Proceedings

Authors:

Hosam ElRakayby, KiTae Kim

Abstract:

Hot isostatic pressing is a near-net-shape manufacturing process that usually uses a metal container to encapsulate powders then consolidate them to fully dense compacts. Metal containers induce the Mises stress to powder compacts due to the rigidity of the container walls. Thus, anisotropic deformation of powder compacts. This paper investigates the effect of glass container encapsulation on densification and deformation behaviors of 316L stainless steel powder during hot isostatic pressing. Finite element results were compared with measured deformed shape of powder compact after hot isostatic pressing to study the capabilities of glass containers to form near-netshape parts. Glass container showed more homogeneous densification and isotropic deformation of compacts than conventional metal containers.

DOI:

https://doi.org/10.59499/EPgfhgsd

Authors:

Alessandra Martucci (1), Giulio Marchese (1,2), Alberta Aversa (1,2), Diego Manfredi (1,2), Sara Biamino (1,2), Daniele Ugues (1,2), Federica Bondioli (1,2), Massimo Messori (1,2), Mariangela Lombardi (1,2), Paolo Fino (1,2)

1- Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy

2- Consorzio Interuniversitario Nazionale per la Scienza e Tecnologia dei Materiali (INSTM), Via G. Giusti 9, 50121 Firenze, Italy

Abstract:

The Powder Bed Fusion-Laser Beam is a promising additive-manufacturing process that allows the production of complex-shaped functional components for many applications. However, the layer-by-layer scanning and high cooling rates result in a high thermal gradient (ΔT) and, thus, in thermally induced stresses that could lead to undesirable cracking and delamination phenomena in the final component. A strategy to reduce the ΔT and facilitate a correct heat flow is using support structures. However, the support geometry needs to be optimised, considering that the thermal resistance increases as the support-height increases and the contact cross-section decreases. Furthermore, it is essential to consider the anchoring function of the support structures. Based on these considerations, two geometric indices and a decision support matrix were developed in the present work for a quick and efficient setting of geometric parameters. The robustness of the developed approach was verified on two different alloys: AlSi10Mg and IN625.

DOI:

https://doi.org/10.59499/EP235725900

Authors:

Ramin Rahmani (1,2), Javad Karimi (3), Farideh Davoodi (4), João C.C. Abrantes (2), Pedro R. Resende (2), Sérgio I. Lopes (1)

1- CiTin—Centro de Interface Tecnológico Industrial, 4970-786 Arcos de Valdevez, Portugal

2- proMetheus—Instituto Politécnico de Viana do Castelo (IPVC), 4900-347 Viana do Castelo, Portugal

3- BIAS—Bremer Institut für Angewandte Strahltechnik GmbH, Klagenfurter Straße 5, 28359 Bremen, Germany

4- DMMM—Department of Mechanics, Mathematics and Management, Politecnico di Bari, V.Ie Japigia 182, 70126 Bari, Italy

Abstract:

The industry 5.0 revolution prioritizes digital transformation and automation, while also focusing on improving human-machine interface (HMI), improving production and reducing work-related injuries. On the other hand, to tackle the challenge of designing lightweight and complicated structures, new high-tech materials have been developed using combined additive manufacturing (AM) and powder metallurgy (PM) techniques. The futuristic subsections of additive manufacturing (AM) produce composite materials that incorporate both metallic and ceramic components, suitable for a range of applications from art to industrial use. This brief overview examines the key features of the fifth industrial revolution, with particular attention to the selective laser melting (SLM) process. Two specific areas of study include the exploration of an antiviral metal-ceramic composite and also reflective metal fabrication using integrated AM-PM technologies.

DOI:

https://doi.org/10.59499/EP235742275

Authors:

Esma Mese (1), Haneen Daoud (1), Wolfgang Hofmann (2), Peter Würtele (2), Uwe Glatzel (1)

1- Neue Materialien Bayreuth, Germany

2- Peter Würtele GmbH, Germany

Abstract:

The nickel-based superalloy (MAR-M247) is a non-weldable alloy with attractive high-temperature properties. However, it has not been possible to print components using classic additive manufacturing processes. Sinter-based processes enable the production of difficult and non-weldable alloys. But cracking and porosity in printed components is high. Therefore, in this study, highly filled metal filaments of MAR-M247 were used to print specimens using fused filament fabrication (FFF). The microstructure and weight change were analyzed after printing, debinding and sintering by optical and scanning electron microscopy and EDX. The high temperature tensile tests for sintered samples are presented.

DOI:

https://doi.org/10.59499/EP235735787

Authors:

T. Lindroos (1), J. Pippuri-Mäkeläinen (1), T. Kinos (1), A. Antikainen (1), T. Riipinen (1), S. Metsä-Kortelainen (1), A. Manninen (1), A. Bertinetti (2), J. O. Odden (3)

1- VTT Technical Research Centre of Finland Ltd., P.O. Box 1000, FI-02044 VTT, Finland

2- Gemmate Technologies s.r.l. - CCIAA Torino REA TO-1189884, Italy

3- Elkem Silicon Product Development AS, Norway

Abstract:

Green electrification is vital for the society’s decarbonization. This sets a strong pressure on manufacturers of electric machines to produce items of higher efficiency and, simultaneously, prepare oneself for forecasted supply risks of raw materials. Additive Manufacturing (AM) is seen as enabler to produce components for novel electric machine architectures with designs and performance unattainable with conventional manufacturing. In this study, a permanent magnet (PM) assisted synchronous reluctance motor based on laser powder bed fusion (L-PBF) AM is introduced. Production of soft magnetic powder tailored for L-PBF and optimization of process parameters and further post treatments to achieve good magnetic properties are shown. Characterized magnetic properties are used as input values for motor design where both performance and possibilities of L-PBF are used as design criteria. Permanent Magnet electric motor of the e-scoot is used as reference. The results show that optimized architectures provide high performance with lower PM content.

DOI:

https://doi.org/10.59499/EP235763996

Authors:

Canto Estany Diana (1), Saula Miquel (1), Sole Macia (1), Puigardeu Aramendia Sergi (1)

1-HP Printing & Computing Solutions, Spain

Abstract:

Ensure test reproducibility and device process repeatability is a must when optimizing or performing a design of experiments on a manufacturing operation. 3D printing additive manufacturing low level subsystem information can be collected and used to trigger investigations on printed parts properties or understand which are the main contributors for a specific one. On 3D HP Binder Jetting printing devices this information is published and can be accessed through an application programming interface (API) or using the HP digital production suite.

DOI:

https://doi.org/10.59499/EP246280947

Authors:

Ahad Mohammadzdeh (1, 2), Alessandro De Nardi (1, 3), Faraz Omidbakhsh (4), Amir Mostafaei (5), Jose Manuel Torralba (1, 3)

1- Imdea Materials Institute, Calle Eric Kandel, 2, 28906, Getafe, Madrid, Spain

2- Department of Materials Engineering, Faculty of Engineering, University of Maragheh, Maragheh, P.O. Box 83111-55181, Iran

3- Universidad Carlos III de Madrid, Av. De la Universidad 30, 28911, Leganés, Spain

4- Department of Mechanical Engineering, College of Engineering, Islamic Azad University, Tabriz Branch, Tabriz, Iran

5- Department of Mechanical, Materials and Aerospace Engineering, Illinois Institute of Technology, 10 W 32nd Street, Chicago, IL, 60616, USA

Abstract:

A novel CoNi-based high entropy superalloy has been developed for fusion-based additive manufacturing processes based on configurational entropy and high entropy alloy principles. A multi-component compound with the chemical composition of Co-35Ni-8Al-4Ti-4V-2W-2Ta-9Cr was prepared via gas atomization. A comprehensive study was conducted to establish a process-structure relationship in laser powder bed fusion processed CoNi superalloy powder. The effect of processing parameters, including laser power and scan speed, on part characteristics was studied using the Design of Experiment approach based on the response surface methodology. Numerical models validated by experimentation were used to develop a process window to attain parts with a relative density of >99.9%. Advanced electron microscopy incorporated with phase analysis was used to observe grain structure and defects (i.e., pores, microcracks) and phase evolution. It was concluded that thermodynamic predictions were in good agreement with microstructure analysis to attain a single-phase fcc solid solution in the powder and as-built coupons.

DOI:

https://doi.org/10.59499/EP235764983

Authors:

D. A. Sandoval (1), L. Larrimbe (1), O. Lavigne (1), V. Girman (2,3), R. Sedlak (2), V. Luzin (4), M. Serra (5), M. T. Méndez (6)

1- Hyperion Materials & Technologies, Spain

2- Institute of Materials Research, Slovak Academy of Sciences, Slovak Republic

3- Institute of Physics, P.J. Safarik University, Slovak Republic

4- Australian Nuclear Science & Technology Organisation, Australia

5- Politecnical University of Catalunya, Spain

6- BRC Global Rolls Ltd., Singapore

Abstract:

Cemented carbide samples with 12 wt.% of binder content and fine and coarse WC grain size are sintered in two different cycles (SC1 and SC2). After assessing the mechanical properties, it is found that sintering conditions affect the hardness-toughness trade-off relationship found in hardmetals. To understand the effect of temperature, materials are deeply characterized by neutron diffraction and transmission electron microscopy (TEM). No substantial difference is observed in the average stress state between fine-grained samples sintered in both conditions. TEM observations reveal same dislocation density for finer specimens, independently on sintering temperature. Nevertheless, further investigation in coarser material discloses that intrinsic plasticity changes when sintering at higher temperatures, showing a greater dislocation density and the presence of stacking faults within WC grains.

DOI:

https://doi.org/10.59499/EP246277229

Authors:

Ernesto Urionabarrenetxea (1,2), Alejo Avello (1,2), José Manuel Martín (1,2)

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

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

Abstract:

Efficient simulation of close-coupled gas atomisation can nowadays be used to improve machine designs and to gain understanding of the complex phenomena taking place in the atomisation process. Two-stage multiphase models can predict particle size distributions by using an Eulerian approach for the primary atomisation and Lagrangian particle tracking for the secondary atomisation. Previous numerical results confirm that these models correctly predict trends of median particle size for varying gas-to-melt mass flow rate ratios, although significant differences between predicted and measured particle size distribution spreads indicate that models need to be improved. In this work, different coupling hypotheses between the primary and secondary atomisation stages are addressed to optimize the model’s capacity to predict the entire particle size distribution. By comparing experimental results with simulations obtained with varying surfaces of particle injections and corresponding boundary conditions, an improved model with better predictive capacity has been obtained.

DOI:

https://doi.org/10.59499/EP235779996

Authors:

Ribeiro, Bernardo L.(1,2); Santos, Rúben F. (1,2,3); Barbosa, Maria (2); Sequeiros, Elsa W.(1,2)

1- LAETA/INEGI - Institute of Science and Innovation in Mechanical and Industrial Engineering, Portugal

2- Departamento de Engenharia Metalúrgica e de Materiais da Faculdade de Engenharia da Universidade do Porto, Portugal

3- CCF – Centro de Competências Ferroviário, Portugal

Abstract:

In recent years, High Entropy Refractory Alloys (RHEAs) have been presented as possible alternatives to the state-of-art Ni-based superalloys, due to an outstanding combination of properties under high-temperature service conditions. The MoNbTaW system has been particularly explored due to its considerable high yield strength at temperatures around 1200 °C. Yet, these alloys present a brittle behaviour at room temperature, narrowing their applications. To improve the MoNbTaW properties, in-situ alloying with additions of Vanadium (V) by Direct Energy Deposition (DED) assisted by thermodynamical simulations (CALPHAD) has been explored to accelerate the screening of promising compositions. In this contribution, we present the room temperature microstructural and mechanical characterisation to evaluate the influence of V on the MoNbTaW system.

DOI:

https://doi.org/10.59499/EP235765551

Authors:

Hans-Wolfgang Seeliger (1), Tillmann R. Neu (2), Paul H. Kamm (2), Francisco García-Moreno(2)

1- Gränges Powder Metallurgy GmbH, Germany

2- Institute for Applied Materials, Helmholtz Zentrum Berlin for Materials and Energy, Germany

Abstract:

For the purpose of the application for an on-tank valve, various Al alloy series were produced and tested, to which different contents of up to 0.3 wt% Sc and Zr were added. The hardening curves were plotted for different temperatures and correlated with the corresponding mechanical tests. The alloys were characterized by hardness measurements, tensile tests. By characterizing the materials, transferring them to simulation models and developing design guidelines, the foundations are laid for technology transfer to other applications of these materials. In order to produce these new materials, the Spray Forming process was used on the systems of the Gränges Powder Metallurgy company. This has the advantage that both the metal powder and the solid material for the forged part can be produced in one manufacturing step.

DOI:

https://doi.org/10.59499/EP246278515

Authors:

Louis Becker (1), Felix Radtke (2), Jonathan Lentz (1), Simone Herzog (2), Christoph Broeckmann (2), Sebastian Weber (1)

1- Chair of Materials Technology (LWT), Bochum, Germany

2- Institute of Applied Powder Metallurgy and Ceramics (IAPK), Aachen, Germany

Abstract:

Laser Powder Bed Fusion/Metal (PBF-LB/M) shows great promise for industrial applications, but its extended production time remains a challenge. To address this, innovative methods such as the shell-core approach have been developed. In this procedure, a component is created with a dense outer shell surrounding a core of either unexposed or minimally exposed powder, drastically reducing processing time. Full densification and specific property adjustment are achieved by subsequent hot isostatic pressing (HIP). This study demonstrates the use of shell-core specimens made from a powder blend of austenitic stainless steel and Si3N4 to produce high-nitrogen steel components that are otherwise difficult to produce due to limited nitrogen solubility in the steel melt. During HIP, Si3N4 dissolves into the austenitic matrix, enriching it with nitrogen and circumventing solubility issues. This results in a material with increased strength and potentially improved corrosion resistance due to the beneficial impact of nitrogen on steel properties.

DOI:

https://doi.org/10.59499/EP246252913