Euro PM2025 Proceedings

Authors:

Anatolii Laptiev (Frantsevich Institute for Problems of Materials Science National Academy of Science of Ukraine, Ukraine) Dmytro Verbylo (Frantsevich Institute for Problems of Materials Science National Academy of Science of Ukraine, Ukraine) Victor Novichenko (Technical Center NAS of Ukraine, Ukraine) Oleksandr Myslyvchenko (Frantsevich Institute for Problems of Materials Science National Academy of Science of Ukraine, Ukraine) Anatolii Laptiev (Frantsevich Institute for Problems of Materials Science National Academy of Science of Ukraine, Ukraine)

Abstract:

Titanium is one of the most important materials for aviation and space industry. High-strength parts can be obtained by powder metallurgy methods from fine-grained powder. However, pressureless sintering of titanium powders requires high temperature (1200-1300 °C) and long holding (2-4 hours). To obtain high-density samples at lower temperatures, of interest is the method of a vacuum compaction of a porous briquette under the action of an impact load, at which the pressure reaches values of 1100-1300 MPa, and the compaction process lasts 0.003-0.005 s. In this study, titanium samples were obtained using two technologies: pressureless sintering of porous briquettes at a temperature of 1300 °C with an isothermal holding time of 80 min, and impact compaction at temperatures of 750, 850 and 950 °C with an isothermal holding time of 30 min before impact. The density, mechanical properties and microstructure of samples after their compaction by different methods were studied.

DOI:

https://doi.org/10.59499/EP256717003

Authors:

Masaru Kawakami (Fujidie Co., ltd, Japan) Sota Terasaka (Tohoku University, Japan)

Abstract:

Phase diagrams of C-Co-W-M (M: V, Ti, Ta, etc.) quaternary system were drawn using software for thermodynamic calculation in multicomponent systems. Pseudo-ternary phase diagrams of triangular prism were constructed by superimposing the Co-WC-MC sections of the tetrahedral quaternary phase diagram for each temperature. The vertical sections with a constant content of Co for the triangular prismatic diagram showed pseudo-binary phase diagrams of (MC-Co)-(WC-Co). The pseud-binary phase diagrams revealed constituting phases during sintering and solubility limits of metal carbides in solid and liquid Co phases. Formation of segregated phases of metal carbides for specified amount of the metal carbides was considered using the pseud-binary phase diagrams.

DOI:

https://doi.org/10.59499/EP256767708

Authors:

Herbert Danninger (TU Wien, Austria) Milad Hojati (TU Wien, Austria) Stefan Geroldinger (TU Wien, Austria) Raquel de Oro Calderon (TU Wien, Austria) Christian Gierl-Mayer (TU Wien, Austria) Robert Hellein (Miba Sinter Austria GmbH, Austria)

Abstract:

In ferrous powder metallurgy, replacing the common alloy elements Ni and Cu by less critical ones such as Cr, Mn and Si is both technically and economically attractive. Combining the masteralloy route with prealloying offers compositional flexibility and rapid homogenization during sintering as well as sinter hardening capability. However, the oxygen affinity of the alloy elements has to be considered. In the present study it is shown that combining starting powders prealloyed with Cr-Mo or Mo with Mn-Si masteralloys results in internal gettering, i.e. oxygen transfer from the base powder to the masteralloy, which shifts deoxidation to higher temperatures. However, the masteralloy thus promotes deoxidation of the base powder particles and consequently enhances interparticle strength even when sintering at moderate temperatures, with just slight loss of alloying effect. This shows that not only the total oxygen content but also the oxygen distribution is of relevance for the mechanical properties.

DOI:

https://doi.org/10.59499/EP256679196

Authors:

Patrícia Freitas Rodrigues (University of Coimbra, Portugal) Patrícia Freitas Rodrigues (University of Coimbra, Portugal) Gonçalo Abrantes (University of Coimbra, Portugal) Bernardo Alves (University of Coimbra, Portugal) Ricardo Coelho (University of Coimbra, Portugal) Daniel Gatões (University of Coimbra, Portugal) Luís Cacho (University of Coimbra, Portugal) Andersan Paula (IME- Instituto Militar de Engenharia, Brazil) Rodolfo Batalha (ISQ - instituto de soldadura e qualidade, Portugal) João Paulo Dias (IPN - Instituto Pedro Nunes, Portugal) Sofia Ramos (University of Coimbra, Portugal) Maria Teresa Vieira (University of Coimbra, Portugal)

Abstract:

The increasing demand for advanced materials that combine mechanical strength, corrosion resistance, thermal stability, and weight reduction has driven significant progress in the development of high-performance shape memory alloys (SMAs). These materials represent a category of metallic systems with the capacity to outperform traditional superalloys in demanding environments, such as those encountered in space. This study introduces the (Ti6Al4V)50Ni36Co14 alloy (non-equiatomic low-density alloy) designed for advanced structural applications. This alloy presents a density of approximately 5.2 g|cm³, positioning it as significantly lighter than conventional NiTi-based SMAs and other low-density high-performance alloys. Beyond its reduced weight, the (Ti6Al4V)50Ni36Co14 alloy demonstrates good mechanical and functional properties. Merging these attributes with the geometric freedom given by processing via additive manufacturing, this alloy stands as strong a candidate for applications in critical environments. This work explores the printability of the (Ti6Al4V)50Ni36Co14 alloy, opening pathways for further advancements in powder metallurgy and manufacturing technologies.

DOI:

https://doi.org/10.59499/EP256767869

Authors:

Thomas Hutsch (Fraunhofer IFAM Dresden, Germany) Vicente Pacheco (Fraunhofer IFAM Dresden, Germany) Johannes Trapp (Fraunhofer IFAM Dresden, Germany) Thomas Weißgärber (Fraunhofer IFAM Dresden, Germany)

Abstract:

Field assisted Sintering Technologies (FAST) like Spark Plasma Sintering (SPS) use current-enhanced sintering kinetics combined with applied uniaxial pressure. The direct current ideally leads to volumetric Joule heating in the sample. In terms of understanding the whole process, the knowledge of pressure- and temperature-depended electrical resistance of the powder body is of fundamental interest. In the talk, an advanced method to determine the electrical resistance will be discussed. First, the pressure-depended electrical resistance at room temperature is determined. Then, the measurement strategy is implemented in the SPS process. Examples will be given for materials like pure metal and composite powders. The documented data will support the simulation of the SPS process and give the opportunity for better understanding of sintering behaviors.The adaption of the determination process to existing or future SPS equipment will be discussed.

DOI:

https://doi.org/10.59499/EP256767978

Authors:

Lennard Hermans (Fraunhofer IAPT, Germany) Jan Scheumann (Fraunhofer IAPT, Germany) Burhan Umur Avci (Fraunhofer IAPT, Germany) Ingomar Kelbassa (Institute for Industrialization of Smart Materials (ISM), Hamburg University of Technology TUHH, Germany)

Abstract:

A time-intensive challenge in material extrusion is determining process parameters for metal injection molding feedstock that enable the production of high-density components. A critical parameter is the extrusion temperature, which significantly influences the feedstock viscosity and, consequently, the material flow rate. Through in-situ measurement of the flow rate during continuous extrusion, both the initial extrusion temperature and the changes in feedstock viscosity can be determined by successively increasing the temperature. The feedstock-specific material flow rate during extrusion must be precisely adjusted to achieve the required line width in continuous deposition. Even minimal deviations in line width or feedstock viscosity can lead to bonding and layer structure defects. In this paper a closed-loop algorithm that efficiently automates time-consuming and experience-based calibration in piston-based extrusion is presented. Following the process parameter determination, ranges of suitable extrusion temperatures along with the corresponding feedstock viscosity values are provided via datasets, enabling faster production cycles.

DOI:

https://doi.org/10.59499/EP256765584

Authors:

Elena De Lamo (Universidad Castilla La Mancha, Spain) Ines Duran (Universidad Castilla La Mancha, Spain) Javier Hidalgo (Universidad Castilla La Mancha, Spain) Raquel Gimenez (Universidad Castilla La Mancha, Spain) Cristina Berges (Universidad Castilla La Mancha, Spain) Roberto Campana (Centro Nacional del Hidrógeno, Spain) Cristina García (Universidad de Valladolid, Spain) Gemma Herranz (Universidad Castilla La Mancha, Spain)

Abstract:

This study presents the design and validation of novel master alloy for powder injection moulding (PIM) and material extrusion (MEX) additive manufacturing of interconnectors for SOFC and SOEC systems. Using Crofer30 as a baseline, alloys with varying cobalt, manganese, and copper contents were developed to optimize thermal expansion, oxidation resistance, and mechanical strength. Feedstock formulations enabled defect-free interconnectors in pellet form for PIM and MEX. Sintering at 1320 °C achieved near-full densification with dispersed precipitates, enhancing hardness compared to Crofer30. Performance was evaluated through oxidation and hydrogenation tests across different temperatures, with microstructural and electrochemical analyses confirming improved corrosion and oxidation resistance. These advancements address current manufacturing challenges, supporting the development of efficient, durable, and cost-effective SOFC|SOEC interconnectors, and significantly advancing green energy technologies.

DOI:

https://doi.org/10.59499/EP256768199

Authors:

Yasin Mohamed El Sayed (RINA, Italy) Alessandro Colaneri (RINA, Italy) Stefano Lionetti (RINA, Italy) Oriana Tassa (RINA, Italy) Domenico Stocchi (ECOR, Italy) Luca Mengoli (ECOR, Italy) Mario Franchi (ECOR, Italy)

Abstract:

This study presents the development of two novel AlSi7Mg-based alloys tailored for additive manufacturing applications. The research was driven by a computational modeling approach to optimize the alloy composition and predict material behavior during processing. Following the modeling phase, gas atomization was employed to produce the alloy powders, ensuring suitable characteristics for powder bed fusion additive manufacturing (PBF-AM). Specimens were fabricated via PBF-AM to assess the printability and mechanical performance of the developed alloys. Comprehensive mechanical characterization (tensile testing, hardness measurements, and microstructural analysis), was conducted to evaluate the alloys performance. Results indicate that the newly developed AlSi7Mg-based alloys demonstrate improved mechanical properties and compatibility with AM processes compared to conventional AlSi7Mg. These findings contribute to the advancement of materials engineering for additive manufacturing, offering enhanced options for lightweight and high-performance applications.UNCLASSIFIED – Based on the Foreground Information under EDA contract No B.PRJ.RT.797 covering the Ad Hoc Project entitled AMALIA

DOI:

https://doi.org/10.59499/EP256767873

Authors:

Oliver Bürgi (IWM at RWTH Aachen University, Germany) Michael Norda (Fraunhofer IFAM, Germany) Anke Kaletsch (IWM at RWTH Aachen University, Germany) Christoph Broeckmann (IWM at RWTH Aachen University, Germany)

Abstract:

Laser beam powder bed fusion of metals (PBF-LB|M) provides exceptional geometric freedom, but the variety of processable materials remains limited. In particular, the precise control of specific microstructures, like coarse carbides for better resistance against abrasive wear, continues to present challenges in research. In this study, hot work tool steel powder was mixed with high-speed steel (HSS) powder and titanium carbides (TiC) to develop an in-situ alloyed carbide-rich cold work tool steel.Thermodynamic calculations were performed to design an alloy system leading to a promising microstructure. During processing, TiC partially dissolved, resulting in coarse undissolved carbides and reprecipitated primary carbides. Carbide-forming elements like molybdenum (Mo), vanadium (V) and tungsten (W) are added as HSS powder to enhance the alloy´s potential for secondary hardening. The influence of PBF-LB|M process parameters on resulting carbides were analysed. In-depth microstructure analyses were conducted using scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD).

DOI:

https://doi.org/10.59499/EP256766986

Authors:

Lea Reineke (Fraunhofer IFAM, Germany) Alena Clausen (Fraunhofer IFAM, Germany) Regina Schlegel (Fraunhofer IFAM, Germany) Malte Sandmann (Fraunhofer IFAM, Germany) Sebastian Boris Hein (Fraunhofer IFAM, Germany)

Abstract:

The development of a curing-free binder system for reactive materials in Metal Binder Jetting (MBJ) aims to simplify the process chain and enhance the possibilities of MBJ technology. Traditional binder systems need a curing step that involve temperature treatment, which can have a negative impact on oxygen and water-reactive powders. This study introduces a new binder system that eliminates the need for curing, enabling the use of reactive powders without temperature influence. By removing the curing step, the proposed system not only shortens the overall MBJ process but also expands the range of materials that can be used in Metal Binder Jetting. The results demonstrate the feasibility of working with sensitive materials while maintaining the integrity and performance of the final part. This innovation paves the way for more efficient, adaptable, and material-diverse applications in additive manufacturing.

DOI:

https://doi.org/10.59499/EP256764448

Authors:

Juan Villemur (Universidad Carlos III de Madrid, Spain) Carlos Romero (Universidad Rey Juan Carlos, Spain) Elena Gordo (Universidad Carlos III de Madrid, Spain)

Abstract:

Proton Exchange Membrane Water Electrolysis (PEMWE) technology relies on porous transport layers (PTLs) to provide efficient gas and liquid transport, electrical conductivity and mechanical support. However, the reliance on platinum group metals (PGMs) poses challenges due to high cost and limited availability. By reducing PGM dependency, this approach aims to develop cost-effective, sustainable PTLs with tailored properties that will improve the efficiency and scalability of PEMWE technology. This study investigates the fabrication of multi-material PTLs, specifically Ti|316 and Nb|316, through a co-sintering process and subsequent nitruration. The nitriding process aims to enhance surface properties and corrosion resistance. The research will focus on analysing interfacial diffusion and the formation of intermetallic regions to ensure mechanical integrity and optimum performance. Electrochemical corrosion tests evaluate the durability and behaviour of these structures, targeting improved efficiency and scalability for PEMWE systems.

DOI:

https://doi.org/10.59499/EP256767643

Authors:

Xinjiang Hao (Globus Metal Powders, United Kingdom) Adam Hunt (Globus Metal Powders, United Kingdom)

Abstract:

Nickel 939 alloy was originally developed as a cast superalloy for high-temperature applications, capable of withstanding temperatures up to 850°C in gas turbine components such as blades, vanes, and burner nozzles. However, the alloy exhibits poor weldability, with extensive microcracks commonly observed during laser powder bed fusion (LPBF) additive manufacturing. By employing alloy design approaches, we successfully modified the minor elemental composition of the 939 alloy, effectively eliminating microcracks in LPBF-fabricated parts. This paper discusses the alloy design approaches, optimisation of printing parameters, and the resulting mechanical properties, including both room-temperature and high-temperature performance. Additionally, the mechanical properties are analysed in relation to the microstructure and fractographic characteristics.

DOI:

https://doi.org/10.59499/EP256767870