Proceedings

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:

Lars Wimbert (GKN Powder Metallurgy, Germany), René Lindenau (GKN Sinter Metals Engineering GmbH, Germany), Kylan McQuaig (Hoeganaes Corporation, USA)

Abstract:

Most mechanical properties of powder metallurgical (PM) components significantly depend on the part’s density. Considering the higher complexity of modern PM parts and the demand for higher strength with less weight, increased green and sintered densities are required. The development of new advanced lubricants is one key factor for this, providing additives with superior lubricity, clean burn-off and unsophisticated usability. This contribution documents recent developments in lubricant technology with experimental results from lab scale to serial production. The presented lubricant solutions allow powder compaction to higher density levels using lower lubricant additions without the need for heated tooling into a tight temperature range. Especially for complex shaped parts, the broader temperature range helps to keep the lubrication sufficient for tool sections with higher friction, resulting in ejection pressures less than 50% of the values seen for amide waxes.

DOI:

https://doi.org/10.59499/WP225371442

Authors:

Francisco Canillas (1), Nerea Ordas (2), Ernesto Urionabarrenetxea (2), Marcelo Roldan (1), Evelin Cardozo (2), Carlos Bloem (3), Edgar Leon-Gutierrez

1- Ciemat, National Fusion Laboratory, Madrid, Spain

2- Ceit-BRTA and Tecnun (Universidad de Navarra), Donostia-San Sebastián, Spain

3- AIDIMME, Paterna, Spain

Abstract:

CuCrZr is a precipitation-hardenable Cu alloy that combines high thermal conductivity and mechanical strength, along with thermal stability up to 350 °C. In this work we demonstrate the feasibility to obtain dense Cu-(0.6-0.9)Cr-(0.07-0.15)Zr (in wt.%) with densities of 99.5%, high thermal conductivity (>80-85% IACS) and enhanced mechanical strength compared to pure Cu, already in the as-built condition, using Powder Bed Fusion Electron Beam (PBF-EB). Further densification was achieved after HIP. Mechanical characterization showed outstanding results, similar or even superior to those reported in the literature for conventional wrought CuCrZr. Microstructural analysis by SEM, EBSD and TEM revealed a multi-scale hierarchical microstructure of ultra-fine Cr-rich precipitates as well as grain and subgrain boundaries, contributing to the excellent mechanical properties achieved. The microstructural stability of the CuCrZr alloy was evaluated by heat treatments in the range of 350 – 550 °C for up to 1080 hours.

DOI:

https://doi.org/10.59499/EP246300683

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:

Jean-Michel Missiaen (Univ. Grenoble Alpes, France), Nicolas Botter (Safran SA, France), Yvan Avenas (Univ. Grenoble Alpes, France), Rabih Khazaka (Safran SA, France)

Abstract:

An assembly for power electronics based on the deposition and pressureless sintering of successive silver layers on an Aluminum Nitride heat sink has been developed. Sintered silver layers act as die attach, current tracks and adhesion layer on the ceramic. This assembly has the advantage to give sintered joints with a high mechanical strength and a high thermal conductivity compared to standard brazing alloys at the highest operating temperature of semiconductor components (200°C). In this paper, aging of the silver tracks and die attach layers is studied. A significant coarsening of the microstructure is observed in confined areas, under the chip and|or far from the external surface, after 200h annealing in air at 200°C, whereas coarsening is essentially inhibited in argon atmosphere. The shear strength and thermal properties of the sintered joint are improved after thermal storage in air. Mechanisms of the microstructural evolution and microstructure-properties relationships are discussed.

DOI:

https://doi.org/10.59499/WP225372071

Authors:

Barbara Rivolta (1), Riccardo Gerosa (1), Davide Panzeri (1), Paolo Veronesi (2)

1- Politecnico di Milano, Department of Mechanical Engineering, Milano, Italy

2- Università degli Studi di Modena e Reggio Emilia, Dipartimento di Ingegneria “Enzo Ferrari”, Modena, Italy

Abstract:

Additive manufacturing is nowadays increasingly adopted to produce a large variety of components, especially with complex geometries. A deep investigation and optimization of the mechanical and corrosion performance of the selective laser melted Alloy 625 is extremely useful to support designers in the transition from the conventional to the additive manufacturing technology. Even though the selective laser melting technique is still associated with too high production costs and low productivity to enable a broader expansion, it permits to obtain excellent mechanical and corrosion properties compared to those of the conventionally manufactured alloy. Despite the additively produced material shows outstanding performance already in the as-built condition, aging treatments permit further strength improvement enabling possibility of reducing thicknesses, mass, resources consumption and environmental emissions. However, the balance between the mechanical and corrosion properties is critical and it requires a careful tuning of the heat treatment parameters.

DOI:

https://doi.org/10.59499/EP246281709

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:

Shweta Singh (Indian Institute of Technology Bombay, India), Ankit Gurjar (Indian Institute of Technology Bombay, India), Eshant Bhatia (Indian Institute of Technology Bombay, India), Ishita Krishnatrey (Indian Institute of Technology Bombay, India), Seema Negi (Indian Institute of Technology Bombay, India), Parag Bhargava (Indian Institute of Technology Bombay, India), Rohit Srivastava (Indian Institute of Technology Bombay, India)

Abstract:

The motivation of this work is to improve fracture toughness and incorporate anti-microbial characteristics in alumina ceramics. In this work, alumina-silver composites are prepared by the addition of 2, 5, 10, and 15 wt. % silver nano-flakes. The microstructural analysis is performed using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). Mechanical properties like flexural strength, fracture toughness, and microhardness are evaluated. Flexural strength is found to decrease with increased silver content while fracture toughness improved significantly. Antibacterial properties are evaluated on E.coli bacteria. All the samples showed antibacterial activity which improved with increased silver content. The present study establishes alumina|silver composite as an antibacterial material with improved fracture toughness which makes it a potential biomaterial for dental and low load-bearing applications.

DOI:

https://doi.org/10.59499/WP225371864