Optimization of PM parts using HIP - Monday 18 October - 11:15 – 12:45
Euro PM2021 Topic: Consolidation technologies
Session Chairs: Dr Anke Kaletsch (RWTH Aachen University, Germany); Mr James Shipley (Quintus Technologies AB, Sweden)
Presentations:
- The CALHIPSO project: towards a larger use of HIP technology in France
Prof Bernard Frederic (ICB - UMR 6303 CNRS | UBFC, France)
- Hot Isostatic Pressing in Additive Manufacturing – a costly necessity or a possibility to add value?
Dr Ing Herzog Dirk (Hamburg University of Technology, Institute of Laser and System Technologies, Germany)
Abstract: Additive Manufacturing (AM) has lately become a true manufacturing option for the serial production of parts, e.g. in the medical and aerospace industries. Especially in these highly regulated markets, Hot Isostatic Pressing (HIP) is often used as a mandatory post-processing measure to ensure fully dense parts. Given the still comparatively low productivity of AM, the necessity of HIP is frequently considered as an additional burden in terms of cost and time.
Instead, this contribution assesses options to add value to parts from different AM processes using HIP beyond merely assuring density. Besides mechanical property-based impacts, it may increase reproducibility thus reducing scrap. Using the capabilities of HIP, the AM process itself may also be adapted for higher productivity. As an example, a combined approach of Laser Powder Bed Fusion and subsequent HIP is presented for Ti-6Al-4V and IN718, leading to significant savings in build time.
Key Industrial Applications of HIP - Monday 18 October - 13:30 - 15:00
Euro PM2021 Topic: Consolidation technologies
Session Chairs: Dr Anke Kaletsch (RWTH Aachen University, Germany); Mr James Shipley (Quintus Technologies AB, Sweden)
Presentations:
- Advanced Technology for Large Scale (ATLAS) PM-HIP
Mr David Gandy (Electric Power Research Institute, USA)
Abstract: Over the past four years, the Electric Power Research Institute (EPRI), Nuclear Advanced Manufacturing Research Centre (NAMRC), NuScale Power, and the U.S. Department of Energy, have spearheaded the development of several major manufacturing and fabrication technologies for small modular reactor (SMR) and advanced reactor (AR) production. In this project, powder metallurgy-hot isostatic pressing (PM-HIP) technologies have been demonstrated at a large scale for production of 2/3-scale reactor heads to date. One of the primary limiting factors in moving to full-scale production with the technology is the size limitation of an available HIP unit to accommodate a 3.048m (10 feet) diameter reactor head. EPRI and Stack Metallurgical have been working with a number of industrial partners to explore the design, procurement, installation, and operation of a very large 3.55m (140-inch) diameter HIP unit that would accommodate the large reactor heads. Furthermore, at this size, the HIP unit would have direct applicability to several other markets including: oil & gas, aerospace, aircraft, energy, etc.
- Faster manufacturing by additive manufacturing of shelled parts followed by HIP
Abstract: Metal additive manufacturing is fast growing as a viable industrial manufacturing tool for complex, end-use parts for critical applications. Especially much progress has been made in laser powder bed fusion (L-PBF) in improved material properties and mechanical performance achieved. The hot isostatic pressing (HIP) process aids in homogenizing the microstructure and closing microporosities, further enhancing the mechanical properties of such parts. In this talk I will discuss and demonstrate the pore closure for a variety of different typical porosities present in L-PBF parts. This will be followed by introducing an approach of manufacturing shelled components (entirely closed cans) directly, leaving the process powder inside the part for full consolidation by a subsequent HIP cycle. Recent work in this approach, including precompensated geometries and mechanical performance tests are presented, based on recently published work in [1]. The L-PBF process can be an order of magnitude faster in this method compared to typical builds, holding significant cost advantages.
Advances and Challenges for Hard Magnets - Tuesday 19 October - 09:00 – 10:30
Euro PM2021 Topic: Materials
Session Chairs: Dr Sebastian Boris Hein (Fraunhofer IFAM, Germany); Mr Peter Kjeldsteen (Sintex a/s, Denmark)
Presentations:
- Recent Developments for Bonded RE-Fe-B Magnets
Abstract: RE-Fe-B bonded magnets have been increasingly used for motor applications across various industries especially in automotive industry. In this presentation, we will review Magnequench latest R&D efforts in developing RE-Fe-B bonded magnets, including the anisotropic RE-Fe-B powders and their bonded magnets for automotive applications. We have successfully developed a series of novel anisotropic RE-Fe-Ga-B powder products (MQA-39-15, MQA-38-17, MQA-37-18 and MQA-36-19), by using rapid solidification, hot deformation and advanced comminution technology. The powder composition-processing-performance relationships have been systematically studied and will be discussed in this presentation. Further, anisotropic bonded magnets consisting of MQA powders and Epoxy, PA12 or PPS binders have also been successfully fabricated by compression molding or injection molding technology. The bonded magnets exhibit good magnetic properties and good thermal stability and corrosion resistance, and are suitable for automotive applications. Case studies for the bonded magnets in motor applications will be presented as well.
- Electric current assisted sintering of NdFeB magnet materials
Abstract: Electric current assisted sintering (ECAS) techniques are highly promising for the processing of advanced materials. These techniques provide electric fields, electric currents, and direct heat transfer as an additional degree of freedom for synthesis, processing, and microstructure tuning of inorganic materials starting from respective powders. If applying during ECAS an additional external load, these techniques offer new possibilities to sinter powders to almost theoretical density, whose particle size distribution and morphology is far from being optimum when compared to the requirements of conventional powder technology. Such kind of powders are usually appear in the case of recycling waste materials. Furthermore, these techniques are discussed to be highly efficient due to their potential of reducing the cycle time to minutes or even seconds. In the present work, the potential of field-assisted sintering technique/spark plasma sintering (FAST/SPS), flash spark plasma sintering (FSPS), and electro-discharge sintering (EDS) is benchmarked concerning densification behavior, microstructure evolution, functional properties, and efficiency. Up to now, there is less information available on the real efficiency of ECAS techniques. Melt spun, commercial NdFeB powder was used as model material due to the following reasons 1). Its platelet-like shape makes this powder extremely difficult to sinter by conventional methods. Therefore, extensive effort is required for powder consolidation, which is usually done by hot pressing with subsequent hot extrusion. ECAS, and here especially FSPS, might become an attractive alternative, also due to enabling to realize anisotropic magnetic properties without the need of hot extrusion. 2) When recycling magnets using an upcycling strategy, crushing and subsequent milling usually leads to acicular shaped powders with a broad particle size distribution, which are almost impossible to densify by conventional sintering techniques. Demonstrating a new technique for successfully upcycling magnet materials would have a huge impact for implement circular economies and establishing sustainable use of limited resources. 3) There are several excellent works available in the literature on FAST/SPS, FSPS, and EDS of NdFeB magnets, which will support the benchmark.
- Advances and Challenges for Hard Magnets
Abstract: Historic advances in human technological development have been closely tied to the production and application of metals; from bronze, iron & steel and more recently aluminium & titanium alloys. Metal manufacturing industry has a significant impact on the environment, with generation of green-house gases and consumption of natural resources. That warrant detailed investigation & independent analysis of sustainability and carbon footprint, in terms of environment, human resource, supply chain management and ethical procurement, against ambitious targets over realistic time frames. Powder metallurgy is recognised as a green technology and the production of metal powder, by inert gas atomisation for advanced manufacturing technologies including additive manufacturing & Metal Injection Moulding (MIM), can provide the key elements of a sustainable low impact production process, which incorporate recycled materials and efficient supply chains. In this presentation, important sustainability strategies, initiatives and targets will be presented, from an metal powder producers point of view.
Functional Materials for Thermal Management - Tuesday 19 October - 10:45 – 12:15
Euro PM2021 Topic: Materials
Session Chairs: Dr Sebastian Boris Hein (Fraunhofer IFAM, Germany); Mr Peter Kjeldsteen (Sintex a/s, Denmark)
Presentations:
- Thermal Management Solutions with Advanced Composite Materials and Additive Manufacturing
Abstract: Thermal management solutions are of great importance in various industrial fields such as power electronics and battery technology to ensure sufficient lifetime and reliability. A lithium-ion battery for mobile applications needs a powerful thermal management to ensure the required lifetime of more than 10 years as well as full power development and availability under all operating and environmental conditions.
Highly conductive composite materials with tailored coefficient of thermal expansion using powder metallurgical technologies can provide innovative solutions for passive cooling. Additionally, PCM-Metal composites could be an option for thermal management of batteries. Additionally, powder based additive manufacturing offers unique options for the design of cooling devices mde out of pure copper. The paper will give an overview how powder metallurgy could offer innovative solutions for thermal management.
- Solid state thermal control devices and circuits
Abstract: Solid state thermal control devices exhibit extraordinary or unusual thermal properties like high thermal conductivity or temperature dependent anisotropy of thermal properties. These devices include thermal diodes, thermal switches, thermal regulators, thermal transistors, thermal conduits, all of which manage heat in a manner analogous to how electronic devices and circuits control electricity. They distinguish themselves from traditional passive thermal management devices in that their thermal properties have sharp, non-linear dependencies on direction and operating temperature, and could lead to more efficient circuits and energy conversion systems than what is possible today. In analogy to electronic circuits such devices in an application can be single, multiple or can even create thermal circuits analogue to electric ones. This contribution concerns the up-to-date review of research activities in the field and its potential for the future exploitation through the additive manufacturing.
- Adding energy harvesting into thermal management – a win-win solution
Abstract: Heat management plays an important role in energy optimization. In some cases, the excessive heat is treated as a by-product, or just waste. Recycling of waste heat can be technically and commercially challenging, when the grade of heat is low and the return of investment is long. Direct energy conversion from heat to electricity by thermoelectric harvester can provide a unique solution. In the talk, some applications and use cases will be discussed.
Sustainability of MIM - Tuesday 19 October - 13:00 – 14:30
Euro PM2021 Topic: Consolidation technologies
Session Chairs: Prof Frank Petzoldt (Fraunhofer IFAM, Germany); Mr Georg Breitenmoser (Parmaco Metal Injection Molding AG, Switzerland)
Presentations:
- Sustainability of Inert Gas Atomised Powders for Additive Manufacturing and MIM
Abstract: Historic advances in human technological development have been closely tied to the production and application of metals; from bronze, iron & steel and more recently aluminium & titanium alloys. Metal manufacturing industry has a significant impact on the environment, with generation of green-house gases and consumption of natural resources. That warrant detailed investigation & independent analysis of sustainability and carbon footprint, in terms of environment, human resource, supply chain management and ethical procurement, against ambitious targets over realistic time frames. Powder metallurgy is recognised as a green technology and the production of metal powder, by inert gas atomisation for advanced manufacturing technologies including additive manufacturing & Metal Injection Moulding (MIM), can provide the key elements of a sustainable low impact production process, which incorporate recycled materials and efficient supply chains. In this presentation, important sustainability strategies, initiatives and targets will be presented, from an metal powder producers point of view.
- Sustainability in MIM: A feedstock producer's view
Abstract: The world is facing major challenges. Climate change is advancing, the world’s population is growing and so is its need for food, energy and clean water. More and more people live in cities and the demand for individual mobility is rising. At the same time, natural resources are limited. More than ever before, we need solutions that make sustainable growth possible. Metal injection molding can play a vital role here, however, decoupling from the consumption of finite resources and reduction of the carbon footprint need to be further driven. In this talk, a feedstock producer´s view on sustainability in MIM is discussed.
- Sustainability of the MIM process from the perspective of a parts manufacturer
Abstract: In this presentation, examples of the general sustainability of the MIM process are shown and discussed using individual components. In addition, an insight into the real energy consumption in the large-scale production of MIM components will be given and ways to further optimize the energy balance will be shown.
Outlook on Hard Materials - Wednesday 20 October - 09:00 – 10:30
Euro PM2021 Topic: Materials
Session Chairs: Prof Luis Miguel Llanes (Catalunya Univ Polytecnica, Spain), Mrs Susanne Norgren (Sandvik, Sweden)
Presentations:
- The evolving regulation of cobalt
Mr Mike Blakeney (Cobalt Institute, United Kingdom)
Abstract: Regulation of cobalt is evolving with new classifications and restrictions either expected or ongoing. Mike will help you understand what has happened this year, what to expected in the future and how industry is responding.
- An analysis of the major end-use applications of tungsten
Dr Burghardt Zeiler (International Tungsten Industry Association, United Kingdom)
Abstract: To improve the understanding of the role of tungsten in technology and economy it is necessary to go beyond first-use considerations. The categorization of first-use is focused on the material produced from tungsten substances, such as hardmetal from tungsten carbide, heavy metal or contact materials from tungsten metal and high speed steel from ferrotungsten to name a few. Going further downstream, hardmetal may be used as tool, such as a cutting insert or microdrill, or as a wear part, in a rotary pump or a deep-hole drill head. In fact, a similar type of cutting insert, for example, may be used either in the automotive industry or for machining of injection moulding tools used in the leisure equipment production. The multiple dimensions of tungsten end-use applications are presented and a structure to enable impact estimations of general trends in technology and economy on the use of tungsten is discussed.
HM Club Projects of EPMA - Wednesday 20 October - 10:45 – 12:15
Euro PM2021 Topic: Materials
Session Chairs: Prof Luis Miguel Llanes (Catalunya Univ Polytecnica, Spain), Mrs Susanne Norgren (Sandvik, Sweden)
Presentations:
- Euro HM Club Projects
Dr Steven Moseley (Hilti AG, Liechtenstein)
Abstract: To be annouced.
- Recent & Current Club Projects of EPMA
Roebuck, B (NPL, United Kingdom)
Abstract: Summary and assessment of ongoing EPMA/EHMG joint projects on topical research projects covering, for example, micromechanics, modelling and measurements of fatigue cracks and thermodynamics. Additional comments on future directions.
- Future Activities of Club Projects
To be announced.
CO2 reduction in Press&Sinter - Part 1 - Thursday 21 October - 09:00 – 10:30
Euro PM2021 Topic: Consolidation technologies
Session Chairs:
Dr Cesar Molins (AMES SA, Spain)
Mrs Caroline Larsson (Höganäs AB, Sweden)
Presentations:
- Innovation to drive net zero carbon operations in material manufacturing
Abstract: Innovation is required to deliver net zero carbon in manufacturing, decarbonising the gas grid, fuel switching, carbon capture, storage, renewable electricity generation, and storage flexibility playing key roles. Biomethane and hydrogen, green hydrogen from renewables, electrolysis as well as blue hydrogen from natural gas, combined with carbon capture, utilisation and storage are needed in two decades to decarbonise the gas grid helping industry achieve net zero carbon emissions. Decarbonising the gas grid leads to decarbonising heat, this is a requirement if the industrial sector is to achieve its targets. Our presentation will discuss the role that decarbonising the gas grid can play in driving net zero carbon operations in manufacturing. In addition, heat decarbonisation through innovative biomass CHP solutions, and the utilisation of waste heat have an important role to play. Many of the solutions available provide an opportunity for facilities to decarbonise, whilst generating additional revenue streams for organisations.
- Corporate Carbon Footprint & Product Carbon Footprint
Mr Marius Gutes (PMG Holding GmbH, Germany)
Abstract: This paper talks about the Corporate Carbon Footprint approach at PMG as well as an example of a Powder Metal Product Carbon Footprint.
- The Road towards Climate Neutrality for the PM Industry from a powder production perspective
Abstract: In order to reach climate neutrality, the different parts of the PM value chain must make significant changes to lower its CO2 emissions. This includes both metal powder- and parts production, and encompasses the sourcing of energy- as well as raw materials used, and the efficiency of each process step. The presentation will focus on today’s main contributions to the climate footprint during production of powders and additives, present challenges to mitigate the sources of greenhouse gases, and future possibilities to reach climate neutrality for production of metal powders.
CO2 reduction in Press&Sinter - Part 2 - Thursday 21 October - 10:45 – 12:15
Euro PM2021 Topic: Consolidation technologies
Session Chairs:
Dr Cesar Molins (AMES SA, Spain)
Mrs Caroline Larsson (Höganäs AB, Sweden)
Presentations:
- An overview on energy efficiency of presses and latest trends for consumption optimization
Abstract: Nowadays, energy efficiency is becoming always more important in industrial production. Not only for the economic benefits of a reduced consumption, but also to minimize the environmental impact of the production itself, important aspect to let companies reach the new required standards.
In powder metal production with new technologies applicable to the machines, not available in the past, it is now possible to optimize even more energy consumption without neglecting performances.
In this perspective, this presentation will provide an overview of energy efficiency solutions applicable to presses. In particular, first of all, it will be given an introduction on energy efficiency on presses. After that, some examples of technical solutions applied to SACMI presses will be presented. Finally, a quick focus on future trends for energy consumption reduction, such as new hydraulic solutions or electrification.
- Opportunities for CO2-reduction in sintering furnaces
Abstract: Continuous sintering furnaces have been successfully used for serial production of PM products for several decades. High temperatures (> 900 °C) are typical for sintering of PM parts, in addition to the presence of an appropriate protective or reacting atmosphere inside the furnace. The furnace energy consumption and the CO2 footprint are coupled to these sintering conditions. A birds-eye view on the sintering process with an overview of the significant sources of CO2 output and opportunities for its reduction will be presented in this seminar.
Topics that will be touched upon in light of CO2 reduction include: (a) energy aspects such as the post-combustion of exhaust gas, (b) the choices between different atmospheres in dewaxing and sintering zones, (c) advantages and limitations in the use of hydrogen burners for (both direct and indirect) heating, and (d) furnace design choices in view of total CO2-production cycle from source to sink.
- Sintering atmosphere in heat treatment furnaces - Contribution of industrial gases for reducing the carbon footprint
Abstract: Within the Press and Sinter processing for PM parts manufacture, sintering is a major process with high-energy intensity and industrial gases needs. Usually done in continuous belt furnaces, the related CO2 footprint of sintering can be assigned to furnace heating energy, cooling energy, sintering atmosphere production, power consumption, peripheral devices and the process itself.
This paper presents an estimation of the CO2 footprint linked to the sintering atmospheres in continuous belt furnaces, often a mix of nitrogen (N2) and hydrogen (H2) for inerting and reducing properties. Several solutions developed by Air Liquide to reduce this carbon footprint will be also described:
- EcoOrigin: low-carbon nitrogen supply with certification.
- Green H2: supply of hydrogen produced by electrolyser using renewable electricity.
- EcoChiller: energy recovery of cryogenic gases evaporation for precooling of the process water.
- Gases transport and storage optimisation by using of artificial intelligence.
- Sustainability and carbon footprint: High Temperature Sintering (HTS) of Structural Parts
Mr Volker Arnhold (PM Solutions, Germany)
Abstracts: Technical feasibility of HTS has been demonstrated by the EPMA Club Projects ‘HTS 1 and 2’ - see publications at the EPMA Congress 2019 (HTS1) and 2021 (HTS2). The HTS-approach allows the processing of improved PM-alloys, combining lower alloy cost plus the reduction of Health and Safety challenges, by changing the classical PM alloy systems. This is achieved by new powder mixes using alternative alloying elements (Cr, Mo, V) to substitute or significantly reduce elements like Ni and Cu. This SIS contribution focuses on the sustainability aspects of the HTS process by comparing the routing of the HTS process via the conventional processing of diffusion alloyed Fe-base powders containing Ni, Cu and Mo as alloying elements to the alternative alloys, with elements like Cr, Mo and Si.
The analysis of the processing combines the evaluation of powder production (the new alloys are not diffusion alloyed, i.e., skipping the 2nd annealing step) plus a detailed comparison of sintering at 1120°C in belt furnaces with the respective processing at 1250°C in a roller furnace. The difference in energy cost directly reflects the difference in Carbon footprint of the 2 processing routes.
Spare parts and Repair using AM - Friday 22 October - 09:00 – 10:30
Euro PM2021 Topic: Applications
Session Chairs: Mrs Adeline Riou (Erasteel, France); Dipl.-Ing Claus Aumund-Kopp (Fraunhofer IFAM, Germany)
Presentations:
- Additive Manufacturing For Repair: Comparison Of Power Bed Fusion And Solid-state Material Deposition Processes
Dr Ing Toualbi Louise (ONERA, France)
Abstract: In the context of aerospace industry, a particular care to material health of additively repaired parts is required to ensure the highest safety.
This study aims to assess the suitability of various additive manufacturing processes to repair parts made of 10-2-3 titanium and 2219-aluminium alloys. Direct energy deposition and power bed fusion processes are potential candidate for remanufacturing, but these processes involving fusion lead to apparition of thermal stresses at the interfacial region between initial and remanufactured material. The need of further heat treatment may be a limitation, especially in the case of massive part. From this perspective, solid-state material deposition technology, such as cold spray or Additive Friction Stir Deposition (AFSD), appears to be promising for repair.
A fine characterization of the microstructure using EBSD mapping gives access to the thermomechanical history of the repaired material. Mechanical tests are conducted on as-fabricated i.e. repaired and initial i.e. healthy samples.
- Reproducibility of LPBF - we have investigated hundreds of samples in a Round Robin for AlSi10Mg
Abstract: When it comes to higher accuracies, new technologies and thrilling applications in Additive Manufacturing, there is no getting around one topic: materials. But is industrial Additive Manufacturing actually reproducible and reliable? Can we trust this technology?
These questions were the motivation for a round robin test on LBPF with AlSi10Mg. In the "Materials" working group of Mobility goes Additive, the leading international network for industrial additive manufacturing, hundreds of samples were comparatively tested for fatigue and strength and many other material properties were determined.
Are you curious what our findings are and how they relate to the forged samples?
Did you know that you can print copper? Another exciting field which were we gathered the latest finding. Look forward to interesting applications that have already been implemented.
- Cold Spray Delivering for Defence – The Moment Critique
Mr Calum Stewart (Spee3d GmbH, United Kingdom)
Abstract: Cold Spray has arrived at the ‘moment critique’ with regards to Defence Industry. Following our experiences it could be argued quite strongly that cold-spray is far more suited to the rigours of Defence Industry and logistical war-fighting than any other AM process. We must therefore, engage now collectively with the Defence industry, pushing the mantra that 3D printing in Defence translates only to cold spray.
Sinter Based AM - Friday 22 October - 10:45 – 12:15
Euro PM2021 Topic: Consolidation technologies
Session Chairs: Mrs Adeline Riou (Erasteel, France); Dipl.-Ing Claus Aumund-Kopp (Fraunhofer IFAM, Germany)
Presentations:
- Comparison of Laser Powder Bed Fusion, Binder Jet & MIM for Stainless Steel alloys
Abstract: The manufacturing process of Metal Injection Moulding (MIM) is well established, producing vast numbers of small complex components, with a high degree of precision & reproducibility. Stainless steels are some of the most important MIM materials and are produced in significant volumes for consumer applications. However, the initial investment in mould tooling and availability of prototype components is a limiting factor. Additive Manufacturing (AM) process of Laser – Powder Bed Fusion (L-PBF) and Binder Jet printing, which leverages established MIM sintering knowledge and the embedded industrial equipment, can provide a solution with the rapid production of prototype & small scale serial production parts. However, the material properties of the AM printed components, including mechanical properties, dimensional tolerances and surface roughness, have to be comparable in order to meet the functional requirements of a MIM component. This presentation aims to provide a comparison of material properties manufactured AM compared to MIM material.
- Market Dynamics of Binder Jetting and Metal FDM
Mr Matthias Schmidt-Lehr (AMPower, Germany)
Abstract: Metal Binder Jetting and Metal FDM are receiving high attention in the Additive Manufacturing community. AMPOWER presents a market analysis to cover the current status of the supplier and user market and take a deep dive into the latest technology trends.