126

Authors:

Ilidio Costa (Faculty of Engineering of the University of Porto, Portugal) Diogo Mota (Faculty of Engineering of the University of Porto, Portugal) Mariana Maia (Hypermetal, Lda., Portugal) Afonso Nogueira (Hypermetal, Lda., Portugal) Jose M. Costa (Faculty of Engineering of the University of Porto, Portugal) Elsa W. Sequeiros (Faculty of Engineering of the University of Porto, Portugal)

Abstract:

This study investigates the comprehensive characterization of Inconel 718 powder and specimens produced by Laser Powder Bed Fusion (L-PBF). The powder exhibited spherical morphology with a D50 of 23 µm, demonstrating good flowability with a Hausner ratio of 1.10 ±0.01 and Hall flow of 21.8 ±0.5 s|50g. As-built specimens showed dendritic microstructure with Laves phase, while heat-treated samples developed wrought microstructure with d phase precipitates. Heat treatment significantly enhanced mechanical properties, increasing yield strength from 566 MPa to 1135 MPa and ultimate strength from 858 MPa to 1286 MPa, though elongation decreased from 36.8% to 19.4%. Microhardness improved from 285 HV0.2 to 492 HV0.2 in the building direction, with anisotropy increasing from 3.6% to 5.4% post-treatment. The builds showed minimal defects and high density (>8.20 g|cm³), demonstrating the effectiveness of the L-PBF process for producing high-quality Inconel 718 components.

DOI:

https://doi.org/10.59499/EP256768283

Authors:

Jose Costa (FEUP, Portugal) Bernardo Tavares (FEUP, Portugal) Gonçalo Cruz (FEUP, Portugal) Ines Silva (FEUP, Portugal) Jose Silva (FEUP, Portugal) Pilar Rodríguez (AIMEN, Spain) Elsa Sequeiros (FEUP, Portugal)

Abstract:

The performance of Laser Powder Bed Fusion (LPBF) is highly dependent on the quality of the metallic powder feedstock. This study characterizes a gas-atomized Ti6Al4V (Grade 5) powder, analyzing morphology, particle size distribution, flowability, true density, chemical composition, phase constitution, and thermal stability. Optical and SEM imaging revealed predominantly spherical particles with some irregular shapes and satellites. Particle size analysis showed that only 46.49% of the volume fell within the specified 5–22?µm range, contributing to poor flowability (Hausner Ratio 1.86; Carr Index 46%). True density (4.35 g|cm³) closely matched the theoretical value, indicating low internal porosity. SEM|EDS confirmed the alloy composition but detected elevated oxygen levels. X-ray diffraction revealed an a-phase structure, while thermogravimetric analysis showed thermal stability up to 400?°C, followed by gradual oxidation. The results emphasize the critical influence of powder characteristics on LPBF processability and highlight the importance of stringent powder quality control to ensure reliable outcomes.

DOI:

https://doi.org/10.59499/EP256768096

Authors:

Miroslav Karlík (CTU Prague, Czech Republic) Hana Thürlova (University of Chemistry and Technology, Czech Republic) Filip Průša (University of Chemistry and Technology, Czech Republic) Jaroslav Cech (CTU Prague, Czech Republic) Petr Hausild (CTU Prague, Czech Republic)

Abstract:

CoCrFeNiMn alloy in equiatomic composition was prepared from pure metals by powder metallurgy, and the reinforcing carbides were formed in situ after adding 1 wt.% of two precursors – machined graphite (C) and plasma-gasified carbon (PG). The powder was either mixed with the precursors, or 30 min. of mechanical alloying (MA) in a planetary ball mill was carried out. The microstructure, phase composition, and mechanical properties of spark plasma sintered (SPS) compacts were studied. During sintering, the matrix remained as an FCC phase while Cr23C6 carbides, which formed throughout MA, transformed to Cr7C3. The best mechanical properties were achieved for the PG-reinforced alloy after 30 min of MA. This material reached a compressive yield strength (CYS) of 1237 ± 50 MPa and ultimate compressive strength (UCS) of 1998 ± 46 MPa, together with ductility of 25%. The MA+SPS reference alloy compacts without carbide reinforcement had CYS of 988 ± 14 MPa; the UCS was not measured because of the very high plasticity of the alloy (no fracture occurred).

DOI:

https://doi.org/10.59499/EP256764300

Authors:

Mark Taylor (MTC, United Kingdom) Ryan Pitchford (MTC, United Kingdom) Kieran Bullivant (MTC, United Kingdom)

Abstract:

The use of cold spray additive manufacturing (CSAM) for large format component manufacture relies on powder suitability and the heat treatment post-processing to achieve the required properties.This study assessed the impact on performance of incorporating recycled non-deposited powder into virgin powder. A benchmark study was conducted, where the mechanical properties of samples produced by CASM using virgin and recycled feedstocks were compared.Recycled powder was tested for suitability for CSAM. Virgin powder was mixed with various proportions of recycled powder and used to manufacture test samples that were subsequently heat treated and mechanical tested, with performance compared against the 100% virgin material benchmark.Initial results showed that morphology of the recycled powder has a large impact on the volume that can be introduced.

DOI:

https://doi.org/10.59499/EP256767945

Authors:

Nathan Liebgott (IRT-M2P, France) Baraa Qaddah (IRT M2P, France) Meher Zaied (IRT M2P, France) Raphael Durand (IRT M2P, France) Benjamin Luiset (Metalor, France) Victor Cribier (Metalor, France)

Abstract:

The demand for high-performance powders from precious metals is growing in the electrical connector market, where superior conductivity and reliability are essential. This study investigates the comparative efficiency of Electrode Induction Melting Gas Atomization (EIGA) and Vacuum Induction Melting Gas Atomization (VIGA) in producing precious metal powders tailored for this application. Key powder characteristics, including particle size distribution, morphology, flowability, cohesive angle, and oxygen, nitrogen, and hydrogen content, are analyzed.Results show that VIGA powders contain smaller particles whereas powders obtained by the EIGA are rounder and more spherical. Furthermore, the VIGA powders shows better static as well as dynamic cohesiveness than EIGA powders. These powders were compared to the precious metal powders obtained by water atomization to evaluate their cohesion regarding morphology and particle size distribution. The static cohesion index of powders produced by VIGA and EIGA is four times lower than that of powders obtained through water atomization.

DOI:

https://doi.org/10.59499/EP256766697

Authors:

Tim Marter (Element22 GmbH, Germany)

Abstract:

This study explores the challenges of sinter-based additive manufacturing for reactive materials, focusing on titanium. Thermal debinding and sintering, crucial steps in shaping, are analyzed with emphasis on polymer binder removal and control of interstitial elements like C and O to meet ASTM F2885-17 standards. While prior research emphasized simpler materials like 316L and 17-4-PH, titanium introduces complexities requiring meticulous process adjustments.The research examines shaping requirements such as green part strength, flexibility (filaments), flowability (Metal Injection Moulding), and crosslinking (Stereolithography). Lithography-Based Metal Manufacturing (LMM) and Cold Metal Fusion (CMF) are highlighted as cost-effective, sustainable alternatives to Metal Injection Moulding for small to medium titanium batches, enabling efficient reuse of feedstock.A detailed comparison of LMM and CMF evaluates mechanical properties, surface finishes, and costs. This study aims to optimize shaping technologies based on mechanical performance, density, interstitial acceptance, complexity, and structural features like wall thickness and overhangs.

DOI:

https://doi.org/10.59499/EP256767043

Authors:

Mark Hash (Ervin Industries, USA) Florian Götz (Ervin Germany, Germany) Paul Abram (Ervin Germany, Germany) Alexander Stawenow (SLV Mecklenburg-Vorpommern GmbH, Germany)

Abstract:

Fine, Type 17-4PH powders made by centrifugal were employed in both Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) applications. Powders at a nominal, particle size ranges of 15-53 or 53-106 micron were used to print LPBF and DED test specimens comparing print quality and speed. Finished parts were characterized for final density, porosity, feature resolution, print consistency, and mechanical properties. Comparable specimens made using commercial, gas atomized powders were printed in parallel to provide baseline levels of performance for comparison. Resulting data and microscopy are presented and discussed with respect to powder manufacturing method describing benefits and limitations of these powders.

DOI:

https://doi.org/10.59499/EP256767926