Authors:
Federico Simone Gobber (Politecnico di Torino, Italy) Paolo C. Priarone (Politecnico di Torino, Italy) Antonio Pennacchio (Politecnico di Torino, Italy) Marco Actis Grande (Politecnico di Torino, Italy)
Abstract:
Additive manufacturing could offer promising advantages for sustainable production, particularly through material efficiency and innovative feedstock solutions. This study investigates the feasibility of producing AM powders from industrial waste, specifically AA5183 aluminum alloy chips from metal forming processes, using vacuum inert gas atomization (VIGA). Briquetted chips were melted under vacuum to minimize oxidation, and the molten metal was atomized with argon gas. The process achieved an overall powder yield of approximately 66% relative to the initial feedstock, with ~35% of the starting mass recovered as powder in the 20-63?µm size range suitable for laser powder bed fusion (PBF-LB|M). The obtained powders demonstrated chemical composition and morphology comparable to powders from conventional ingot feedstock, with only a slight increase in oxygen content due to chip surface oxides. Despite inherent challenges, such as dross formation reducing melting yield and persistent alloy hot-cracking tendencies, this work identifies a potential sustainable recycling route towards resource usage efficiency in AM applications.
DOI:
https://doi.org/10.59499/EP256764726
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Authors:
Christoph Höhnel (TU Dresden, Germany) Inge Lindemann-Geipel (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Germany) Bruno Weise (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Germany) Markus Schneider (GKN Sinter Metals Engineering GmbH, Germany) Thomas Weißgärber (TU Dresden, Germany)
Abstract:
Contrary to common understanding of die-compacted powder metallurgy parts, the strength of soft magnetic composites (SMCs) compacted to very high densities does not increase with rising density. Instead, SMCs exhibit a reduction in transverse rupture strength (TRS) when high green densities are achieved during compaction. This phenomenon has been investigated across six distinct SMC materials, varying in coating systems and particle sizes, alongside pure iron powder. The observed decline in TRS is consistent across all powders studied, primarily due to reduced oxygen penetration during the debinding process and subsequent heat treatment. Notably, powders with smaller particle size distributions demonstrate a more pronounced decrease in TRS at earlier stages. To address this issue, strategies aimed at minimizing the reduction in TRS will be explored and discussed, offering potential solutions for improving the performance of SMCs in practical applications.
DOI:
https://doi.org/10.59499/EP256767851
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Authors:
Magdalena Nowak-Coventry (Toyota Motor Europe, Belgium) Artur Jojczyk (Toyota Motor Europe, Poland) Nicola Casari (ToffeeX, United Kingdom)
Abstract:
In this study, a physics-driven generative AI software was employed to design conformal cooling for a casting tool. The cooling performance was analysed using casting simulation software and compared to current pin cooling and self-designed conformal cooling. The results demonstrated significant improvements in temperature, heat transfer coefficient (HTC) and soldering. Additionally, the time required to design appropriate cooling can be reduce by 50%. The optimized tool was subsequently printed and is scheduled for testing in production.
DOI:
https://doi.org/10.59499/EP256779436
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Authors:
Jakub Szalatkiewicz (Phoenix Surowce Sp. z o.o., Poland) Roman Szewczyk (Warsaw University of Technology, Poland) Marzena Szałatkiewicz (Phoenix Surowce Sp. z o.o., Poland) Adrian Radoń (Łukasiewicz Research Network – Institute for Non Ferrous Metals, Poland) Anna Czech (Łukasiewicz Research Network – Institute for Non Ferrous Metals, Poland) Wojciech Rogalski (Phoenix Surowce Sp. z o.o., Poland) Ivan Patapenka (Phoenix Surowce Sp. z o.o., Poland) Marcin Śladowski (Phoenix Surowce Sp. z o.o., Poland) Piotr Gazda (Warsaw University of Technology, Poland) Michał Nowicki (Warsaw University of Technology, Poland) Aleksandra Kolano-Burian (Łukasiewicz Research Network – Institute for Non Ferrous Metals, Poland)
Abstract:
The article presents the potential and quality of Critical Raw Materials (CRM), concerning powders from NdFeB magnets composed of Rare Earth Elements (REE) recovered by a tailored robotized disassembly system backed up by Artificial Intelligence and Machine Vision. The technology focuses on processing the end-of-life Hard Disk Drives (HDDs) from Waste of Electric and Electronic Equipment (WEEE). It allows the recovery of high-quality metals and rare earth elements magnets. From the HDDs, NdFeB magnet powder was generated by a hydrogenation process for its use in new magnet manufacturing, ie. by sintering or 3D printing. The composition of recovered hard disk drive magnet powder and its characterization are presented, as well as the description of the mass balance and recycling process. Next to recovery of critical raw materials, secure and environmentally friendly data destruction with its carriers, of the end-of-life computer hard disk drives, is presented and described. The presented solution opens a new approach to robotized, highly efficient recycling of tailored waste of electric and electronic devices. Finally, the article confirms the importance
DOI:
https://doi.org/10.59499/EP256779721
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Authors:
Ilídio Costa (Faculty of Engineering of the University of Porto, Portugal) Bernardo L. Ribeiro (Faculty of Engineering of the University of Porto, Portugal) Dinis Carneiro (Faculty of Engineering of the University of Porto, Portugal) Bruno Cunha (Faculty of Engineering of the University of Porto, Portugal) José Monteiro (Faculty of Engineering of the University of Porto, Portugal) Elsa W. Sequeiros (Faculty of Engineering of the University of Porto, Portugal)
Abstract:
Inconel 718 (INC718) components manufactured by Directed Energy Deposition (DED) require optimized post-processing heat treatments due to their distinct solidification conditions and resultant microstructures compared to conventional manufacturing methods. While extensive research exists on heat treatments for wrought and powder bed fusion-produced INC718, limited studies address DED-specific heat treatment optimisation. This study and explores the effects of various solutions and ageing heat treatments on DED-manufactured INC718 through samples' mechanical and microstructural characterisation by using OM, SEM|EDS|EBSD, and Vickers hardness testing. The as-deposited material exhibited significant niobium segregation and Laves phase formation in interdendritic regions. Solution treatment at 1150°C proved more effective at dissolving Laves phase compared to conventional 980°C treatment. Modified solution and ageing parameters (1150°C|1h + 720°C|8h + 620°C|8h) resulted in significantly improved hardness (491±13 HV0.2) compared to standard heat treatments. These findings demonstrate the necessity of developing specific heat treatment protocols for DED-manufactured INC718 to achieve optimal properties.
DOI:
https://doi.org/10.59499/EP256767779
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Authors:
Julie Campbell Tremblay (Rio Tinto Metal Powders, Canada) Amir Shirani (Rio Tinto Metal Powders, Canada) Chantal Labrecque (Rio Tinto Metal Powders, Canada)
Abstract:
Various strategies can be explored to minimize costs in PM technology. These include increasing density to reduce the need for alloying elements. Higher density also results in greater strength, allowing for cost reduction by design. Another cost-reduction strategy is improving processability to increase production throughput. The pursuit of high-performance parts extends beyond developing higher alloyed materials to include comprehensive premix solutions. Binder treatment solutions and improved lubrication are essential for enhancing part properties.The current paper will present the results from a new chromium grade in an improved premix with improved lubricant solutions. It will detail the sinter hardening properties and compare the premix improvements to standardized grades.
DOI:
https://doi.org/10.59499/EP256767949
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Authors:
Katherine Pérez Zapata (Helmholtz Zentrum Hereon, Germany) Eshwara Nidadavolu (Helmholtz Zentrum Hereon, Germany) Thomas Ebel (Helmholtz Zentrum Hereon, Germany) Martin Wolff (Helmholtz Zentrum Hereon, Germany) Heike Helmholz (Helmholtz Zentrum Hereon, Germany) Regine Willumeit-Römer (Helmholtz Zentrum Hereon, Germany) Berit Zeller-Plumhoff (Helmholtz Zentrum Hereon, Germany)
Abstract:
The integration of 3D printing and Mg-5Gd alloys is revolutionizing biomedical applications, particularly in scaffolds for bone implants. Scaffolds facilitate bone growth and repair, requiring precise fabrication to achieve a balanced degradation rate that aligns with bone regeneration while maintaining mechanical support during healing. This study optimizes 3D printing parameters for Mg-5Gd alloy feedstock (40 vol.% binder loading) to produce high-quality magnesium structures with controlled degradation rates. Key parameters, including printing speed, extrusion rate, layer thickness, and post-processing techniques, were refined to achieve dense discs and scaffolds with pore sizes of 700–1250 µm, matching cortical bone structure. Using a 0.3 mm nozzle and printing speeds of 10–20 mm|s, structures with densities up to 97% and degradation rates below 1 mm|year were achieved. Results demonstrate that scaffold degradation rates can be tailored by adjusting geometry, pore size, and wall thickness, showcasing AM potential to advance regenerative medicine and biomedical implants.
DOI:
https://doi.org/10.59499/EP256767218
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Authors:
Taiko Tanimoto (Kyushu University, Japan) Naoki Orita (Kyushu University, Japan) Zhenying Wang (Kyushu University, Japan) Chihiro Inoue (Kyushu University, Japan) Jun Horiuchi (JFE Steel, Japan) Takuya Takashita (JFE Steel, Japan) Kazutoyo Yamada (Iwate University, Japan) Noriharu Yodoshi (Kyushu University, Japan)
Abstract:
To elucidate the gas atomization process as a thermo-fluid phenomenon, we successfully performed high-speed Schlieren imaging up to one million frame per second for the first time to resolve deformation and fragmentation of a tin droplet subjected to a supersonic nitrogen jet at Mach number of 1.5. We identify two atomization processes by tracking the deforming ligaments in a Lagrangian manner. Inside the supersonic jet, the large aerodynamic force shears the droplet into tiny particles partially interacting with the shock waves inside the jet. Rebounded above the jet, the rest droplet deforms to be ligaments, which break dominated by the capillarity producing large particles. We find that the distinct atomization mechanisms result in a bi-modal distribution of the produced particle size. This fact indicates that the molten droplets in a practical apparatus collide with gas jets at multiple times, leading to a converged mono-modal distribution.
DOI:
https://doi.org/10.59499/EP256766631
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Authors:
Jannis Lemke (CNR Icmate, Italy) Carlo Biffi (CNR Icmate, Italy) Alberto Coda (CNR Icmate, Italy) Jacopo Fiocchi (CNR Icmate, Italy) Ausonio Tuissi (CNR Icmate, Italy)
Abstract:
Additive Manufacturing methods like laser-powder-bed-fusion are a promising preparation route for NiTi-based shape memory alloys as this class of material could benefit from the process inherent freeform capabilities to design a new generation of high-temperature transforming actuators. Powder quality and characteristics are crucial in achieving a stable high-temperature transformation, as it is sensitively affected by chemical composition and impurities. In addition, transformation temperatures can be shifted up by applying a stress to the material according to Clausius-Clapeyron’s law.In this study we report on the capabilities of NiTi-based Shape Memory Alloys powders processed by additive manufacturing for the realization of high temperature actuators. Particular emphasis is placed on the material transformation behaviour at high stresses. Differential Scanning Calorimetry, Scanning Electron Microscopy as well as mechanical tests in tensile and compression mode are performed to access microstructure, thermal properties and shape memory performance.
DOI:
https://doi.org/10.59499/EP256767895
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Authors:
Wolfgang Limberg (Helmholtz-Zentrum Hereon, Germany) Vasil M. Garamus (Helmholtz-Zentrum Hereon, Germany) Eshwara Nidadavolu (Helmholtz-Zentrum Hereon, Germany) Thomas Ebel (Helmholtz-Zentrum Hereon, Germany) Berit Zeller-Plumhoff (Helmholtz-Zentrum Hereon, Germany)
Abstract:
Partly degradable implants consisting of a titanium and a magnesium part allow for novel therapies in medical treatment of bone fractures. In this study, as test specimens MIM-produced titanium tensile test specimens were coated around the gauge length with magnesium MIM feedstock via injection moulding. The magnesium coating was then removed by two different ways: At some specimens mechanically by cutting and grinding and at the other specimens chemically by degradation in 0.9 wt.% NaCl solution.The tensile test properties of the permanent titanium component before and after the removing of the temporary magnesium part were evaluated at room temperature. Hydrogen loading of the titanium parts after chemical degradation was observed. This increase of Hydrogen content of more than 2000 µg|g led to massive embrittlement. Plastic elongation decreased from over 12% to below the detection limit and tensile strength decreased from more than 800 down to 500 MPa.
DOI:
https://doi.org/10.59499/EP256764931
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Authors:
Naiara Azurmendi (TECNALIA, Spain) Iñigo Agote (TECNALIA, Spain) Xabier Gómez (TECNALIA, Spain) Irati Zurutuza (TECNALIA, Spain) Cristina Fernandes (PALBIT S.A., Portugal) Daniel Figueiredo (PALBIT S.A., Portugal) Bruno Guimarães (PALBIT S.A., Portugal)
Abstract:
Additive manufacturing of hard metals is gaining attention for its ability to create complex parts and innovative designs. Binder Jetting (BJ) is particularly promising due to its low cost, fast production, and ability to produce stress- and crack-free parts with isotropic properties. The correct binder selection plays a significant role in determining both the green part properties and, especially, the depowdering performance. This study investigates the influence of two different binders (AQUAFUSE and CLEANFUSE-commercial designations) on the properties of hard metal parts manufactured by BJ using commercially available WC-12%Co powder (WOKA 3111FC). The green part properties (green density, green strength), as well as sintered part properties (density, shrinkage, and microstructure), obtained using each binder type, were evaluated and compared. The results suggest that binder selection is a critical factor in optimizing the performance of BJ-manufactured hard metal parts and highlight the potential of CLEANFUSE for applications requiring higher mechanical integrity.
DOI:
https://doi.org/10.59499/EP256767731
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Authors:
Lucia Garcia de la Cruz (Universidad Carlos III de Madrid, Spain) Gabriel Caballero (Universidad Carlos III de Madrid, Spain) José Manuel Torralba (Universidad Carlos III de Madrid; IMDEA Materials Institute, Spain) Robin Kromer (I2M, Université de Bordeaux, Arts et Métiers, CNRS, France) Mónica Campos (Universidad Carlos III de Madrid, Spain)
Abstract:
Powder selection to manufacture metallic materials via Material Extrusion Additive Manufacture (MEX) highly affects the ability to process the designed parts, where criteria such as availability or price, are considered. However, powder properties have a major impact in the stages of MEX. In this study, two 316L stainless steel powders with different granulometry were selected (d50 of 12 and 33 mm with Sw of 3.14 and 5.95 respectively), to assess the influence of particle size and PSD on feedstock performance in g-MEX. Feedstock with 55 (vol.)% solid loading was prepared and characterized through rheological oscillatory testing to analyze the effect of temperature and frequency in its fluid-like behavior. The two feedstocks were then evaluated in terms of extrudability, investigating the ability to extrude continuously and the particle size distribution in the strand. Additionally, debinding and sintering were carried out to evaluate the effect of granulometry on the final part.
DOI:
https://doi.org/10.59499/EP256768017
