Authors:
Diego Monzón Martín (CEIT-BRTA, Spain) Gabriela Sarriegui (CEIT-BRTA, Spain) Nerea Burgos (CEIT-BRTA, Spain) José Manuel Martín (CEIT-BRTA, Spain) Valentina Zhukova (UPV|EHU, Spain) Arkady Zhukov (UPV|EHU, Spain)
Abstract:
This study presents a direct metallurgical approach for recycling end-of-life (EoL) sintered Nd-Fe-B magnets into competitive bonded magnets. The scrap was classified based on its rare earth content and converted into fresh recycled Nd-Fe-B powders via gas atomization. Three alloys were produced to analyze the effects of Ti and Zr additions at varying concentrations. Previous research showed that helium (He) as the atomizing gas results in finer powders with nearly fully amorphous particles. Based on this, two alloys were processed with He and one with argon (Ar), confirming that Ti and Zr enhance the glass forming ability of Nd-Fe-B alloys. After microstructural optimization by annealing, the powders exhibited improved magnetic properties. Laboratory specimens were produced by compression molding with epoxy resin as the bonding phase. Magnetic characterization of the isotropic bonded recycled Nd-Fe-B magnets revealed that this route could meet market demands for competitive bonded magnets.
DOI:
https://doi.org/10.59499/EP256767753
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Authors:
Polline Mwambe (Stellenbosch University, South Africa) Natasha Sacks (Stellenbosch University, South Africa) Johannes Pötschke (2Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Germany)
Abstract:
Pure nickel (Ni) is known for its low mechanical properties, which limits its range of applications. This study explored the possibility of improving the tensile properties of Ni through the addition of titanium carbonitride (TiCN) reinforcement using laser powder bed fusion. Horizontally built tensile specimens of 100wt% Ni and Ni-10wt% TiCN were tested according to ASTM E8|E8M-21. The Ni-10wt% TiCN samples had an ultimate tensile strength (UTS) of 751.65 MPa, a yield strength (YS) of 550.30 MPa and an elongation (EL) of 11.08 %. Compared to the pure Ni, this represents an increase of 112.31 % in UTS and 79.36 % in YS respectively with a reduction of only 4.15 % in EL. The findings demonstrate that the TiCN reinforcement enhanced the tensile properties of Ni while retaining a desirable ductility. Thus, there is potential for application of these materials where currently duranickel is used, for example spring contacts.
DOI:
https://doi.org/10.59499/EP256708008
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Authors:
Maheswaran Vattur Sundaram (Höganäs AB, Sweden) Michael Andersson (Höganäs AB, Sweden) Philipp Scholzen (Höganäs AB, Sweden)
Abstract:
Astaloy® CrS is a sustainable alternative to Fe-Cu-C PM steels that can also be heat treated in a conventional way with gas carburization and oil quenching. When heat treated this material has the potential to reach performance levels of Mo-prealloyed PM steels. To achieve improved fatigue performances, the evaluation was performed in two stages. First by varying the heat treatment parameters such as carburisation temperature and holding time. Secondly, Ni and graphite amounts were varied, applying carburisation at low temperature, to realise the full potential of this material. The performance was benchmarked against other materials. By optimising heat treatment and mix compositions, fatigue performance has significantly improved, making Astaloy CrS superior to Fe-Cu-C and equivalent to that of Mo-prealloyed PM steels.
DOI:
https://doi.org/10.59499/EP256767821
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Authors:
Mohammad Ibrahim (Norwegian University of Science and Technology, Norway) Tiziano Trapletti (Norwegian University of Science and Technology, Norway) Ragnhild Elizabeth Aune (Norwegian University of Science and Technology, Norway)
Abstract:
A functionally graded strategy was employed to address brittleness and thermal-expansion mismatches in four nickel-silicon-based alloys—NiSi11.9Co3.4, NiSi10.15V4.85, NiSi11.2Mo1.8, and NiSi10.78Ti1.84B0.1—during Directed Energy Deposition (DED) on S355 steel. Each alloy was deposited atop an Inconel 625 transition layer, producing 30?mm cylinders for structural evaluation. Except for NiSi10.78Ti1.84B0.1, all alloys printed successfully, exhibiting stable builds as they demonstrated minimal hot cracks and low porosity. Microstructural examinations using Optical Microscopy, Scanning Electron Microscopy and Energy-dispersive X-ray spectroscopy mapping showed a uniform distribution of secondary phases and grains, suggesting robust solidification conditions throughout the builds, confirming that Inconel 625 effectively mitigates residual stress and thermal mismatch issues between Nickel Silicide alloys and S355 steel. This functionally graded approach demonstrates the feasibility of DED processing for nickel-silicon-based alloys, providing a versatile solution to compositional and thermal constraints.
DOI:
https://doi.org/10.59499/EP256768149
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Authors:
Tim Marter (Element22 GmbH, Germany)
Abstract:
Sinter-based additive manufacturing of Titanium and its alloys faces challenges from deformation and shrinkage during sintering, limiting its adoption for complex geometries and small batch sizes. To address these issues, this presentation explores Finite Element Method (FEM)-based sinter simulations, incorporating sinter stress, gravity load, viscosity, friction, and time-temperature-densification effects. Traditional simulation models require hard-to-measure parameters and fail to match experimental curves, such as dilatometric studies.A phenomenological approach, leveraging real-world data from dilatometer measurements, overcomes these limitations by reducing the need for extensive material-specific investigations. This approach enables accurate simulations using a single temperature-time profile, simplifying data collection and improving predictive accuracy.The talk highlights the integration of these simulations into the Cold Metal Fusion (CMF) process, comparing real-world and simulated results, and discussing potential refinements. This research aims to optimize sinter-based additive manufacturing, minimizing costs in time, labour, and materials while enhancing process efficiency.
DOI:
https://doi.org/10.59499/EP256766761
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Authors:
Ángel Biedma (Universidad Carlos III de Madrid, Spain) Sandra Gordon (Hilti A.G., Liechtenstein) Olivier Ther (Hyperion Materials & Technologies, Spain) Luis García (Hyperion Materials & Technologies, Spain) Steven Moseley (Hilti A.G., Liechtenstein) Elena Gordo (Universidad Carlos III de Madrid, Spain)
Abstract:
This work investigates the thermodynamic design and experimental validation of Ti(C,N)-based cermets, focusing on the role of different secondary carbides (WC, Mo2C) and Co-free Ni-based metallic binders. A CALPHAD-based approach is used to predict the influence of single and combined phases on carbon activity, liquidus temperature, and secondary phase formation.This step-by-step methodology integrates thermodynamic predictions with experimental validation to guide the design of Co-free Ti(C,N)-based cermets. Experimental methods include differential thermal analysis (DTA) to assess melting temperatures, contact angle measurements to assess wettability, and microstructural characterisation to determine phase distribution. The study aims to systematically investigate each component's effect on sintering behaviour and microstructural evolution, providing insight into their contribution to expanding the carbon equilibrium range and optimising processing conditions.
DOI:
https://doi.org/10.59499/EP256765968
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Authors:
Ji-Woon Lee (Kongju National University(CAMP2), Korea, Republic of) Soon-jik Hong (Kongju National University(CAMP2), Korea, Republic of) Gian Song (Kongju National University(CAMP2), Korea, Republic of) Jin-Kyu Lee (Kongju National University(CAMP2), Korea, Republic of) Jongun Moon (Kongju National University(CAMP2), Korea, Republic of)
Abstract:
Additive Manufacturing (AM) has garnered significant attention in recent years for the fabrication of metallic components. The processability and quality of AM-produced parts are strongly influenced by the flow behavior of feedstock powders. Therefore, a thorough understanding of powder flowability and its governing characteristics is essential for optimizing AM processes. In this study, spherical, fine metallic powders of IN625, Maraging steel, Hastelloy C-22, and STS316L with a uniform particle size distribution (PSD) were produced via gas atomization. The dynamic flowability of these powders was systematically evaluated as a function of their PSD and material properties. The results highlight the critical role of intrinsic material characteristics in determining flowability and powder performance, providing valuable insights into the selection and optimization of feedstock powders for AM applications.
DOI:
https://doi.org/10.59499/EP256779608
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Authors:
Gee Hyuk Lee (Korea Institute of Industrial Technology (Korea National Institute of Rare Metals, Incheon, Republic of Korea), Inha University, Korea, Republic of) Yong Kwan Lee (Korea Institute of Industrial Technology (Korea National Institute of Rare Metals, Incheon, Republic of Korea), Korea University, Korea, Republic of) Yong Yeon You (Korea Institute of Industrial Technology (Korea National Institute of Rare Metals, Incheon, Republic of Korea), Korea University, Korea, Republic of) Seok Jun Seo (Korea Institute of Industrial Technology (Korea National Institute of Rare Metals, Incheon, Republic of Korea), Korea, Republic of) Jae Jin Sim (Korea Institute of Industrial Technology (Korea National Institute of Rare Metals, Incheon, Republic of Korea), Korea, Republic of)
Abstract:
Nickel nanopowders, known for their excellent electrical conductivity and oxidation resistance, are essential in industries such as electronics and energy storage. As internal electrode materials in MLCCs (multilayer ceramic capacitors), they play a key role in achieving high capacity and miniaturization. Conventional processes like PVD and CVD produce high-purity nickel powders but face challenges such as broad particle size distribution and high production costs. Wet chemistry offers a cost-effective and efficient alternative, enabling precise particle size control and reduced agglomeration. This study optimized key process variables, including reducing agents, additives, and precursor concentrations, to evaluate their effects on particle size, purity, and carbon content. The synthesized nanopowders were characterized using SEM, PSA, XRD, and ICP-OES. Results confirmed the feasibility of producing high-purity and low-carbon nickel nanopowders suitable for MLCC applications.
DOI:
https://doi.org/10.59499/EP256765921
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Authors:
Sara Varetti (Leonardo S.p.a, Italy) Luca Margaria (Politecnico di Torino, Italy) Antonio Coluccia (Politecnico di Torino, Italy) Giorgio De Pasquale (Politecnico di Torino, Italy) Alessandro De Zanet (Leonardo S.p.a., Italy) Evanthia Pappa (Leonardo S.p.a., Italy) Abhishek Kumar (Leonardo S.p.a., Italy) Mattia Cabrioli (F3nice, Norway) Matteo Vanazzi (F3nice, Norway)
Abstract:
Joining technologies in aviation ares considered as a backbone. Traditional mechanical methods, like rivets and fasteners add weight, require complex assemblies, and can damage the configuration of composites such as continus fibre breakage during handling. These challenges highlight the need for alternative solutions. The EU-funded MIMOSA project proposes a novel approach for joining metal (AlSi10Mg from Additive Manufacturing, AM) and CFRP, addressing these limitations. The proposed technology focuses on the implementation of mechanical interlocking mechanism between CFRP and 3D metal anchors based on AM (patented design and manufacturing process). The AM process associated with heat treatmens requires customized fatigue characterization of the material to measure the S-N curves as function of some fundamental fabrication parameters (part orientation, surface finishing and heat treatment). This study reports the experimental results of the fatigue tests to assess the feasibility of producing the innovative multi-material joints proposed.
DOI:
https://doi.org/10.59499/EP256766258
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Authors:
Milad Bemani Lirgeshas (Eurecat, Spain) Marc Mares (Eurecat Centro Tecnológico de Cataluña, Spain) Sergi Parareda (Eurecat Centro Tecnológico de Cataluña, Spain) Michel Encrenaz (HP Printing and Computing Solutions S.L, Spain) Rocio Muñoz Moreno (HP Printing and Computing Solutions S.L, Spain) Antonio Mateo (UPC University, Spain) Raj Das (RMIT University, Australia) Andrey Molotnikov (RMIT University, Australia) Daniel Casellas (Eurecat Centro Tecnológico de Cataluña, Spain)
Abstract:
This study applies rapid fatigue testing, the stiffness method, to assess the fatigue resistance of 17-4 PH metal binder jetting (MBJ) precipitation-hardened martensitic stainless steel. Traditional fatigue tests are costly and time-consuming, limiting the generation of comprehensive data about the different stages of the fatigue mechanism. Especially for additive manufacturing (AM) parts in which the process-induced defects and anisotropy could result in different fatigue resistance and pending to be characterized compared to conventionally fabricated counterparts. The stiffness method has been validated for metal sheets and AM products recently and can estimate the fatigue limit within a day. This brings instrumental value for accelerating the AM industrial adoption ramp when fatigue performance is required. In this work, the method was used to evaluate the fatigue limit of MBJ specimens printed in different directions, showing its ability to estimate the fatigue limit with 90% time and cost savings compared to conventional methods.
DOI:
https://doi.org/10.59499/EP256779339
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Authors:
Ernesto Urionabarrenetxea (CEIT-BRTA, Spain) Alejo Avello (CEIT-BRTA, Spain) José Manuel Martín (CEIT-BRTA, Spain) Enrique Manuel Huerta (CEIT-BRTA, Spain)
Abstract:
Since gas atomized powders can exhibit significant variations depending on the scale of the atomization unit, powders produced in laboratory-scale units may differ noticeably from those obtained in industrial-scale units, even under seemingly identical atomization conditions. In this work, the initial experimental results obtained with a new industrial-scale atomization unit using the original gas and melt nozzles are firstly presented. It was observed that the resulting powders were coarse, the primary disintegration stage was far from optimal and premature solidifications were formed. In order to increase the productivity of the process, several melt nozzles were designed, simulated using CFD techniques and tested. The new designs enabled the production of powders with similar characteristics to those obtained with the laboratory-scale atomization unit. Numerical and experimental results are presented, analyzing the influence of key operational variables, including the preheating of the atomizing gas, on productivity and energy consumption.
DOI:
https://doi.org/10.59499/EP256767701
