P&S SIS: Challenges and Advantages of Uniaxially Pressed Parts
Session 5 – Monday 30 September – Time: 14:00 – 15:30
Chairs:
Dr Caroline Larsson (Höganäs AB, Sweden)
Dr Cèsar Molins (AMES SA, Spain)
Presentations:
Time 14:00 – 14:30
Author Bio: Born in Remscheid, dtuy of mechanical engineering and safety engineering at the university of Wuppertal, PHD thesis in low cycle fatigue and fracture, working as global director R&D at GKN, former focus was reliability, fatigue and fracture, current topic: sintered hard magnets.
Abstract: Hydrogen-induced cracking in materials such as high-strength steels, bolts, and springs is a widely recognized and extensively researched phenomenon. Stress corrosion cracking is a unique type of damage caused by hydrogen, in which corrosion can cause the absorption of hydrogen into parts, leading to the formation of cracks and potential failure. However, this damage mechanism is unknown or has not been recognized as such in sintered components. There are no mentions of this damage mechanism in the conference proceedings of the powder metallurgy associations FPM (Germany), EPMA (Europe), and MPIF (USA) in recent years. The susceptibility of selected materials is investigated by constant load testing. The samples are exposed to a medium that triggers corrosion during these tests. Hydrogen content measurements are performed in this context so that critical load-hydrogen combinations can be derived from these tests.
Time 14:30 – 15:00
Author Bio: Industrial Engineer, Energy Engineer, Nuclear Engineer. CEO of a sintered metal parts manufacturer with plants in Spain, USA, Hungary and China. Metallurgical engineering. Member and past vice-President of Barcelona Chamber of Commerce Industry Commission Member of several Boards of Directors and advisory Councils: EADA Business School Barcelona, UPF University Social Council, IMDEA Madrid Industrial Advisory Board, CIMNE Tecnologia Advisory Board. Vice-President and past President of EPMA European Powder Metallurgy Association. Developed international cooperation programs between the main world’s PM associations: MPIF, EPMA, JPMA, APMA, PMAI. Member of Board of SERNAUTO Spain’s Association of Automobile Components Manufacturers. Advisory Council of PIMEC Employers’ Association. Past Member of CAREC economic advisory Council to the President of Catalonia.
Abstract: As the consumers of PM parts demand ever tighter tolerances and a total absence of defects, so the importance of non-destructive testing techniques to the parts producers becomes ever greater. Furthermore, the need to maximize the speed and reliability of these techniques becomes more vital in order that they should not cause bottlenecks in the production and delivery of defect-free parts.
This presentation looks at a number of different NDT methods, and considers a few of the ways in which they can be made more efficient, including automation and the application of machine-learning.
Time 15:00 – 15:30
Author Bio: Engineering and product development in the segment of electric machines since 2004
Abstract: Soft Magnetic Composite (SMC) gives new possibilities in the design of electric motors. This article deals with the benefits of using SMC for 3D-flux-concentration on the tooth-tip in Axial Flux Motors (AFM). There are several aspects for maximizing the airgap area compared to the available space for the whole motor. One is the influence on the inductance, an other one is to have more permanent magnetic material for maximizing the coupled flux with the windings and furthermore there is the possibility to enhance the efficiency of the machine. Additionally in this article one possible mechanical design for serial-production of such an motor is shown.
HIP SIS: PM-HIP and Near Net Shape
Session 7 – Monday 30 September – Time: 14:00 – 15:30
Chairs:
Dr Ing Anke Kaletsch (RWTH Aachen University, Germany)
Mr Jim Shipley (Quintus Technologies AB, Sweden)
Presentations:
Time 14:00 – 14:30
Author Bio:
Abstract: Beam intercepting devices are typically designed to absorb significant thermal power deposited by the particle beam. In many instances, due to various considerations, the heat deposited within a component is dissipated by cooling another material that is in direct contact with the initial part. The effectiveness of this cooling relies on minimising the thermal resistance at the interface.
It has been observed that diffusion bonding minimises (and in some cases eliminates) the thermal resistance at the interface and additionally establishes a clean (ultra-high vacuum compatible) and mechanically robust junction between two components. This ensures reliable and efficient operation over time, even under demanding environment typically found in beam particle accelerators (such as UHV, radiation, thermal/mechanical fatigue, etc).
In the last decade, CERN has studied, tested and implemented diffusion bonding techniques by means of Hot Isostatic Pressing (HIP) on operational devices.
Specifically, components made of CuCr1Zr with embedded 316L tubes have been produced and employed as heat sinks in the Proton Synchrotron and Super Proton Synchrotron beam dumps. These devices have been operational since 2021.
Bonding of Glidcop or Discup with stainless steel pipes has also been investigated as a potential candidate for some devices.
This presentation focuses on the development, tests and studies conducted at CERN concerning the application of this technique. This encompasses the production of multiple prototype components submitted to non-destructive examinations, microstructure inspections as well as thermal/mechanical testing of the bonded interfaces.
Time 14:30 – 15:00
Author Bio:
Abstract: ANSTO is implementing the ANSTO Synroc Waste Treatment Plant for the immobilisation of radioactive wastes arising from its radiopharmaceutical production. Critical to Synroc Technology and the waste treatment plant is the use of hot isostatic pressing (HIPing) for wasteform consolidation. This process results in the formation of a highly durable material with high waste loading that is suitable for disposal.
ANSTO Synroc has a long-demonstrated history advancing hot isostatic pressing for the immobilisation of a broad range of radioactive wastes and associated tailored wasteform solutions (ceramics, glasses, and composite materials such as glass-ceramics and cermets) for efficient and safe disposal. HIPing offers substantial advantages for radioactive waste immobilisation through the ability to tailor the wasteform, control wasteform assemblage, and carefully control the chemistry within the HIP canister. Another distinct advantage of the technology is the ability to minimise radionuclide volatilisation (a common challenge with other waste immobilisation technologies) resulting in modest off-gas system designs for the process.
This presentation will outline the development and implementation of the HIP technology for the Synroc Waste treatment Facility. This includes wasteform design and the development of HIPing parameters to achieve a final wasteform product with the required performance characteristics. It will also examine the role of failure modes within the HIP for process design and safety as well as detail how this affects the engineering design for the HIP machine and supporting services. Unique challenges have been overcome during the implementation of this HIP system integrated into an industrial scale process plant, through the partnership between the original equipment manufacturer and our engineering team. The HIP system has been installed within the hot cell enclosure and site accepted with the machine performing beyond the specified design requirements.
HM SIS: Sustainability in Hard Materials
Session 21 – Tuesday 01 October – Time: 08:30 – 10:00
Chairs:
Dr Raquel de Oro Calderon (TU Wien, Austria)
Dr Jose Garcia (Sandvik Coromant, Sweden)
Presentations:
Time 08:30 – 09:00
Author Bio: Associate Professor of Chemistry for Technologies at the University of Cagliari, Department of Civil and Environmental Engineering and Architecture, AS has developed her scientific and teaching activity in the field of green and coordination chemistry in a multidisciplinary and international context, cooperating with companies and scientists of different background from all around the world. With a career spanning over two decades, AS co-authored more than 100 papers, 4 international patents, 3 book chapters and was co-founder of 3R Metals Ltd (University Spin-Off), mainly dealing with the design of sustainable leaching agents and processes for valuable and critical metals recovery from technological and industrial waste. Her patents on environmentally friendly metal recovery have earned her the Best Italian Inventor and the European recognition awards from ITWIIN and EUWIIN (2010-11) for innovative patents and entrepreneurship, as well as recognition among the best 5 “Green Technologies” Italian patents at the Intellectual Property Award Forum 2021.
Abstract: Hard-metal (HM) sector, strategic for world-wide economy, is suffering from the reduced availability and price volatility of its main feedstock: critical W and Co. Turning HM scrap to urban mines for Critical Raw Materials (CRMs) is a desirable opportunity for both environmental and economic reasons. Despite the significant good recovery practices already established in HM manufacturing chain, there is still considerable room for improvement in materials and energy enhancement for pursuing a technical-economic-environmentally sustainable circular economy model. Indeed, conventional largely applied and versatile Chemical Modification heavily impacts with high costs for hazardous chemicals and harsh operative conditions, while Direct Recycling pays a lower carbon footprint with a narrow spectrum of recyclable materials. In the last decade, research efforts have been spent on implementing new more sustainable materials reclamation processes from HM scraps based, for example, on the use of bio-based organic acids with the view to increase the rate and quality of the recycled materials as well as to preserve natural resources and prevent the disposal of toxic/polluting substances. In this context Horizon Europe RESQTOOL project, aimed at recovering CRMs from end-of-life tools, investigates the implementation of improved chemical and direct recovery processes with the primary goal to make HM recycling industrial practice the most reliable and sustainable route to feed future HM tool production.
Time 09:00 – 09:30
Author Bio: Dr. Anna Furberg works at the department of Sustainable development, Environmental Science and Engineering at KTH where she conducts research on environmental impacts of digitalization using life cycle assessment (LCA). During her PhD at Chalmers University of Technology, she assessed environmental, resource and human health impacts of hard materials. After her PhD, she worked at the Norwegian Institute for Sustainability Research NORSUS. In 2022, she was awarded with the SETAC Europe Young Scientist Life Cycle Assessment Award, which recognizes exceptional achievements by a young scientist in the field of LCA.
Abstract: The conventional hard material of cemented carbide is of great importance for the manufacturing industry. Its outstanding properties, e.g., in terms of high hardness and wear resistance, have caused its use in a wide range of applications. At the same time, cemented carbide is associated with environmental, resource and health impacts throughout its life cycle, including raw material acquisition, production, use and waste management. For example, cemented carbide mainly consists of the geochemically scarce elements tungsten and cobalt and material substitution to more abundant and largely carbon-based materials, such as polycrystalline diamond, could potentially lead to decreased use of scarce resources. This presentation will address environmental, resource and health aspects of these hard materials as well as potentials for material substitution from a life cycle perspective.
Time 09:30 – 10:00
Author Bio: Riina Aromaa-Stubb is a doctoral researcher at Aalto University in Finland. Currently she is studying the environmental impacts of cobalt production and recycling using process simulation and life cycle assessment.
Abstract: Closed-loop recycling forms a substantial part of the supply for new hardmetal products. The environmental impacts of hardmetal recycling depend on multiple factors including raw material composition, process flowsheet, and geographical location. Life cycle assessment can be used to evaluate and quantify the environmental impacts of both direct emissions and background impacts such as consumption of chemicals and utilities. Use of process simulation in combination with life cycle assessment allows for detailed investigation of the environmental impacts of a process in the absence of measured primary data such as in the case of prospective processes. The aim of this work was to evaluate the environmental impacts of the recovery of tungsten, cobalt, tantalum, and niobium from hardmetal scrap by both industrial and prospective processes.
HM SIS: Coatings for Hard Materials
Session 29 – Tuesday 01 October – Time: 11:00 – 12:30
Chairs:
Mrs Alexandra Kusoffsky
Prof Walter Lengauer (Vienna University of Technology, Austria)
Presentations:
Time 11:00 – 11:30
Author Bio: Lars Johnson is the technology area manager for PVD at Sandvik Coromant R&D, where he is responsible for the for the development of hard PVD coatings for metal cutting applications. He received his PhD in Thin Film Physics from Linköping University, and his research interests include synthesis, mechanical properties, and phase transformations in transition-metal nitrides and related systems.
Abstract: Since their introduction to the market a little more than 50 years ago, hard coatings have seen a rapid development and growth. Both in number of applications, as there are many that benefits from improved wear resistance, and in variety and performance of the various technologies forming the hard coating family. Key examples are the hard nitride and oxide coatings for metal cutting tools, carbon-based coatings for wear and friction reduction applications. Some of the quintessential coating materials, such as TiN, TiAlN, and TiSiN, have proven to be excellent model systems for research into the fundamentals of coating growth, mechanical properties, and phase stability. Similarly, multiple deposition techniques, such as Physical Vapour Deposition (PVD), or Chemical Vapour Deposition (CVD), have been developed to meet the various materials and application demands. Given this strong interest from both commercial and academic sides, it is not strange that a plethora of coating materials, microstructures, and deposition methods exists today. This talk aims to give a brief but structured overview and introduction to this fascinating field of hard coatings.
Time 11:30 – 12:00
Author Bio: Dr. Giselle Ramirez has a PhD in Materials Science (2012, Universitat Politècnica de Catalunya). Since December 2023, she is Assistant Professor at the Universitat Politècnica de Catalunya and researcher in the Center for Research in Structural Integrity, Reliablility and Micromechanics of Materials (CIEFMA). She was the Head of the Tribology Research Line at a Technological Center in Catalunya (Eurecat), where she was working since 2010 During this period, she was mainly working of projects related with wear resistance improvements of: forming tools for automotive sector, mining components, and machining monitoring of tools for AM components. She has been involved as Project Manager and Researcher in different national and European projects, where her main contributions are related with the tribo-mechanical characterization of bulk and coated materials for forming tools and high-speed machining applications. She was a guest researcher in Oerlikon Balzers Liechtenstein (2014-2015) as part of TecnioSpring Fellowship Program. Dr. Ramirez has published around 20 articles in indexed journals and contributions in around 19 international material conferences.
Abstract: Hard coatings are widely applied in the design of tools and components for improving their wear resistance. Among the wide range of surface modification techniques, physical vapor deposition is still one of the most suitable routes to meet the demanding requirements of surface finish and dimensional tolerances that need some specific forming tools, such as those for the automotive sector. Although thin films tend to reduce some tool wear mechanisms under service conditions, the resistance against chipping at the cutting edge still remains a challenge. The latter has been emphasized in punching processes, where the introduction of advanced materials (such as high strength steels, thick stainless steel strips, etc.) requires higher contact pressures than those used in conventional materials. In those cases, the load is mainly supported by the substrate. Thus, if any subsurface damage occurs in coated tools, then a premature detachment of the layer, or even more, chipping of cutting edge could be produced reducing the tool life under service condition.
The main objective of this work is to address the interaction between tool steel and thin coating during contact fatigue at different length scales, in order to discern the most relevant micro-mechanisms of damage. Micro-mechanical lab tests and advanced microstructural characterization techniques have been complemented with evaluation of industrial tools to properly understand the synergies between coating and tool material substrate. Microstructural characteristics such as the chemical nature, size and distribution of primary carbides have a direct influence on the topography and contact fatigue response of hard coating conventionally used on forming tools.
Time 12:00 – 12:30
Author Bio: After graduating in chemistry as Diplom-Chemiker, Dirk Stiens received a PhD in surface technology from Technische Universität Braunschweig in 2005.
In 2004 Dirk joined the Sandvik-owned German precision tool manufacturer Walter AG as a research and development engineer for coatings by chemical vapor deposition (CVD). Apart from a short engagement in product management, Dirk has remained active in the research area ever since.
Currently he is manager CVD development at Walter AG, and chair of the CVD technology team in Sandvik Machining Solutions. Since 2024 Dirk holds a strategic mobility grant from the Swedish Foundation for Strategic Science (SSF), working part-time as visiting researcher in the materials microstructure physics division at Chalmers University of Technology in Göteborg.
Abstract: The introduction of coatings by chemical vapor deposition (CVD) increased the lifetime and usability of cemented carbide tools for machining of metals by orders of magnitude. More than fifty years after the first products, the journey towards better CVD coatings is ongoing. This presentation gives an overview of the historical development and the state-of-the-art of CVD coated tools. Relations between properties of coating materials as titanium carbonitride (Ti(C,N)), alumina (Al2O3) and aluminum titanium nitride ((Al,Ti)N) and their usage in coated cemented carbide grades will be shown. Selected areas of current research and development will be highlighted with a special emphasis on CVD (Al,Ti)N
MIM SIS: Advances in MIM Materials and Processes – Part I
Session 37 – Tuesday 01 October – Time: 14:00 – 15:30
Chairs:
Dipl. Ing. ETH, MBA Georg Breitenmoser (Parmaco Metal Injection Molding AG, Switzerland)
Prof. Dr. Frank Petzoldt (Ingenieurbüro Dr. Frank Petzold, Germany)
Presentations:
Time 14:00 – 14:30
Author Bio: Studied physics at Swansea University and completed a PHD in the field of Material Science. Two years post-doc. research related to the fracture of ferritic steels used in the nuclear industry. Five years’ experience in steel industry working in the automotive and defence sectors. Employed by Sandvik Additive Manufacturing (AM) for more than 17 years in a technical & marketing sales capacity, specialising in the fields of powder metallurgy, with a particular focus on the applications of Metal Injection Moulding and AM. Currently hold a strategic marketing & technical solutions position at Sandvik AM – Powder Group. A committee member of EPMA MIM & AM sectors group. And represents the UK at ISO Standards committees for Additive Manufacturing.
Abstract: The range of metal powders suitable for Metal Injection Moulding (MIM) continues to expand, providing opportunities to explore new MIM applications. This presentation will review the development of metal powders for MIM from carbonyl iron powders, blended with master-alloys to produce steels and stainless steels, which enhance sintering performance and resist slumping and distortion in the early stages of sintering. To unique alloys developed for MIM, including nickel free stainless steels, originally developed for medical applications, but have also found mass production applications in consumer products. The materials available for MIM now cover a wide portfolio, including soft magnetic, low & controlled expansion alloys, medical grades like cobalt chromium & titanium and aerospace materials including nickel based super alloys. And while the growth of the MIM industry has slowed in recent years. Increasing efficiency, lowering costs, improving tolerances and enhancing surface finish, should opening up new opportunities.
Time 14:30 – 15:00
Author Bio: After graduating in Physics at Kharkiv University, Ukraine, Vlad Kruzhanov worked at the University from a junior researcher to the Head of the Laboratory. Since 1994, he worked at the University of Dortmund, Germany as a Researcher and then as a Head of Materials Technology Department. In 2001, he moved to industry to the position of Director R&D Europe at the company GKN Sinter Metals. Since his retirement, Dr. Kruzhanov is a self-employed Consultant in the field of Powder Metallurgy.
Abstract: A novel technology of titanium powder production by means of two stages reduction of titanium dioxide, using magnesium and calcium, has been developed and patented by VELTA, Ukraine. In addition to grades of pure titanium, the proposed technology makes it possible to obtain the powders of titanium alloys by joint reduction of titanium dioxide with oxides of alloying elements. The powder particles have a low content of interstitial elements below the standard for Ti Grade 1. The powder with a particle size distribution with D50 near 50 µm has a large number of very fine, almost spherical particles under 2 µm. The classification of the powder into fractions makes it suitable for several applications, particularly in MIM. The fraction under 45 µm has been tested for MIM using catalytic and water-soluble feedstocks. Sintered samples meet the Ti-400 standard for MIM components used in medical, chemical, aerospace and other industries.
Time 15:00 – 15:30
Author Bio: Lane Donoho is President of Advanced Metalworking Practices in Carmel, Indiana. He has 28 years of experience in powder metal with the last 12 years at AMP. Lane graduated from University of Illinois with a Bachelor of Science in Metallurgical Engineering and from Vanderbilt University with a Master of Engineering in Technology Management. Lane serves on the MPIF Industry Development Board.
Abstract: Working closely with your feedstock supplier is a key method paramount to optimizing MIM binder systems in order to suit specific applications and to solve problems. Attributes of the two major, commercially available binder systems – POM based and wax based – will be discussed. Examples of collaborative efforts and pathways for expediting outcomes will be explored. Enhanced practices for standardization in sintering will also be addressed.
EHQS SIS: Sustainability & Standards for PM
Session 38 – Tuesday 01 October – Time: 14:00 – 15:30
Chairs:
Mr Kenan Boz (EPMA, France)
Dr Bruno Vicenzi (EPMA, France)
Presentations:
Time 14:00 – 14:30
Author Bio: Richard Freeman worked for Collins Aerospace in the UK from 1990-96 as a Production Metallurgist, dealing with the manufacture of a wide range of actuation components. He then joined TWI, a UK R&D technology consultancy in 1996, where he led the aerospace industry sector activities, eventually becoming an Associate Director in the company. He was heavily involved in winning large contracts with major aerospace and defense OEMs.
After 25 years at TWI he joined the Performance Review Institute (PRI) in 2021, to lead the Metallic Materials Manufacturing Task Group as a Principal Staff Engineer. PRI administers the Nadcap industry managed aerospace program, and the Metallic Materials Manufacturing Task Group covers the manufacture of forgings, sand and investment castings, and metallic powder manufacture on behalf of the aerospace OEM community. He also leads the Additive Manufacturing Task Group, which audits AM suppliers using the laser & EB powder bed fusion process. Audit criteria for Directed Energy Deposition AM technology is also being developed for publication in late 2024.
Richard obtained a BSc Honors degree in Metallurgy in 1987 from Sheffield University, and a PhD in 1994 while working full-time on R&D projects at Collins Aerospace. He is a UK Chartered Engineer and a Fellow of the Institute of Materials. He has been the UK representative on the ISO TC44 SC14 welding in aerospace committee, and also the ISO TC 261 committee with ASTM F42 personnel on additive manufacturing for aerospace, for the last 16 years. He also represents the UK on the AWS D17 welding in aerospace committee, and has done so for over 25 years.
Abstract: Nadcap is an industry-managed approach to conformity assessment that brings together technical experts from both Industry and Government to establish requirements for accreditation, to accredit Suppliers and define operational programme requirements. It is administered by PRI (Performance Review Institute), on behalf of 60+ major aerospace OEM’s such as Boeing, Airbus, Rolls-Royce, GE, Honeywell, Raytheon and countless others. Nadcap currently audits 24 different technical critical manufacturing processes. Audit criteria is collaboratively developed by Task Groups comprised of industry professionals from aerospace OEM’s, who subscribe to the Nadcap program, and many suppliers.
Nadcap is progressing well with the development of audit criteria for the manufacture of metallic powder material for use in aerospace AM processes. This criteria is being peer reviewed by aerospace OEMs and powder manufacturers such as AP&C, Carpenter, Tekna, Hoganas and Aubert & Duval, and is going through the ballot process after trial audits, before planned publication in Q4 2024. The audit criteria draws heavily on AMS7002A, and ASTM requirements for powder testing.
The publication of this audit criteria will also support the Nadcap Additive Manufacturing Task Group, who have developed audit criteria for auditing AM suppliers using the laser and electron beam powder bed fusion processes. Work is also progressing to publish audit criteria for Directed Energy Deposition AM processes (including the laser blown powder process) during 2024.
This presentation will cover a review of the Nadcap aerospace industry managed programme, the development of the metallic powder manufacturing audit criteria with industry, trial audits at powder manufacturing facilities, and the hiring of auditors to conduct future audits in the production of metallic powder using the gas atomization and plasma wire processes.
Time 14:30 – 15:00
Author Bio: Before founding Granutools, Filip has managed various businesses for the electronic microscopy subsidiary of Thermo Fisher Scientific known as FEI company. Filip started his career working for the Dutch semiconductor equipment manufacturer ASML in R&D in the Netherlands and then in customer facing roles in Japan. Filip holds a Master Degree in Applied Physics from the Free University of Brussels (Belgium) and an MBA from INSEAD (Singapore). He has numerous publications in scientific journals and holds multiple patents.
Abstract: Granutools introduces the classical tests like Hall and Hausner as well as their limitations. Most recent developments of powder flow measurements standards in metal AM are discussed. Spreadability measurements for various metal alloys inside printers will be shown and a link with intrinsic powder properties making use of a rotating drum.
Time 15:00 – 15:30
Author Bio: Kenan Boz received a BS degree in Electrical & Electronics Engineering (1993, Istanbul) and an MS degree in Systems & Control engineering (1995, Istanbul). He worked from 1995 to 2017 as production manager, technical manager and shareholder in various companies working in the area of light metals casting and machining, mainly dealing with machine design and CAD/CAM systems. He has been the technical manager and R&D consultant of Sentesbir A.S. in 2017, where he has been working on development of Co-Cr metal powders to be used in additive manufacturing of dental prostheses by Laser Powder Bed Fusion until February 2019. He joined EPMA in April 2019 as the technical manager responsible for several sectoral groups (EuroAM, EuroHIP and EuroHM), working group EHQS, as well as EPMA’s EU and Club projects. He is currently coordinating EU project RESQTOOL on recycling of Hard Metals and Critical Raw Materials.
Abstract: Like many other industries, Powder Metallurgy is also facing new challengesfor adapting to new regulations of the European Union like the Green Deal, Net-Zero Industry Act, and the Critical Raw Materials Act. This presentation will make an overlook on all these issues from the prespective of Powder Metallurgy industry
MIM SIS: Advances in MIM Materials and Processes – Part II
Session 45 – Tuesday 01 October – Time: 16:30 – 18:00
Chairs:
Dipl. Ing. ETH, MBA Georg Breitenmoser (Parmaco Metal Injection Molding AG, Switzerland)
Prof. Dr. Frank Petzoldt (Ingenieurbüro Dr. Frank Petzold, Germany)
Presentations:
Time 16:30 – 17:00
Author Bio: The author completed his studies at Institute of Technologies and Materials, Faculty of Mechanical Engineering, Slovak University of Technology in 2010. He has worked at Gevorkyan company more as thirteen years as part and tool designer. Important part of his activities covers development of completely new PM and MIM parts including transferring from another production technologies.
Abstract: The paper deals with presentation of interesting MIM projects that has been developed at Gevorkyan company over last years. Description of development process motivation, challenges, improvements and benefits, both of absolutely new parts and parts that have been transferred to MIM from another production technologies, provides real view on the possibilities and limits of MIM technology verified in condition of serial production.
Time 17:00 – 17:30
Author Bio: Team Leader of sales and Product Specialst in the area of sample presentation
Abstract:
Component quality, energy consumption and total output of a production process becoming more and more important for manufacturing with the lowest resource input.
In this presentation we would like to focus on quality, energy consumption and highest possible number of parts out of a MIM production process.
Simulations will be presented that have enabled a production furnace to be optimally optimized for the highest possible output and component quality. Furthermore, the necessary energy consumption in the context of a MIM process will be discussed.
Time 17:30 – 18:00
Author Bio:
Abstract: Production of a MIM part gave a overall rejection rate of 20% based on dimensions not being within specifications, the approach to reducing this was using six sigma in order to reduce the variation of the dimension and end with rejection rates below 1%. The presentation will include the effect of several different molding parameters, visual indications and placement inside the furnace.
The presentation will follow the Six sigma DMAIC method, and will help a non user in getting a good idea of the workflow, and why this method is very suited for process improvement.
AM & HIP SIS: Post Processing Using HIP
Session 53 – Wednesday 02 October – Time: 08:30 – 10:00
Chairs:
Mrs Adeline Riou (Aubert&Duval, France)
Dr Ing Anke Kaletsch (RWTH Aachen University, Germany)
Presentations:
Time 08:30 – 09:00
Author Bio: Lars Nyborg, professor, Chalmers University of Technology, Department of Industrial and Materials Science. Member of Royal Academy of Engineering Sciences. Author and co-author to >300 journal publications in the field of powder metallurgy ´, additive manufacturing, surface engineering, hot isostatic pressing, coatings, corrosion and oxidation. Psrticular focus and interest in materials development in field of powder metallurgy and additive manufacturing as well as powder metallurgy surface science. Experience in running large number of academia-industry collaborative projects including for example large scale H2020 project on metal additive manufacturing. Currently, Director for Production Area of Advance at Chalmers.
Abstract: Powder bed fusion – laser beam allows manufacture of high performance like nickel base alloys in advanced geometrical design. Oven it is possible to optimize a process by proper choice of print parameters to reach nominally full density. Still, even if there is an optimised process it is not sure that this means that there is defect-free printing in all parts of a component.. This challenge calls for the application of on-line process monitoring to mitigate and control such events. In this communication, results are presented for Alloy 718, how on-line monitoring with so-called optical tomography (OT) validated by XCT, can be applied to depict the formation of spatter phenomena and how post-processing hot isostatic pressing is an invaluable aid to reach the necessary fatigue properties irrespective of the in-line processing control and optimized printing parameters control. The presentation will provide results for defect-free and defect-containing builds which afterwards have gone through solutionizing and ageing for Alloy 718 as well as such heat treatment integrated in hot isostatic pressing. The fatigue testing shows clearly how you can reach target life time towards 2 million cycles at 700 MPa stress range with HIP and good print, while bad print without HIP will lead to inferior fatigue properties, evidenced by life time less than 100,000 cycles at the same stress level. The key hometake is how we can provide a strategy for high quality first part right capacity.
Time 09:00 – 09:30
Author Bio: Johannes is an enthusiastic engineer and professor for Digital Additive Production at RWTH Aachen University. He serves as Scientific Director of the ACAM (Aachen Center for Additive Manufacturing), a joint collaboration of renowned institutes and leading industrial partners. Besides this, Johannes is an active entrepreneur and co-founder of several start-ups in the field of advanced manufacturing and digital technologies. He brings his broad knowledge from industry and the Aachen High Tech Campus into sustainable industrial production.
Abstract:
Time 09:30 – 10:00
Author Bio: Dr. Mahesh Kumar Mani is a Senior Research Specialist in the GKN Aerospace, Powder Bed AM team. After joining GKN Aerospace as Materials Scientist in 2014, he has been extensively involved in testing and qualification of (i) Powders, (ii) Process, (iii) bulk AM materials and (iv) post-processing (HT) of AM materials for aerospace end use applications. He has worked on numerous AM technical development programs towards industrialisation of powder bed (EBM & LPB) technologies with various materials such as Ni-superalloys, Ti-alloys and steels for aerospace, military, and space applications. He has lead multiple technology projects on post-processing of Titanium and Nickel alloys produced by AM and proposed alternate economical heat treatment routes that yielded modified microstructures and superior mechanical properties.
Abstract: Metallic materials produced by additive manufacturing (AM) are typically subjected to the post-build thermal treatments developed for conventional manufacturing processes such as castings and forgings. Thermal treatments for laser powder bed fusion (L-PBF) materials often consists of: (a) stress relief treatment utilised to reduce the internal stresses resulted from high cooling rates; (b) hot-isostatic pressing (HIP) to close internal voids produced during manufacturing; (c) homogenisation treatment to dissolve any detrimental phases, which might be formed during slow cooling, as experienced in the conventional HIP vessels; and (d) solution and ageing treatments, provided the materials are precipitate hardenable. In addition to high cost and time associated with conventional thermal treatments, L-PBF materials lose the unique and advantageous microstructural features of AM. To retain the fine morphologies that are formed during AM and to tailor the microstructure based on the requirements, alternate heat treatments have been explored using modern HIP vessels. This discussion outlines the difference in the properties that can be obtained between conventional and two alternate heat treatments in Ti-6Al-4V and between two different heat treatment routes in a novel precipitate hardenable Titanium alloy. High-pressure heat treatment (HPHT) furnaces developed by Quintus Technologies have been exploited in this study to enhance material performance and to reduce the number of post-build thermal operations.
FM SIS: Initiatives on Hard Magnets for the future
Session 54 – Wednesday 02 October – Time: 08:30 – 10:00
Chairs:
Dr Sebastian Hein (Fraunhofer IFAM, Germany)
Mr Peter Kjeldsteen (Sintex a/s, Denmark)
Presentations:
Time 08:30 – 09:00
Author Bio: Material Scientist Magnetic Materials, 1986 – today
Abstract: Bonded Magnets can be distinguished by materials, production processes and magnetization orientation.
Ferrite magnets are available in isotropic and anisotropic form, produced by injection molding, only. compression molding is not possible/reasonable due to the magnetic behavior and small particle size.
Nd-(Pr,Ce,La)FeB powders are produced by jet casting (isotropic) or HDDR (anisotropic) technologies resulting in isotropic magnets by compression or injection molding or anisotropic magnets by compression or injection molding, both.
SmFeN powders are produced by jet casting or calciothermic co-reduction and from both techniques available for isotropic and anisotropic magnets.
All materials are used and are in competition to each other for different applications. This is a comparison showing advantages and disadvantiges in properties and cost.
Time 09:00 – 09:30
Author Bio: Born in Remscheid, dtuy of mechanical engineering and safety engineering at the university of Wuppertal, PHD thesis in low cycle fatigue and fracture, working as global director R&D at GKN, former focus was reliability, fatigue and fracture, current topic: sintered hard magnets
Abstract: Developed in parallel in Japan and the US Nd2Fe14B hard magnets have revolutionized the electric traction motor design in terms of size, power and weight from 1984 onwards and have replaced the older hard magnet grades. During that time Germany had a vital hard magnet industry which has disappeared due to the Asian cost pressure.
It is a stroke of fate that this ignored, neglected and outsourced product group became of strategic importance for all OEM’s and the entire German automotive industry due to its importance for BEV’s. The Nd crisis in 2011 where the raw material price of Nd jumped to twenty times higher and the subsequent Co crisis have shown how strong the German industry depends on Asian raw material imports with all the macroeconomic consequences.
GKN stepped into that business to provide a safe, sustainable, resilient and independent value chain for all OEM’s and tier 1 suppliers.
Time 09:30 – 10:00
Author Bio: Julie Maisonneuve is a materials engineer and holds a PhD in Materials Science and Engineering from MINES-Paritech. After more than 10 years in R&D project management in industry, she joined CEA LITEN in 2018, where she has been involved in several industrial and institutional projects as research engineer and/or project manager. Since 2021, she has been working on permanent magnets, in particular with the management for the CEA of a national project aimed at developing a sustainable French manufacturing sector for permanent magnets, including end-of-life magnet recycling and reduction of critical raw materials (MAGNOLIA Project).
Abstract: The market of permanent magnets is today largely dominated by the sintered Neodynium-iron boron magnets. These magnets exhibit the highest performances ever reached at the industrial scale and no alternative material has been identified despite intensive research all over the world.
An increase by a factor 5 for the automotive sector and a rise by a factor 3 for wind energy are anticipated according to some scenarios of energy transition. The current European domestic production of raw materials and magnets is far from covering such needs. China largely dominates the value chain of the magnets production. It is worth noting that NdFeB magnets contains about 30 % in mass of rare earth elements. These are in majority Nd and Pr plus small quantities of Dy and Tb added for sustaining high temperature operation. The European Union, with no active mining extraction of these elements, exhibits an industrial capacity that represents only 1% for oxides and metal transformation, as well for magnet manufacturing. On the other hand, automotive and energy industries are strongly implanted in EU. This imbalance points out the dependence of EU on the monopolistic position of China
Rare earth permanent magnets are mostly produced in industry by the powder metallurgy route. This versatile route offers many opportunities to improve the performance with a rationale use of critical materials.
Based on its strong background in this field CEA with its ORANO partner is currently developing a pilot line for promoting more circular economy in the manufacturing of high performance permanent magnets. The presentation deals with the main objectives of this initiative regarding the reduction and substitution of critical raw materials (heavy and light rare earth elements), the eco-design of magnets and electrical machines, and finally, the close-loop magnet recycling.
AM SIS: Large Scale AM
Session 61 – Wednesday 02 October – Time: 11:00 – 12:30
Chairs:
Mrs Adeline Riou (Aubert&Duval, France)
Dipl-Ing Claus Aumund-Kopp (Fraunhofer – IFAM, Germany)
Presentations:
Time 11:00 – 11:30
Author Bio: Dr. Maximilian Schniedenharn studied mechanical engineering at the RWTH Aachen. After receiving his diploma in 2012, he went on to work for the L-PBF group at the Fraunhofer Institute for Laser Technology ILT, Aachen, focusing on the influence of focal shift and process by-products on the Laser Powder Bed Fusion process. He joined Nikon SLM Solutions in 2018, taking over the role as Head of Process Development in 2020. The group focusses on development of the Shielding Gas Flow, Thermal Management and Build Data Preparation.
Abstract: The ability to produce ever larger parts while reducing the time it takes to produce them is a game changer in the metal additive manufacturing market. Clearly aiming at serial production, the NXG XII 600 generation represents the latest evolution in the design of additive manufacturing machines from Nikom SLM Solutions.
Throughout the session, practical examples are explored, illustrating how the NXG XII 600 machine, featuring 600×600 mm2 build envelope, a build height of up to 1500 mm and powered by 12 times 1,000 W lasers, has transformed production processes and drives cost efficiency.
In response to the increasing dimensions of applications and production volumes, there is a growing need for automation and accompanying processes that simplify component and powder management. Practical examples illustrate the growing significance of peripherals and smart data preparation.
Time 11:30 – 12:00
Author Bio:
Abstract: Embark on a journey of discovery into the new horizons of additive manufacturing with large scale laser powder bed fusion system opening up new possibilities of applications. The talk will demonstrate AMCM mission making applications such as rocket engines more flexible, less expensive, and faster. AMCM GmbH is a member of the EOS Group and focuses on the customization and tuning of EOS metal systems.
The development of the M 8K sets a new milestone for large scale LPBF system and is supported by a national grant to AMCM to improve the competitiveness of the Ariane 6 program. With larger parts and longer print runs, process control and validation become increasingly important. The first application will be the printing of the combustion chamber of the Ariane Group’s Prometheus rocket engine. Printed in CuCr1Zr with a height of > 1,000 mm and a maximum diameter of 800 mm, this combustion chamber will be a benchmark in terms of dimensions and quality.
Beyond the space industry the development of a large LPBF system opens a new world for large component design, such as heat exchangers, which was not possible before.
Time 12:00 – 12:30
Author Bio: Enis Jost spearheads business development efforts for Eplus3D in Europe, overseeing seamless after-sales operations, logistics, and continual optimization of the company’s innovation center. With 5 years of experience in metal LPBF-OEMs, he brings a strong background in application development for polymer PBF and automotive industry integration from his previous roles.
Abstract:
The rapid evolution of large size Powder Bed Fusion (PBF/LB-M) Systems, exemplified by those pioneered by Eplus3D, has transformed the use of metal powder. These systems, boasting build volumes from 40L to nowadays 2000L or more, signify a significant leap in industrial additive manufacturing capabilities. However, with this expansion comes a pressing need to address the challenges surrounding the handling and requirements of metal powders within these systems.
This presentation delves into the critical considerations and evolving demands associated with managing several tons of metal powder within the confines of these advanced machines. Specifically tailored for industrial users, the session will elucidate the intricacies of powder handling and shed light on the requisite adaptations in system design to meet industrial standards. Furthermore, the presentation offers invaluable insights into the implications of transitioning from smaller to larger build volumes within a remarkably short span. Attendees will gain a comprehensive understanding of how these shifts reverberate across the market, influencing operational dynamics, production scalability, and technological advancements in powder metallurgy.
FM SIS: Biomedical Functional Materials
Session 62 – Wednesday 02 October – Time: 11:00 – 12:30
Chairs:
Dr Sebastian Hein (Fraunhofer IFAM, Germany
Mr Peter Kjeldsteen (Sintex a/s, Denmark)
Presentations:
Time 11:00 – 11:30
Author Bio: Dr. Efraín Carreño-Morelli, PhD in Physics from the National University of Cordoba (Argentina), is a professor at the University of Applied Sciences and Arts Western Switzerland since 2001 and head of Powder Technology and Advanced Materials since 2011. He has more than 20 years of experience in the field of powder technology and additive manufacturing. He has been responsible for setting up the technologies of powder compaction, powder injection molding, tape casting, selective laser melting and binder jetting. His research interests are in the field of net-shape processing of metal, ceramic and metal-ceramic composite parts from powders. He has led several projects on PM and AM of steels, aluminum alloys, titanium alloys, shape memory materials, magnetic materials, ceramic reinforced metals, cemented carbides and diamond tools. He is a member of EPMA and APMI International. He has authored or co-authored over 100 publications and 5 patent applications.
Abstract: The use of shape memory and superelastic materials (SMAs) is well established for niche applications in several sectors, including dental and medical. Near-stoichiometric nickel-titanium alloys have been the most widely used SMAs for specific implants and surgical devices, due to their unique mechanical performance, corrosion resistance and biocompatibility. Conventional transformation processes include ingot casting, followed by wire and tube extrusion, rolling, followed by machining and laser cutting. Difficulty of machining and cost are current issues driving research and development of near net shape solutions based on powder metallurgy and additive manufacturing.
In most cases, post-processing heat treatments and shape-setting are required.
In addition to nickel-titanium, less expensive copper- and iron-based SMAs could be of interest for biomedical applications where biocompatibility is not mandatory, such as in medical instruments, prostheses and orthoses.
An overview of the past and present of SMA devices in the biomedical sector is necessary for a realistic view on future developments.
Time 11:30 – 12:00
Author Bio: Dr. György Harakály is the Head of R&D Materials at Incus GmbH, an Austrian firm specializing in Lithography-based Metal Manufacturing (LMM) systems. He earned his B.S. and M.S. degrees in chemical engineering and pharmaceutical engineering from Budapest University of Technology and Economics. He then completed his Ph.D. at Technische Universität Wien, Austria, focusing on developing photopolymerizable resins for additive manufacturing in orthodontics. Since 2021, Dr. Harakály has led the research and development efforts at Incus, leveraging his expertise in polymer chemistry, material science, and stereolithography.
Abstract: Lithography-based Metal Manufacturing (LMM) is a sinter-based additive manufacturing technology capable of producing functional metal components with intricate designs and high feature resolution. LMM yields material properties comparable to Metal Injection Molding and achieving surface Ra surface roughness values below 2 µm. The high design freedom facilitates the creation of complex geometries and unique designs, which enables the production of customized medical solutions, such as dental and surgical tools. These examples illustrate the potential to significantly advance healthcare by offering tailored and intricate metal components.