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:
Tobias Deckers (Linde GmbH, Germany), Thomas Ammann (Linde GmbH, Germany), Kai Zissel (Linde GmbH, Germany), Franz Wolf (Linde GmbH, Germany), Gerd Witt (University Duisburg-Essen, Germany)
Abstract:
This paper aims to investigate the influence of the process gas atmosphere during the Powder Bed Fusion of Metals using a Laser Beam (PBF-LB|M) of a Nickel-Chromium alloy on the melt pool geometries of single laser tracks and on the discoloration of process by-products. The trials were performed on an EOS M290, which was equipped with a photodiode-based melt pool monitoring system (MPM). First results indicated differences in the intensity levels of the MPM signal and in the penetration depths. Furthermore, a correlation between the discoloration of the sampled powder material and the intensity level of the MPM signal was detected.
DOI:
https://doi.org/10.59499/WP225372132
Authors:
Juan Jiménez (1), Javier Hidalgo (1), Cristina Berges (1), Roberto Campana (2), Gemma Herranz (1)
1- DYPAM Research Group, INEI-ETSII, Universidad de Castilla-La Mancha (UCLM), ETSI Industriale
2- Centro Nacional del Hidrógeno, Prolongación Fernando el Santo s/n, Puertollano, 13500, Ciudad Real, Spain
Abstract:
This study explores innovative approaches to boost the Solid Oxide Fuel Cell (SOFC) interconnector industry, integrating intelligent master alloy design and powder injection molding (PIM). Current challenges in interconnector fabrication via powder metallurgy include the economic high-scale production of complex designs for improved SOFC performance and the restricted availability of commercial powders. To address these limitations, we propose the use of commercial high-Cr master alloys combined with ferrous powders, aiming for compositions equivalent to or surpassing standard Crofer 22. This strategy overcomes powder scarcity challenges and enables precise control over shrinkage and thermal expansion coefficient, crucial for producing ambitious large thin-walled interconnector geometries through PIM. A comprehensive comparative study, covering all PIM stages and properties characterization, is conducted, comparing Crofer 22 pre-alloyed powders with a modified Fe-Cr alloy incorporating additional elements for enhanced performance.
DOI:
https://doi.org/10.59499/EP246282995
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
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Authors:
Dominic Peachey (1), Vivès Solange (2), Yining He (1), Pimin Zhang (1), John Clark (1), Zara Hussain (1), Thomas Wagstaff (1), André Nemeth (1), David Crudden (1)
1- Alloyed Ltd., Oxford, UK
2- Aubert & Duval, Paris, France
Abstract:
The evolution of additive manufacturing (AM) has sparked a growing interest in using nickel-based superalloys, particularly for high-temperature applications above 1000°C. Traditional alloys, intended for casting or wrought processes, face challenges in AM due to the rapid heating/cooling rates and multiple melt cycles, resulting in compromises to material performance or part design freedom. Here we introduce ABD®-1000AM, a novel high gamma prime nickel-based superalloy designed computationally using the Alloys-by-Design (ABD®) approach, tailored for high-temperature AM applications. ABD®-1000AM exhibits world leading performance in terms of both processing capability as-well-as high temperature mechanical and environmental performance at 1000°C. The study discusses the alloy design and development strategy, highlighting the trade-offs in key performance parameters and the intricate process-microstructure-performance optimization undertaken to achieve the alloy's exceptional creep resistance. Based on the insights gained the future direction of alloy development of superalloys for complex AM components is discussed.
DOI:
https://doi.org/10.59499/EP246283346
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Authors:
W. Schoeffmann (1), C. Knollmayr (1), K. Mehrabi (1)
1- AVL List GmbH, Austria
Abstract:
The goal of zero carbon operation of powertrain systems requires compatibility for Ethanol, Methanol and in particular Hydrogen as future energy carriers for internal combustion engines (ICE) as well as Fuel Cell systems. Future AM applications will include complex components in combination with high grade materials, such as high temperature, alcohol and hydrogen resistant steel and nickel alloys, for low and medium volume production. Multi-material AM processes, combining multi-metal manufacturing, are subject of research programs and will support the mobility change by extending the applications to E-Motors, Fuel Cell systems and battery components. Focus of the paper is on the application of metal-AM for prototype and small series of appropriate powertrain components providing material compatibility for CO2 neutral fuels. The motivation for the conversion from conventional to additive manufacturing is discussed in regard of functional optimization with AM-process related production design, as well as economically to achieve higher profitability.
DOI:
https://doi.org/10.59499/EP246281384
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Authors:
Rafael Cury (Plansee Tungsten Alloys, France), Pascal Mahot (Plansee Tungsten Alloys, France), Heinrich Kestler (Plansee, Austria)
Abstract:
Amour Piercing fin-stabilized discarding sabot is a type of a non-explosive kinetic energy penetrator ammunition used on anti-tank weapons. It requires material showing remarkable characteristics such as high density, high mechanical and impact resistance in order to provide the best penetration possible against targets. Tungsten Heavy Alloys are commonly used for this type of penetrators. Recently, with the increasing interest on Tungsten Heavy Alloy additive manufactured parts, it became mandatory to investigate the influence of this process on material properties. Thus, additive manufacturing was used to obtain bars, which were submitted to solid-liquid sintering under hydrogen and processed under vacuum to avoid embrittlement. These alloys were fully characterized with respect to their microstructure and mechanical characteristics. Results shown that additive manufacturing is a viable process for this type of alloys.
DOI:
https://doi.org/10.59499/WP225371922
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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
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Authors:
Sebastian Riecker (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Germany), Robert Teuber (Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Branch Lab Dresden, Germany), Anne Mannschatz (Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Germany), Bernhard Müller (Fraunhofer Institute for Machine Tools and Forming Technology, Germany)
Abstract:
Pseudoelastic behavior with elastic strains of up to 8 % and the shape memory effect are well-known features of nickel-titanium alloys (Nitinol). These properties are highly interesting for the fabrication of e.g. functional auxetic and programmable structures as well as for solid state joints and compliant mechanisms. To extend the current range of available geometries and to enable near-term fabrication of customized complex devices, sinter-based additive manufacturing (AM) of NiTi components via Fused Filament Fabrication (FFF) has been investigated. For this purpose, a highly filled thermoplastic filament (63 vol.-% powder) has been developed which could be printed to complex geometries using standard FFF printers. The AM post-processing steps of debinding and sintering were aiming for extraction of O, C and N to achieve the desired properties. Green state machining experiments resulted in high part quality and low surface roughness of Ra <5 µm.
DOI:
https://doi.org/10.59499/WP225371432
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Authors:
Saeed Khademzadeh (Chalmers University of technology, Sweden), Yijun Zhou (Uppsala University, Sweden)
Abstract:
Additive Manufacturing of non-assembly metallic mechanisms is highly desirable because of their potentially higher performance and low costs due to enhanced structural features and the reduced need for labour-intensive procedures. However, fabrication of such mechanisms using metal AM techniques faces many challenges. For instance, down-skin inclined surfaces suffer from an insufficient quality due to the staircase effect and partially melted attached powder particles that may deteriorate the function of the mechanism since residuary stuck material can block the clearance space. In this work, a novel scanning strategy was employed for the fabrication of non-assembly functional micromechanisms. A threshold angle was defined for activation of a new set of process parameters for down-skin surfaces. Non-assembly ball joints were additively manufactured using laser powder bed fusion technology. The effects of threshold angle, overlap between in-skin and down-skin surfaces, and input energy on the functionality of non-assembly joints was investigated using micro-computed tomography
DOI:
https://doi.org/10.59499/WP225371467
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Authors:
Kay Reuter (Fraunhofer IFAM Dresden, Germany), Inge Lindemann-Geipel (Fraunhofer IFAM Dresden, Germany), Thomas Studnitzky (Fraunhofer IFAM Dresden, Germany), Olaf Andersen (Fraunhofer IFAM Dresden, Germany), Thomas Weißgärber (Fraunhofer IFAM Dresden, Germany), Raphael Koch (Ford Werke GmbH, Germany)
Abstract:
Energy-efficient electric motors are crucial for the progress of electromobility. Soft magnetic materials with a high silicon content, such as Fe6.5Si, offer the possibility of high electrical resistance, high saturation magnetization and comparatively low power losses. However, due to the brittleness of Fe6.5Si, this material cannot be processed using conventional manufacturing methods (such as stamping). By means of 3D screen printing process, this material can be processed through a powder metallurgical processing route. Thus, electric steel sheets with low thickness, high alloying content and high productivity can be realized. We present results of printed and sintered Fe6,5Si electric steel sheets with thicknesses between 100 and 350 µm. The power loss can be reduced below 35 W kg-1 at 1000 Hz and 1 T. The magnetic properties of the sheets will be discussed in dependence on the sintering parameters and the powder properties.
DOI:
https://doi.org/10.59499/WP225371624
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Authors:
Didier Fonta (Pollen AM, France), Thibaud Deshons (Pollen AM, France)
Abstract:
Characterization of metal 3D printed parts produced by direct MIM feedstock extrusion.
DOI:
https://doi.org/10.59499/WP225371995
