Proceedings

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

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:

Matteo Zanon (Kymera International | Ecka Granules Germany GmbH, Germany), Darek Kossakowski (Kymera International | Ecka Granules Germany GmbH, Germany)

Abstract:

As an alternative to pure cobalt, "prealloyed" powders have by now firmly established themeselves as metallic matrixes in the diamond cutting tools industry. While technically high performing, they must rely on an elaborated production process and face increasing supply chain pressure with regard to cobalt. Moreover, the low compressibility implies high green-to-sinter dimensional change, thus compromising the achievable dimensional precision via free sintering. A new family of cobalt-free premixed materials for diamond cutting tools was developed to fill such gaps. Pressing and sintering results will be presented for several grades; their interaction with syntethic diamonds and their degree of metallurgical bonding was studied as well.

DOI:

https://doi.org/10.59499/WP225371523

Authors:

Ivan Lorenzon (1), Mirko Nassuato (1), Alberto Prete (1), Giorgia Leto (1), Francesco Bortolotti (1)

1- Pometon SpA, Venice, Italy

Abstract:

In the heart of the EV but also of electronic components, copper is used throughout because of its high electrical conductivity, durability and malleability. EV use more than double the copper of an internal combustion engine automobile and it is also used heavily in EV-infrastructure like charging stations and in electrical grid infrastructure. Sintered Copper components could be cornerstone not only for the Powder Metallurgy future in automotive applications but also for the EV revolution. Pometon, by the experience on production of ECP and WA copper, is developing some ready to press products to meet the needs of the classical sintering production process for the fabrication of copper components. This study shows the developing a high purity and highly densifying copper powder given fundamental guidelines to facilitate the classical sintering to obtain the chemical, physical and mechanical characteristics needed for E-automotive and electronic applications.

DOI:

https://doi.org/10.59499/EP235762996

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:

Takuya Hazama (Sumitomo Electric Sintered Alloy, Ltd., Japan), Jumpei Hara (PT. Sumiden Sintered Components Indonesia, Indonesia), Yu Akiyama (Sumitomo Electric Sintered Alloy, Ltd., Japan), Masato Uozumi (Sumitomo Electric Sintered Alloy, Ltd., Japan), Kazuhiko Suganaga (Sumitomo Electric Sintered Alloy, Ltd., Japan)

Abstract:

The use of sinter hardening material (SH material) was examined for the purpose of cost reduction by simplifying the part manufacturing process in our company, in response to the fact that many 4WD coupling cam parts adopt a sintering method that allows the cam shape to be formed with a net shape. The SH material has high hardenability, however it is not applicable for parts that require bending fatigue strength due to its low toughness. Accordingly, bending fatigue strength was improved and the required strength of the parts was successfully satisfied by achieving a mixed phase structure of martensite and austenite due to the addition of Ni to SH material.

DOI:

https://doi.org/10.59499/WP225371870

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:

Chris Schade (Hoeganaes Corporation, USA), Corina Junghetu (Hoeganaes Europe, Romania), Tom Murphy (Hoeganaes Corporation, USA)

Abstract:

In general, hard materials for tooling and wear resistant applications are very difficult to machine with the most common forming method being grinding. Utlizing a grinding operation severly limits the shape of the final product which can be acheived. Additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), alloys for intricate shapes to be formed form most all alloy materials. However due to their brittle nature many of the materials with high hardness tend to crack in the LPBF process. This paper highlights the mechanical properties and microstructure of a family of wear resistance alloys that can be used in LBPF for a range of applications (from alloy steels to stainless steel). In addition to mechanical properties, case studies of the materials in real-life applications are presented and the wear mechanisms are reviewed and compared to their machined counter parts.

DOI:

https://doi.org/10.59499/WP225371811

Authors:

Christophe Reynaud (CETIM, France), Oriane Baulin (CETIM, France), Xavier Boulnat (Université de Lyon, INSA Lyon, MATEIS UMR CNRS 5510, France), Bastien Reinwalt (CETIM, France)

Abstract:

Cetim has launched further material project development on binder technologies. This work deals with the development of the tool steel X40CrMoV5-1 or H13 on two Metal Binder Jetting technologies, namely DM P2500 (Digital Metal) and Lab P-1 (Desktop Metal). The whole MBJ H13 has been developed by adjusting the 17-4PH powder printing parameters and by developing a specific sintering recipe by using a vacuum metallic furnace under controlled atmosphere (one step debinding sintering). The presentation will be focused on sintering development. Controlling the final carbon content and achieving high density level without excessive component distortion by using SLPS process are the main challenges to overcome. The microstructure and the mechanical properties are compared. For both technologies, as sintered mechanical properties are consistent with data coming from MIM H13 materials and wrought materials.

DOI:

https://doi.org/10.59499/WP225371745

Authors:

Markus Weinmann (1), Melanie Stenzel (1), Jan Johannsen (2), Christian Lauhoff (3), Thomas Niendorf (3)

1- TANIOBIS GmbH, Goslar, Germany

2- Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT, Hamburg, Germany

3- University of Kassel, Institute of Materials Engineering, Kassel, Germany

Abstract:

The development of spherical Ti/Nb/Ta alloy powders with compositions Ti-xNb-6Ta (x = 20, 27, 35 wt%) by electrode induction melting gas atomization (EIGA) and their processing by laser beam powder bed fusion (PBF-LB/M) are reported. Microstructure investigations by X-ray diffraction and scanning electron microscopy including energy dispersive X-ray spectroscopy and electron backscatter diffraction reveal a significant impact of the composition on the structural properties, i.e., phase evolution and texture, and the possibility for a direct microstructure design. Ti-rich alloys preferably solidify in the orthorhombic α’’-phase, whereas in Nb/Ta-rich alloys the body-centered cubic (bcc) β-phase is observed. The alloys possess a very broad processing window and can be printed to full density over a wide range of printing parameters. Additively manufactured Ti-27Nb-6Ta shows a unique behavior, since strength and elongation at failure strongly depend on the printing parameters applied. The underlying microstructural mechanisms, i.e., the influence of the laser energy on texture effects and phase formation, are discussed.

DOI:

https://doi.org/10.59499/EP246268362

Authors:

Mariana Rossi (1), Pedro Kuroda (1), Vicente Amigó (2), Conrado Afonso (1)

1- Materials Engineering Department (DEMa), Universidade Federal de São Carlos (UFSCar), 13.565-905, São Carlos, SP, Brazil

2- Universitat Politècnica de València, Institut de Tecnologia de Materials, Camí de Vera S/n, València, 46022, Spain

Abstract:

Ti and its alloys with a titanium oxide (TiO2) nanotubes (NTs) surface have received attention in the biomedical field to enhanced biocompatibility by the nanostructured surface. The aim of this study was to investigate the structural and morphological properties of the formation and crystallization of TiO2 NTs on different Ti substrates (c.p-Ti, Ti-15Nb, Ti-40Nb and Ti-35Nb-6Sn alloys). The crystallization of NTs was analyzed by XRD as a function of annealing temperature. The morphology was characterized using FE-SEM equipment and the roughness was evaluated using confocal microscopy. For the c.p-Ti was identified only the presence of rutile oxide and for another ones the mixture of anatase and rutile. The diameter of the NTs was different depends on the substrate and can be represented as: c.p-Ti≈Ti-40Nb >Ti-15Nb≈Ti-34Nb-6Sn. As the same way, the roughness surface increase after annealing treatment and can be represented as: c.p-Ti>Ti-40Nb>Ti-34Nb-6Sn≈Ti-15Nb.

DOI:

https://doi.org/10.59499/EP235735526