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Authors:

Mikael Luoto (1), Dr. Enrico Daenicke (2), Ralf Müller (2), Dr. Thomas Hartwig (1)

1- Fraunhofer IFAM, Bremen

2- Rolls-Royce Deutschland Ltd. & Co.KG, Germany

Abstract:

Although Metal Injection Moulding (MIM) is a process for parts with complex designs, not all geometries are feasible. The goal of the project was to find a way to bond individually moulded parts before the sintering step and to assess the quality of the achieved sinter joining. Material Inconel 713 Low Carbon was selected for this study. The bonding of the parts was realized by applying adhesive pastes on the parts after solvent extraction. The mechanical properties of sinter joined parts were assessed by using tensile, fatigue (low cycle) and creep (stress rupture) tests. The tensile test showed that the proof stress and ultimate tensile strength were comparable to unjoined baseline material, but a drop in elongation was observed. The creep properties were similar to unjoined baseline material, but a decrease of fatigue properties was measured. A “housing” geometry that is not producible using the conventional MIM-process was manufactured as a demonstrator and it showed that it is plausible that sinter joining could be used for serial production.

DOI:

https://doi.org/10.59499/EP246278323

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:

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

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

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

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