Euro PM2025 Proceedings

Authors:

Gul Cagri Sahin (Omtas Otomotiv Transmisyon Aksami San. ve Tic. A.S., Turkey) Ilven Mutlu (Istanbul University - Cerrahpasa, Turkey) Hakan Olca (Omtas Otomotiv Transmisyon Aksami San. ve Tic. A.S., Turkey) Ogulcan Keskin (Omtas Otomotiv Transmisyon Aksami San. ve Tic. A.S., Turkey) Ecenur Cakan (Istanbul University - Cerrahpasa, Turkey) Berra Tuman (Istanbul University - Cerrahpasa, Turkey) Merve Demirci (Istanbul University - Cerrahpasa, Turkey) Batuhan Ceren (Omtas Otomotiv Transmisyon Aksami San. ve Tic. A.S., Turkey)

Abstract:

In this project, innovative alloys have been developed using both artificial neural networks and first-principles techniques, incorporating experimental data. The effects of alloying elements have been investigated both experimentally and through computational materials engineering. DFT-based CASTEP software was used within the scope of computational materials science. Structure and geometry optimization, as well as unit cells and elastic constants, have been determined for alloys with different compositions. Additionally, phase transformation temperatures have been studied with the help of data obtained from preliminary trials using artificial neural networks. The alloys have been produced using powder metallurgy method. The calculations were performed on a high-performance computing server (supercomputer).

DOI:

https://doi.org/10.59499/EP256767385

Authors:

Carlos Matos (University of Aveiro, Portugal) Vítor Costa (University of Aveiro, Portugal) Duncan Fagg (University of Aveiro, Portugal) Georgina Miranda (University of Aveiro, Portugal)

Abstract:

The fabrication of high-performance coatings with enhanced wear or corrosion resistance is of highest importance to numerous strategic industries, from aerospace to automotive sectors. Laser technology has been explored to fabricate protective coatings, especially laser cladding, either using powder feeding or preplaced powder systems. For non-planar surfaces, powder feeding laser systems coupled with robotic arms are especially interesting, however, the interaction of the powder jet with the laser and the collision between particles can affect the material layer morphology and density. Moreover, due to laser interaction, the reuse of powders is limited due to changes in powder size and morphology. In this work, an alternative approach is explored, namely metal-polymer films integrating Ni alloys having the ability to comply with non-planar surfaces. After fabricating and characterizing the obtained films, the laser-processed coatings deposited on stainless steel substrates are assessed regarding densification and microstructure, targeting both industrial coating and repair processes.

DOI:

https://doi.org/10.59499/EP256766797

Authors:

Yin Nan Kok (Powderloop Technology Ltd., United Kingdom)

Abstract:

Hardmetal powders used in today’s metal Additive Manufacturing (AM) processes were made from pre-manufactured carbides, originally formulated for thermal spraying. The conventional powder manufacturing process involves multiple high-energy stages to pre-manufacture carbide including carburisation and pulverisation. During metal AM process, a melt-pool is created by a laser beam during which chemical reactions occur within the melt-pool. When pre-manufactured carbide is used, the carbide is re-heated, leading to carbide decomposition and the formation of unfavourable brittle eta-carbide phase which is detrimental to the coating performance. This paper presents a novel powder developed for AM using a novel resource-efficient powder manufacturing process. The powder was produced by agglomerating fine particles of elemental materials instead of pre-manufactured carbide. This powder forms carbide in the melt pool during laser processing, resulting in improved material properties, a chemically more stable coating, and a cleaner interface with metallurgical bonding between the precipitated carbide and the matrix.

DOI:

https://doi.org/10.59499/EP256761557

Authors:

Masaaki Eida (Sumitomo Electric Sintered Alloy,Ltd., Japan) Yuki Hirao (Sumitomo Electric Sintered Alloy,Ltd., Japan) Tatsuya Saitou (Sumitomo Electric Sintered Alloy,Ltd., Japan) Tomoyuki Ueno (Sumitomo Electric Sintered Alloy,Ltd., Japan)

Abstract:

As moving vehicles become more electric and home appliances and industrial equipment become more efficient, there is a growing need for smaller, lighter, and more efficient motors. Compared to the currently popular radial flux motor, axial flux motor (AFM) is a thinner motor that can provide high torque, and is attracting attention as one of the motors that meet the need. AFM requires a magnetic core that is compatible with AFM’s three-dimensional magnetic circuit, and it is preferable to use soft magnetic composites (SMC) that are magnetically isotropic and have high design flexibility in shape. So, to further improve motor performance, authors have developed SMC core with insulation coating that has high withstand voltage despite its thin thickness of several tens of micrometers. By applying this developed core for AFM, we have confirmed improvements in the space factor and heat dissipation of the coil, which we report in this paper.

DOI:

https://doi.org/10.59499/EP256778920

Authors:

Alexander Holzer (TU Wien, Austria) Simon Pfeifenberger (TU Wien, Austria) Atul Anand (TU Wien, Austria) Christian Gierl-Mayer (TU Wien, Austria)

Abstract:

Sinter-based additive processes, such as lithography-based metal manufacturing, enable properties and design possibilities that cannot be manufactured any other way. The final properties and geometrical precision of indirect additive manufacturing techniques are strongly affected by the quality of the debinding procedure. Therefore, several aspects - temperature, atmosphere and pre-treatments like heat treatment or solvent debinding - play an important role. In this work, the main influences and consequences of the debinding procedure are shown. Results show that the key factor is the thickness of the sample. Therefore, the temperature and dwelling time is adjusted to allow the diffusion processes. In general, synthetic air allows better removal of carbon. The process window for the optimum treatment is narrowed by the stability before sintering. Those consequent possible errors, like deformation, fragility and too high carbon content can be avoided and allow a higher performance of the component in the end.

DOI:

https://doi.org/10.59499/EP256763871

Authors:

Peter Lindecke (amsight GmbH, Germany) Daniel Rommel (Colibrium Additive, a GE Aerospace company, Germany)

Abstract:

This study investigates powder management and associated mechanical properties in the additive manufacturing (AM) of aluminum using Laser Powder Bed Fusion (L-PBF). The focus is on the development of a novel, holistic data management system for digital capture and analysis of the complete powder lifecycle. For the first time, the system enables comprehensive documentation of all quality-relevant powder parameters such as particle size distribution, chemical composition, and flow behavior in conjunction with process data and resulting component properties. In a long-term study, the aging behavior of aluminum powder was systematically investigated over multiple reuse cycles. The results demonstrate that optimized powder reconditioning can be achieved while simultaneously ensuring component quality. The developed data management system thus forms the foundation for cost-efficient and sustainable powder utilization in the L-PBF process while meeting regulatory requirements.

DOI:

https://doi.org/10.59499/EP256767166

Authors:

Yusuke Hirayama (National Institute of Advanced Industrial Science and Technology, Japan) Keigo Kobayashi (Mitsubishi Materials Corporation, Japan) Yuji Shigeta (National Institute of Advanced Industrial Science and Technology, Japan) Zheng Liu (National Institute of Advanced Industrial Science and Technology, Japan) Kenta Takagi (National Institute of Advanced Industrial Science and Technology, Japan) Jun Kato (Mitsubishi Materials Corporation, Japan) Kazuki Okada (Mitsubishi Materials Corporation, Japan)

Abstract:

We found that an alloy containing a minimal amount of rare earth elements in aluminum significantly improves the sinterability of aluminum in a pressureless state. In this presentation, we dynamically observed the sintering process and evaluated in detail how the sintering progressed. Liquid phase sintering is achieved by the liquid phase that is produced when a minimal amount of rare earth element dissolves in aluminum below the melting point of aluminum.

DOI:

https://doi.org/10.59499/EP256768153

Authors:

Songyi Kim (KITECH, Korea, Republic of) Dohun Kwon (KITECH, Korea, Republic of) Hwijun Kim (KITECH, Korea, Republic of)

Abstract:

Nickel-based oxide dispersion strengthened (Ni-ODS) alloys are promising materials for high-temperature applications due to their excellent mechanical properties.This study investigates the effects of composition and dispersoid additions on the high-temperature strength of Ni-ODS alloys. Alloys were made by mechanical alloying and vacuum induction hot pressing. FE-SEM and EDS analysis were performed for microstructure analysis, and Gleeble test was performed to evaluate the high temperature mechanical properties. The results showed that the Nb-Si and Y2O3 composite dispersion strengthened alloy exhibited excellent high-temperature mechanical properties by effectively suppressing grain growth and dislocation motion in the alloy. Based on these findings, Ni-ODS alloys have significant potential for application in aerospace and power generation industries, where high-temperature strength and stability are critical.

DOI:

https://doi.org/10.59499/EP256766938

Authors:

HyunJoong Kim (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of) Sung-Jae Jo (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of) Jongun Moon (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of) Jiwoon Lee (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of) Gian Song (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of) Soon-Jik Hong (Division of Advanced Materials Engineering, and Center for Advanced Materials and Parts of Powders (CAMP2), Kongju National University, Korea, Republic of)

Abstract:

Powder characteristics in Directed Energy Deposition (DED) processes significantly impact the final product quality, yet the role of moisture content remains underexplored. This study evaluates the impact of varying powder humidity levels on flowability, microstructure, and mechanical properties during the DED process. Powder with different moisture levels were analyzed for particle size distribution, moisture content, and oxide layer thickness. Results from Hall Flowmeter and Dynamic Avalanche testing revealed that higher moisture content reduced flowability. When applied to the DED process, reduced flowability affected the dimensional accuracy and surface roughness of the resulting alloys. Microstructural analysis showed that elevated moisture levels promoted coarse oxide formation, identified as MnSiO3 and Cr2O3 through EBSD analysis. Tensile tests revealed that the oxides decreased tensile strength and elongation. These findings highlight the necessity of maintaining low humidity storage conditions or pre-drying powders to ensure high-quality, defect-free components in AM processes.

DOI:

https://doi.org/10.59499/EP256779291

Authors:

Vania Rodriguez (Technical University of Denmark, Denmark) Naiqi Shang (Politecnico di Milano, Italy) Thomas Dahmen (Asgaard Metals ApS, Denmark) Venkata Nadimpalli (Technical University of Denmark, Denmark)

Abstract:

Binder jetting (BJ) is an emerging additive manufacturing (AM) technique offering a cost-effective route for producing complex metal parts. Compared to other AM processes, BJ does not involve rapid melting and solidification, minimizing defects and residual stresses. This makes BJ an attractive alternative for AM alloys with low-weldability such as high-carbon steels. This work explores the effect of sintering parameters on the microstructure of D2 cold work tool steel produced via BJ. Overspray powder as a bi-product from the Spray Forming process (SF) was used as a resource efficient alternative feedstock. The effects of sintering parameters on densification, linear shrinkage and microstructural evolution regarding grain size and phase composition were studied. After sintering, a density of 98% and a hardness of 680 HV were obtained. The study also discusses the potential influences of the sintered microstructure on the properties of the steel addressing opportunities for future

DOI:

https://doi.org/10.59499/EP256779530

Authors:

Vuokko Marjamaa (VTT, Finland) Atte Antikainen (VTT, Finland) Juha Lagerbom (VTT, Finland) Pentti Kalliotiura (VTT, Finland) Tomi Lindroos (VTT, Finland)

Abstract:

The effect of sintering parameters on the properties of austenitic nickel-free stainless steel was investigated using a rate-controlled sintering approach. This study focused on optimizing sintering parameters, including the influence of different gas atmospheres (argon, nitrogen, and hydrogen) with varying partial pressures of nitrogen. The goal was to explore how these parameters affect phase formation, mechanical properties, and corrosion resistance. Mechanical properties were evaluated using indentation-based methods, providing a comprehensive assessment of hardness and elastic modulus. Additionally, corrosion resistance was studied through electrochemical testing. Simulation results, calculated with Thermocal software, were used to complement and compare experimental findings. The results revealed critical insights into the relationship between sintering atmosphere, phase evolution, and material performance, offering a deeper understanding of how sintering conditions can be optimized for enhanced mechanical and corrosion properties in nickel-free stainless steel.

DOI:

https://doi.org/10.59499/EP256765960

Authors:

Yuji Shigeta (National Institute of Advanced Industrial Science and Technology (AIST), Japan) Yusuke Hirayama (National Institute of Advanced Industrial Science and Technology (AIST), Japan) Keigo Kobayashi (Mitsubishi Materials Corporation, Japan) Zheng Liu (National Institute of Advanced Industrial Science and Technology (AIST), Japan) Kenta Takagi (National Institute of Advanced Industrial Science and Technology (AIST), Japan) Jun Kato (Mitsubishi Materials Corporation, Japan) Kazuki Okada (Mitsubishi Materials Corporation, Japan)

Abstract:

Aluminum (Al) is very difficult to sinter because of the stable oxide layer on its surface. Recently we found that sinterability can be dramatically improved by adding a small amount of rare earth oxide (REO). The relative density of over 95% can be achieved by sintering of Al-REO mixed powder even without pressurization for 1 hour. Similar densities were obtained at longer sintering up to 48 hours. However, the effect of sintering time on the sintered microstructure of the mixed powder is unclear. Therefore, in this report, the change in the sintered microstructure of Al-REO mixed powder with sintering time will be discussed.

DOI:

https://doi.org/10.59499/EP256768281