Proceedings

Authors:

Elena Mihalcea (Universidad Autónoma de Zacatecas, Mexico), Didier Bouvard (Université Grenoble Alpes, France), Omar Jimenez (Universidad de Guadalajara, Mexico), Luis Olmos (Universidad Michoacana de San Nicolás de Hidalgo, Mexico)

Abstract:

This works presents the fabrication of a two-layer material composed of a porous Ta core and a dense Ti6Al4V (Ti64) shell by pressing and sintering. It is part of a research project that aims at fabricating multimaterial bone implants that will allow a faster osseointegration. The sintering behavior of two-layer samples is studied by dilatometry. The interface bonding between the Ti64 and Ta layers is analyzed by SEM. Two layers are clearly obtained with a bonding developed by the solid state diffusion of Ta particles into Ti64 during sintering. The mechanical properties of the component are mainly dominated by the porous layer showing a wide pore size distribution, which should contribute to improve the cell and bone growth. The density of such materials is much lower than the one of pure Ta. It is concluded that hybrid materials can improve the response to osseointegration.

DOI:

https://doi.org/10.59499/WP225371363

Authors:

Quentin Charron (CETIM, France), Anna Trump (Desktop Metal, USA), Oriane Baulin (CETIM, France), Jeff Cunningham (Desktop Metal, USA), François Dary (Desktop Metal, USA)

Abstract:

Processing of the AISI 304L Stainless Steel on Desktop Metal’s Binder Jetting Shop System suite (both printer and sintering furnace) has been investigated. This development has been performed in close collaboration between Desktop Metal and Cetim.Several printing and sintering parameters such as green density, sintering atmosphere or sintering temperature were studied and their impact on microstructure and mechanical properties is evaluated and discussed. It has been demonstrated that high green density and nitrogen-based atmosphere are key factors for dense parts and optimal material performance.Final material exhibits mechanical properties compliant with MIM 316L standards (MPIF Std 35 | ISO 22068) and with ASTM A420. It opens several key markets for Metal Binder Jetting, including luxury, energy…

DOI:

https://doi.org/10.59499/WP225371757

Authors:

Tiphaine Giroud (1), Philippe Egea (1), Peter Vikner (2), Solange Vivès (2), Charlotte Mayer (1)

1- Aubert & Duval, Les Ancizes-Comps, France

2- Aubert & Duval, Paris, France

Abstract:

Stellar® InvHard is a Nb-enriched Invar designed for additive manufacturing (Laser Powder Bed Fusion). It will be launched on the market in 2023. Compared to Invar 36, Stellar® InvHard exhibits increased mechanical strength while maintaining a low coefficient of thermal expansion. The hardening of this alloy is inspired by superalloys 706 and 718 strengthened by Ni3Nb-γ'' phase that precipitates in the austenitic matrix; also containing carbides and Nb-rich δ phase. The precipitation of the γ'' phase can be controlled through annealing and aging treatment’s optimization, leading to a hardness in a range: 300-420 HV and the effect on coefficient of thermal expansion increase is limited thanks to the small size of such precipitates. Insights on microstructure and processability will also be presented along to coefficient of thermal expansion.

DOI:

https://doi.org/10.59499/EP235749781

Authors:

Maxime Baudry (CEA Liten, France), Guillaume Savelli (CEA Liten, France)

Abstract:

Nowadays, Additive Manufacturing (AM) has revolutionised current production methods in many areas like aeronautics, military or medicine. Among these methods, Laser Powder Bed Fusion (L-PBF) is prevalent to printing complex metallic parts for small and medium series. Recent studies in L-PBF processing develops the production of new materials via this process, including thermoelectric (TE) materials. This study presents the manufacturing of silicon-germanium alloy by L-PBF, a TE material intended for high temperature applications. It is the first time that this material is manufactured by AM technology. Several dense samples were produced, and a first process window was identified. Structural analyses have been performed, highlighting very good densification but unfortunately mechanical cracking.

DOI:

https://doi.org/10.59499/WP225367605

Authors:

Taiki Yamashita (1); Tomohiro Sato (2); Ken-ichi Saitoh (2); Masanori Takuma (2); Yoshimasa Takahashi (2)

1- Engineering Science Major, Mechanical Engineering, Kansai university, 3-3-35 Yamate-cho, Suita 564-8680, Osaka-fu, Japan

2- Kansai University ,3-3-35 Yamanote-cho ,Suita 564-8680, Osaka-fu, Japan

Abstract:

In the machine parts as sliding members, complex shapes and small-lot production are required. Therefore, manufacturing with Fused Deposition Modeling (FDM) technology using resin materials has attracted attention. However, in this method mechanical properties are inferior to those of metallic materials. In addition, many of the resin materials are petroleum-based resins, and environmental problems are a concern. In this study, it was tried to improve it by mixing polylactic acid (PLA) with MoS2 as solid lubricants. PLA is a material with carbon-neutral properties. In the experiment, we used specimens made by a 3D printer after mixing raw materials and passing through intermediate materials. The stability of the composite is worse than that of PLA alone in friction tests. However, the coefficient of friction was partially low. This is thought to be the result of the function of the properties of MoS2 as a solid lubricant.

DOI:

https://doi.org/10.59499/EP235763571

Authors:

Ella Staufer (1,2), Christian Edtmaier (1), Elisabeth Ballok (1), Jelena Horky (2), Thomas Klein (3), Duyao Zhang (4), Mark Easton (4), Martin Schmitz-Niederau (5)

1- Institute of Chemical Technologies and Analytics, Vienna University of Technology, Austria

2- RHP-Technology GmbH, Austria

3- LKR Light Metals Technologies Ranshofen, Austrian Institute of Technology, Austria

4- Centre for Additive Manufacturing, School of Engineering, RMIT University, Australia

5- Voestalpine Böhler Welding Germany GmbH, Germany

Abstract:

The growing demand for titanium alloys, particularly in the aerospace industry, arises from their remarkable strength-to-weight ratio. However, the commonly used Ti-6Al-4V (Ti64) alloy exhibits columnar grain growth after additive manufacturing, such as powder bed fusion or direct energy deposition, resulting in anisotropic mechanical properties. To overcome this, Ti-Cu-based alloys are introduced for equiaxed grain growth, but their mechanical properties fell short of Ti64. Ternary and quaternary alloying elements (Fe and Cr) are incorporated to enhance mechanical properties. Firstly, several alloys (Ti-6.5Cu-xCr-yFe) produced via powder hot-extrusion exhibit promising microstructure under light microscopy and SEM. Hardness and tensile strength are improved, even exceeding the tensile strength of Ti64. The most promising ones underwent the blown-powder Plasma Metal Deposition process for in-situ alloying, revealing fine microstructures, equiaxed grains, and increased tensile strength. These findings highlight their potential for aerospace applications, presenting isotropic mechanical properties and dense samples.

DOI:

https://doi.org/10.59499/EP246278391

Authors:

Srinivasan Suresh (1), Gillham Joe (1), Marshall M. Jessica (1)

1- University of Warwick, Coventry, United Kingdom

Abstract:

First wall (FW) materials for future fusion reactors have tungsten (W) and ferritic/martensitic steel (FMS) as prime materials. The significant difference in thermo-physical properties of W-FMS joints, specifically, high ductile-brittle transition temperature (DBTT) in W making it brittle at low temperatures and embrittlement due to recrystallization. Cemented tungsten carbide (cWC)-reactive sintered boride (RSB) composites are considered as promising candidate to develop reliable joining technology albeit cWC-RSB to steel joint is challenging. Brazing is a prospective technology; brazing experiments were conducted using Cu-based and FeCr-based interlayers/foils with low-activation elements and high Z-materials. This study compares the effect of brazing compositions, temperature and holding time. The microstructures, mechanical properties, and the strength of brazed joints were investigated using SEM, EDS and EBSD analysis with microhardness and fracture toughness. The results show that cWC-RSB to steel successfully joined by brazing, achieved like W-steel joints and boron in cWC-RSB suppresses the thermo-physical property mismatch.

DOI:

https://doi.org/10.59499/EP246283792

Authors:

Ricardo Mineiro (1), J. Rodrigues (2), C.M. Fernandes (2), D. Figueiredo (2), B. Ferrari (3), A.J. Sanchez-Herencia (3), A.M.R. Senos (1)

1- Department of Materials and Ceramic Engineering, CICECO – Aveiro Materials Institute, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal

2- Palbit S.A., P.O. Box 4, 3854-908 Branca, Albergaria-a-Velha, Portugal

3- Instituto de Cerámica y Vidrio, CSIV, C/ Kelsen 5, 28049, Madrid, Spain

Abstract:

Cubic boron nitride (cBN) is normally used as the hardest phase of composites, together with ceramic and/or metallic matrixes, to form PcBN (Polycrystalline cubic Boron Nitride) materials applied in machining and finishing operations. While high PcBN (70–90 vol% cBN) is only produced by HPHT (High Pressure High Temperature) techniques, low PcBN (40–70 vol% cBN) can also be consolidated by SPS (Spark Plasma Sintering) since higher volume of binders are present. In this work, a cBN micrometer powder is combined with TiCN and Ni to produce composites with hard matrix phases, predicted by the calculated phase diagram. The SPS technique is used for the thermal consolidation of different PcBN compositions with a varied content of Ni, up to 15 vol%. A structural and microstructural characterization of the PcBN composites was performed for different compositions and maximum SPS temperatures.

DOI:

https://doi.org/10.59499/EP235765022

Authors:

Oriane Baulin (CETIM, France), Christophe Reynaud (CETIM, France)

Abstract:

The metallic glasses are knowing an increasing interest for the past decades. They exhibit very exceptional properties; however the main drawback is the limited size of the samples.The MBJ is a promising solution to obtain larger dimensions and high-resolution samples. Using SPS after MBJ process, ensure the production of high density, fully amorphous parts.In this study, a printing recipe has been found to get metallic glass green parts using the HERAEUS powder AMLOY ZR01. After finding that the curing and debinding steps have no influence on the amorphous character of the materials, a pre-sintering recipe in a sintering furnace has been developed. Meanwhile, after finding the parameters of the sintering process on the raw powder using SPS, the printed and pre-sintered parts have been sintered using SPS. The influence of carbon residues on the densification and stability of the materials have been discussed.

DOI:

https://doi.org/10.59499/WP225368716

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:

Melanie Stenzel (1), Bahar Fayyazi (1), Shaumik Lenka (2), Nicholas Sim (2), Thomas Wagstaff (2), Yuji Ishino (2), Pimin Zhang (2), Yining He (2)

1- TANIOBIS GmbH, Goslar, Germany

2- Alloyed, Yarnton, United Kingdom

Abstract:

Many applications among aerospace, defense and energy generation require materials being capable to perform in high temperature environments. Nb-base alloys are becoming particularly interesting if the temperatures exceed ~1050°C as they are outperforming even the most advanced Ni- and Co-base alloys. Notably, conventional production methods for Nb-base alloys are challenging, especially if parts with complex shapes are to be manufactured. The use of powder-based processes e.g. AM or HIP, opens up new opportunities to economically produce complex-shaped parts. However, for these processes the application of suitable high-quality powders is mandatory. In this context, the production of Nb-base alloys as powder feedstock using the electrode induction-melting gas atomization (EIGA) is reported. Powders and additively manufactured parts were investigated by X-ray diffraction, scanning electron microscopy, mechanical tests, and electro-thermal mechanical testing (ETMT). The mechanical performance, i.e., strength of parts processed by laser beam powder bed fusion (PBF-LB) clearly outperforms that of conventionally manufactured parts.

DOI:

https://doi.org/10.59499/EP246278262

Authors:

Aintzane Fayanás (1,2), Nerea Ordás (1,2), Isaac Valls (3), Ernesto Urionabarrenetxea (1,2), Íñigo Iturriza (1,2), Ángela Veiga (1,2)

1- Ceit-Basque Research and Technology Alliance (BRTA), Manuel Lardizabal 15, 20018, Donostia / San Sebastián, España

2- Universidad de Navarra, Tecnun, Manuel Lardizabal 13, 20018, Donostia / San Sebastián, España

3- Rovalma, S.A, Carrer Collita, 08191 Rubí (Barcelona), España

Abstract:

In this work, the feasibility of Powder Metallurgy (PM) routes as processing methods for Nickel-Aluminium Bronze (NAB) alloys have been studied to produce components with good mechanical properties and corrosion resistance for the marine industry. Conventional PM (compaction and sintering) and PM-HIP (Hot Isostatic Pressing of encapsulated powder) have been explored to obtain fully dense NAB from gas atomised powder with Cu-9Al-4.5Ni-4.1Fe-0.9Mn (wt.%) composition. The results show that an adequate selection of raw materials and process parameters lead to fully dense materials with a microstructure similar to that of a NAB alloy produced by conventional production process. Final heat treatments are responsible for further microstructural refinement and dissolution of detrimental brittle phases, like retained martensitic β.

DOI:

https://doi.org/10.59499/EP235768755