World PM2022 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:

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:

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:

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:

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:

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:

Shuigen Huang (KU Leuven, Belgium), Eric Wong (KU Leuven, Belgium), Jun Qian (KU Leuven, Belgium), Jozef Vleugels (KU Leuven, Belgium)

Abstract:

Direct Ink Writing (DIW), also known as robocasting, is a paste extrusion-based layer-by-layer additive manufacturing technique suitable for manufacturing complex geometry green compacts. In this study, NbC-Ni matrix cermets with either a porous scaffold structure or a pore-free rectangular bar geometry were prepared using a combination of DIW and sintering. The water based feedstock ink contained 40 vol% cermet powder mixture and 25 wt% pluronic F-127 hydrogel. The ink was rheologically characterized and printed using a DIW device. Thermogravimetric analysis (TGA) of the paste was performed to define the thermal debinding cycle. After debinding, the printed parts were sintered for 90 min at 1420 °C in vacuum. The microstructure and room temperature hardness of the printed parts were investigated and compared with cermets obtained by conventional press and sinter powder metallurgy.

DOI:

https://doi.org/10.59499/WP225368559

Authors:

Iain Berment-Parr (The Manufacturing Technology Centre Ltd., United Kingdom), Owen Larkin (The Manufacturing Technology Centre Ltd., United Kingdom), Kieran Bullivant (The Manufacturing Technology Centre Ltd., United Kingdom), Simon J Graham (The University of Sheffield, United Kingdom), Ahmad El-Kharouf (The University of Birmingham, United Kingdom)

Abstract:

Net shape powder consolidation is often perceived to be a slow and costly manufacturing method, unsuitable for high throughput batch production of intricate components. This work seeks to challenge that perception by introducing the use of dissolvable space holding inserts that impart an impression into densifying powders. When used under appropriate conditions, these enable simple cylindrical HIP canisters and FAST dies to be used to process complex geometry components and porous structures. Feasibility trials have evaluated the use of water soluble table salt (NaCl) in various forms, combining it with sustainable titanium powders obtained through low energy processing. High integrity titanium samples have been densified, and then extracted by dissolving the salt in water. Fabrication of an innovative hydrogen electrolyser bipolar plate has showcased the industrial potential of this manufacturing method. An embodied carbon analysis has also highlighted significant circular economy advantages compared to traditional energy intensive titanium supply chains.

DOI:

https://doi.org/10.59499/WP225367167

Authors:

Elias Ganthaler (Free University of Bozen, Italy), Hoomaan MoradiMaryamnegari (Free University of Bozen, Italy)

Abstract:

The manufacturing process of sintered components requires the compaction of metal powder in a rigid die, performed for example by a hydraulic powder press. This paper presents a novel, fully coupled model combining a physical hydraulic system model and a Finite-Element-based (FE-based) compaction model to simulate a full press cycle of a powder compaction press. The first model calculates the piston's position by modelling the hydraulic circuit including the valves, hoses, and double-acting cylinders as well as the low-level controller. The piston positions are then passed as input to an FE-based software that implements an adapted multi-surface constitutive model for granular media. This allows to investigate the influence of different trajectories and controllers. In contrast to literature, the fully coupled model allows the simulation of the whole press-cycle instead of the compaction phase alone.

DOI:

https://doi.org/10.59499/WP225371405

Authors:

Vladimir Ivannikov (Helmholtz-Zentrum Hereon, Germany), Fritz Thomsen (Flensburg University of Applied Sciences, Germany), Regine Willumeit-Römer (Helmholtz-Zentrum Hereon, Germany)

Abstract:

A novel discrete element method based approach for modeling of the early stage solid state sintering of metallic powders is proposed. It couples the mass transport driven evolution of geometry of individual contact pairs of spherical particles and their mechanical interaction in a 2-step staggered numerical scheme. At a given time, for each pair of contacting particles a system of mass transport equations is solved to update the parameters describing its local geometry. The changes in the distances between the centers of the particles are converted into the corresponding sintering forces. These are then applied as external loads to a DEM discretization of a compound. The developed approach was used to simulate sintering of packings with several thousands of particles. The numerically predicted neck growth and shrinkage rates agree well with the experimental data obtained for titanium powders for different sintering temperatures.

DOI:

https://doi.org/10.59499/WP225368028