61
1 May 30 th – 31 st , 2018 Haifa International Congress Center (ICC), Israel www.tms.org/time2018
1
May 30th – 31st, 2018
Haifa International Congress Center (ICC), Israel
www.tms.org/time2018
2
Table of Contents
Introduction.……….………………………………….….……..…..…. 3
Committee……….……………………………….……………..……... 5
Sponsors …………….……………………………………….………... 6
Exhibitors ……..…………………………………………….………… 7
Notable Speakers….……….…………………….…………………….. 8
Program.…………………………..………………..……...…….......…10
Abstracts.………………………....………………..……...…….......…17
3
To increase the impact of global RTD efforts the TIME event is set to bridge industrial demand and
technological supply in the field of metal technologies. The TIME events are set to be bi-annual
events in which a discussion between industrial, governmental and innovative technological sectors is
promoted.
TIME2018 is co-organized by Youngstown state university (Ohio, USA) and the Technion – Israel
institute of technology (Haifa, Israel). It incorporates global experts from industrial related metals
innovation and is a two days event (May 30th-31st 2018). The first day is set to emphasize the
industrial needs from the upcoming metal technologies (materials and processes) and the second one
will showcase the upcoming technologies from the RTD sector.
The Chairman of TIME2018 is Distinguished Prof. Emeritus Dan Shechtman, 2011 (chemistry)
noble laurate and the event is sponsored by the TMS* organization.
Though heavily industry-oriented in its nature, the event welcomes anyone whose work interests
involves metal developments at high maturity of Technology Readiness Levels (TRL)** 4-9.
The purposes of this event are:
a. Screen and review the modern challenges in the current and near future markets applications.
b. Introducing engineers to the latest applicative developments which can be likely to be seen in
the manufacturing companies in the upcoming years.
c. Providing a market review and trends for different technological markets.
d. Creating a platform for industrial cooperation, R&D collaboration and knowledge exchange.
e. Introduce activities and capabilities of innovative companies and research institutes in the
field.
f. Hold a thematic open discussion forum for increased networking of participants.
This symposium aims to bring together experts from industry, academia, and government. The intent
is to bring attention to industrial innovations, mega-trends impacting the metals industry, emerging
technologies that could advance or disrupt the metals industry. Key topics of interest for TIME2018
are:
1) Additive manufacturing
2) Alloys and critical materials
3) Metals processing through shaping, forming, and solidification (including “Advanced
manufacturing in metal processing” experts panel)
4) Applications
Please consider yourself invited to explore the attached agenda and join us at the event to discuss
upcoming industrial technologies and trend in the metals industries.
4
blanc
5
Committee Members:
Iver Andersen, Ames Laboratory
Norbert Babcsan, Aluinvent Zrt
Raj Banerjee, University of North Texas
Menachem Bamberger, Technion, Israel Institute of Technology
Warren Bath, TWI
Dennis Butcher, U.S. Air Force Research Laboratory
Brett Conner, Youngstown State University (Co-organization party)
Santiago Cuesta Lopez, ICAMCyL Foundation: International Research Center in
Advanced Materials and Raw Materials
Narendra Dahotre, University of North Texas
Noam Eliaz, Tel Aviv University
Shai Essel, Technion Israel Institute of Metals (Co-organization party)
Nahum Frage, Ben Gurion University
Dirk Landgrebe, Fraunhofer Institute Forging Technology and Tool Machine
(IWU) Chemnitz
Gideon Levy, Technology Turn Around, CIRP Fellow
Sarang Pande, Marwadi University
Timotius Pasang, Auckland University of Technology,
Maria Letizia Ruello, Università Politecnica delle Marche
Peter Sachsenmeier, VP Hankou University
Virgil Solomon, Youngstown State University
A. Erman Tekkaya, TU Dortmund
Ivan Todaro, University of Bologna
Rafi Wertheim, TU Chemnitz Fraunhofer Institute
Henning Zeidler, Technische Universität Bergkademie Freiberg
6
In Partnership with:
Silver Sponsor:
ISCAR is the largest of the 15 companies comprising the IMC (International Metalworking Companies).
Together, they supply a dynamic comprehensive line of precision carbide metalworking tools. These
companies produce a wide range of carbide inserts, carbide end mills and cutting tools, covering most
metal cutting applications. IMC also provides engineering and manufacturing solutions to major
industries throughout the world. Many innovative products, designed especially for customer
requirements, have made the IMC a world leader in the major manufacturing industries such as
automotive, aerospace and die & mold production.
http://www.iscar.ch/index.aspx/CountryID/26
7
Exhibition sponsors:
http://daya-amt.com/
https://3deimention.co.il/
http://www.kanfit3d.com/
www.lrps.info
www.microtech.co.il
http://www.sharon-tuvia.com/en/
www.shimshon.co.il/en/
https://www.sti-laser.com/
http://www.su-pad.co.il/Why-Work-With-Su-Pad
8
Notable Speakers:
Prof. Dan Shechtman (TIME2018 Chairman) - Professor of Materials Science at
the Technion – Israel Institute of Technology, an Associate of the US Department of
Energy's Ames Laboratory, and Professor of Materials Science at Iowa State University.
Awarded the 2011 Nobel Prize in Chemistry for the discovery of quasicrystals.
Dr. Terry Wohlers - Industry consultant, analyst, author, and speaker Terry Wohlers
is president of Wohlers Associates, Inc., an independent consulting firm he founded
31 years ago. He is a principal author of the recently published Wohlers Report 2018,
the undisputed industry-leading report on additive manufacturing and 3D printing for
23 consecutive years.
Prof. Dr. Gideon N. Levy - Prof. Levy’s career has been mainly in advanced R&D in
Mechanical / Electronic world with leading Swiss machinery industries. Specializing in
Manufacturing technologies, Technology management, Market - Product strategies, key
customers, industrial, scientific, technical and practical aspects of product design and
advanced manufacture, market launch and technology transfer.
Prof. Brett Conner (TIME2018 co-organization) - Director of Advanced
Manufacturing Research Center and Associate Professor of Manufacturing
Engineering at Youngstown State University. Dr. Conner is the Director of the
Consortium for Advanced Hybrid Manufacturing – Integrating Technologies.
Prof. Dr.-Ing. Andreas Schubert - Prof. Dr.-Ing. Andreas Schubert – Head of
Professorship Micromanufacturing Technology at Chemnitz University of Technology.
Experienced in Technology and Knowledge Transfer. Head of Competence Center
Micromanufacturing and Surface Technologies – KoMOT at the Fraunhofer Institute
Machine Tools and Forming Technology.
Eng. Rob Gorham - joined the America Makes team in 2013 as the Deputy
Director of Technology Development and in May 2014 was promoted to Director
of Operations. In May 2017, Rob was promoted to Executive Director of
America Makes. He has more than a decade of solid defense research and advanced
manufacturing experience.
9
Dr. Alex King – Dr. Alex King’s research focuses today on a broad range of issues
related to the supply chains of critical elements for clean energy technologies, but
he hasalso worked in the modeling and characterization of materials – and particularly
their interfaces and interfacial junctions – for a diverse range of applications ranging
from nuclear reactors to microelectronics.
Dr. Santiago Cuesta-López – General Manager of ICAMCyL Foundation,
International Center for Advanced Materials and Raw Materials of Castilla y Leon.
A European level expert in the field of critical raw materials and a researcher in the
field of modelling and first principle simulations of materials.
Prof. Dr.-Ing Henning Zeidler – Heading the Additive Manufacturing professorship
at TUBA Freiberg. Chairman of the Board of Beckmann-Institute for Technology
Development (BTE). Former Chief Executive Engineer at the micro manufacturing
professorship at TU Chemnitz, Prof. Zeidler is teaching at TUBA Freiberg, an
independent entrepreneur and winner of multiple EC grants.
Univ.-Prof. Dr. Leopold Weber – Former head of the Department of Geosciences
and Geotechnical Engineering (today Department of Raw Materials) of the Austrian
Federal Ministry for Economy, Univ. Prof. of the University of Vienna. Former
Austrian representative of the Raw Minerals Supply Group in Brussels and member
of the EC critical minerals ad hoc working group. Prof. Weber is co-editor and
co-author of the annual World Mining Data, the Metallogenetic Map of Austria, the
Handbook of Mineral Deposits, Industrial Minerals and Energy Resources of Austria
the Austrian Resource Information System IRIS and the Austrian Mineral Resources
plan. Amongst high level awards he was awarded with the Serge von Bubnoff Medal
for his work.
10
Conf
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11
10:0
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ffee
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mat
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velo
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ube
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itive
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anuf
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ring
Am
non
Shiri
zly
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ernm
enta
l sup
port
of
indu
stria
l inn
ovat
ion
in Is
rael
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ebre
w)
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ka N
irC2 In
tern
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ram
ewor
ks fo
r R&
D fu
ndin
gN
ili M
ande
lblit
D1
- Inv
ited:
Tita
nium
in C
hem
ical
Indu
strie
s a
nd M
edic
al A
pplic
atio
ns:
Lab
orat
ory
Rese
arch
and
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stria
l Per
form
ance
Mic
hael
Sch
orr
E1- I
nvite
d: U
AM
Sol
id-s
tate
add
itive
man
ufac
turin
g an
d po
st-
proc
essi
ng o
f the
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tem
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an M
iriye
v
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l A
Hal
l A
Hal
l A
Hal
l A
11
11:0
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al-t
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pr
oces
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ith E
OST
ATE
OT
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av M
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ence
of S
hiel
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Gas
Co
mpo
sitio
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Mic
rost
ruct
ure
and
Mec
hani
cal P
rope
rtie
s of
Wire
and
Arc
Add
itive
M
anuf
actu
red
Inco
nel 6
25M
atija
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ić
Allo
ys a
nd C
ritic
al M
etal
s I
Chai
r:Iv
er A
nder
son
D2
Stu
dyin
g th
e Co
mbi
nato
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Effe
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f Pla
tinum
Gro
up M
etal
s a
nd R
are
Eart
hs fo
r Cat
alyt
ic P
erfo
rman
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nhan
cing
for
Auto
mot
ive
App
licat
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Iako
vos Y
akou
mis
E2 Mat
eria
l Dev
elop
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ts in
Bin
der
Jet 3
D P
rintin
gA
ndre
w K
lein
11:2
0A
3Ad
vanc
ed M
anuf
actu
ring
of
Nea
r-N
et-S
hape
Par
ts fr
om
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tiona
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D P
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ous
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n-G
a M
agne
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emor
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lloys
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w o
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actu
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in M
etal
For
min
g at
the
IUL
Ram
ona
Höl
ker-
Jäge
r
C3 -
Invi
ted:
Revi
ew o
f goa
ls a
nd re
sults
of
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izon
2020
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AG p
roje
ct
- Dev
elop
men
t of n
on-r
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eart
h an
d ra
re-e
arth
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per
man
ent
mag
nets
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imir
Popo
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D3
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ed L
ight
Insp
ectio
n:A
Nov
el Te
chni
que
to E
nhan
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resc
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ye a
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agne
tic
Part
icle
Insp
ectio
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eoff
Dia
mon
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E3 Lith
ogra
phy-
base
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ditiv
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anuf
actu
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of M
etal
-bas
ed
Susp
ensi
ons
Ger
ald
Mitt
eram
skog
ler
11:4
0A
43D
Prin
ting
of
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Ni5
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5.5Z
r7B4
Cu1
Hig
h Te
mpe
ratu
re M
agne
tic P
owde
rsVi
rgil
Solo
mon
B4 Mec
hani
cal P
rope
rtie
s of
EB-
wel
ded
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-SLM
AlS
i10M
g A
lloy
Mos
he N
ahm
any
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lera
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stitu
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for R
are-
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h Pe
rman
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agne
tsTh
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Log
rass
o
D4
Pers
pect
ives
of X
CT
for
Non
dest
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of
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ro a
nd N
ano
Stru
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esEh
renf
ried
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E4 Met
hodo
logy
for M
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Eval
uatio
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der B
ed
Addi
tive
Man
ufac
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sed
on M
RL a
nd N
DE
Ori
Yehe
skel
12:0
0 Lu
nch
13:1
5Pl
enar
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ssio
n #2
– D
r. Te
rry
Woh
lers
– T
he fu
ture
of M
etal
Add
itive
Man
ufac
turi
ng
13:4
5Pl
enar
y Se
ssio
n #3
– P
rof.
Gid
eon
Levy
– A
dditi
ve M
anuf
actu
ring
- The
Ena
blin
g Sp
ace
for F
utur
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nova
tion
Gam
e-Ch
angi
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cent
ach
ieve
men
ts a
nd e
mph
ases
14:1
5O
pen
disc
ussi
on (P
anel
): A
dditi
ve m
anuf
actu
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cur
rent
sta
te a
nd fu
ture
cha
lleng
es
(Rob
Gor
ham
, Pr
of. G
ideo
n Le
vy, P
rof.
Bret
t Con
ner,
Hai
m R
osen
son,
Dr.
Terr
y W
ohle
rs)
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erat
or P
rof.
Zeid
ler T
UBA
F
15:0
0Co
ffee
brea
k
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l A
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l A
Hal
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13
Para
llel S
essi
ons
– In
dust
rial
Inno
vati
ons
Add
itive
Man
ufac
turi
ng II
I -
Dire
cted
ene
rgy
depo
sitio
nM
etal
s pr
oces
sing
IIA
lloys
and
Cri
tical
Met
als
IIA
pplic
atio
ns II
Add
itive
Man
ufac
turi
ng IV
AM
App
licat
ions
and
Te
chno
logy
Hal
l AH
all B
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all E
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son
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5 - I
nvite
d:M
icro
stru
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volu
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Def
ect C
ontr
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Com
pone
nts
Fabr
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ed v
ia
Dire
cted
Ene
rgy
Dep
ositi
on
(DED
) N
oam
Elia
z
B5 –
Invi
ted:
Impr
ovem
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in W
eldi
ng
Prop
ertie
s th
roug
h th
e U
se o
f In
terla
yer
Tim
otiu
s Pa
sang
C5 –
Invi
ted:
Roug
hnes
s to
ughn
ess
corr
elat
ion
and
desi
gn
para
met
ers
of fu
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allo
ysSh
mue
l Oso
vski
D5
– In
vite
d: C
lose
d Ce
ll A
lum
iniu
m F
oam
A
pplic
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orbe
rt B
abcs
an
E5 -
Invi
ted:
Addi
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turin
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6Al4
V (E
LI) M
edic
al Im
plan
tsW
illie
Du
Pree
z
16:0
0A
6M
ulti-
Mat
eria
ls a
nd M
ulti-
Func
tiona
lity
Enab
led
by H
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Ad
ditiv
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anuf
actu
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Bret
t Con
ner
B6 Wea
r Pro
pert
ies
of F
rictio
n St
ir Pr
oces
sed
Alu
min
ium
-M
agne
sium
Allo
ySe
bast
ian
Balo
s
C6 Fact
s an
d M
yths
of N
iobi
um
Recy
clin
gA
ndre
as B
artl
D6
Com
paris
on o
f Var
ious
Pro
pert
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of T
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ys fo
r Im
plan
t Mak
ing
Raj S
oni
E6 App
licat
ion
of A
dditi
ve
Man
ufac
turin
g fo
r Vet
erin
ary
Med
ical
Impl
ants
Gar
y M
ulle
r
16:2
0A
7A
Com
para
tive
Stud
y of
Las
er
Surf
ace
Mel
ted
and
LEN
STM
D
epos
ited
Gra
y Ca
st Ir
onRa
jars
hi B
aner
jee
B7 Man
ufac
turin
g of
Fun
ctio
naliz
ed
Surf
aces
for I
nflue
ncin
g th
e Tr
ibol
ogic
al B
ehav
ior o
f Met
allic
Pa
rts
by C
uttin
g O
pera
tions
And
reas
Sch
uber
t
C7 Gra
phen
e as
an
Effec
tive
Supp
ort
for N
icke
l Nan
opar
ticle
s as
a
Cata
lyst
for M
etha
nol E
lect
ro-
oxid
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n in
Alk
alin
e M
ediu
mFi
gen
Kadi
rgan
D7
Influ
ence
of L
ow Te
mpe
ratu
re
on Im
pact
Ene
rgy
and
Mic
rost
ruct
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of U
nallo
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AD
I M
ater
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Dra
gan
Rajn
ovic
E7 Lase
r Add
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Pro
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of a
Fu
nctio
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ded
Inte
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Fr
actu
re F
ixat
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Plat
eSr
iniv
as A
dity
a M
antr
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16:4
0A
8M
icro
n-sc
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Addi
tive
Man
ufac
turin
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sing
Las
er
Tran
sfer
of M
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sZv
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ler
B8 Lase
r and
Ele
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am W
eldi
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of A
dditi
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anuf
actu
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and
Conv
entio
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C8 Nan
ostr
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naly
sis
of P
CBN
an
d PC
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site
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lexa
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Ano
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Hea
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Cas
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Bal
listic
Pr
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Seba
stia
n Ba
los
E8 3D B
iopr
intin
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Hyb
rid
Mat
eria
ls fo
r Reg
ener
ativ
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edic
ine
Impl
emen
tatio
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In
nova
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SMEs
Robe
rt P
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17:0
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ablin
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ater
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evel
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for c
ompl
ex a
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rill V
olch
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B9 Mod
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ed d
iscu
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100,
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Ton
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quire
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arin
a O
ksen
hand
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C9 Nic
kel O
xide
Fun
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phen
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xide
–
Poly
acry
lam
ide
Nan
ocom
posi
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Fige
n K
adirg
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D9
Infil
trat
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of m
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to p
orou
s Si
C pr
efor
m:
indu
stria
lizat
ion
and
appl
icat
ions
of
CM
CItz
hak
Mut
zary
E9 Biol
ogic
al tr
ansf
orm
atio
n in
fluen
cing
man
ufac
turin
g of
m
etal
com
pone
nts
usin
g A
M
tech
nolo
gies
Rafa
el W
erth
eim
18:0
0G
uide
d to
ur a
t the
Bah
a’i G
arde
ns ,
Hai
fa (S
hutt
le w
ill le
ave
from
the
ICC)
14
May
31st
201
8
08:3
0Pl
enar
y Se
ssio
n #4
– P
rof.
Bret
Con
ner –
Adv
ance
d m
anuf
actu
ring
in m
etal
indu
stry
09:0
0Pl
enar
y Se
ssio
n #5
– M
r. Ro
b G
orha
m, E
xecu
tive
Dire
ctor
of A
mer
ica
Mak
esA
mer
ica
Mak
es a
nd S
mar
t Col
labo
ratio
n: A
Dis
cuss
ion
on A
dvan
cem
ents
in th
e A
dditi
ve M
anuf
actu
ring
Indu
stry
09:3
0Co
ffee
brea
k
Para
llel S
essi
ons
– In
dust
rial
Inno
vati
ons
Add
itive
Man
ufac
turi
ng V
: A
dvan
cem
ents
in P
owde
r Bed
Fu
sion
Met
als
proc
essi
ng II
I -
Allo
ys a
nd C
ritic
al M
etal
s III
App
licat
ions
Add
itive
man
ufac
turi
ng V
I: A
M
Tool
ing,
Sur
face
Con
trol
,
Hal
l AH
all B
Hal
l CH
all E
Hal
l D
Chai
rBr
ett C
onne
rPe
ter S
achs
enm
eier
And
reas
Bar
tlIv
er A
nder
son
Sara
ng P
ande
10:0
0A
10 –
invi
ted:
Mec
hani
cal P
rope
rtie
s of
A
lSi1
0Mg
Spec
imen
s Fa
bric
ated
by
Add
itive
Man
ufac
turin
g U
sing
Se
lect
ive
Lase
r Mel
ting
(AM
-SLM
)N
aor U
zan
B10
– In
vite
d:Bu
rnis
hing
of A
ISI 4
140
allo
y st
eel s
urfa
ce u
sing
dia
mon
d m
atrix
com
posi
te to
ols
Mag
dale
na S
zutk
owsk
a
C10
– In
vite
d:
Criti
cal R
aw M
ater
ials
and
thei
r in
fluen
ce in
the
key
pres
ent
and
futu
re te
chno
logi
cal a
nd
indu
stria
l val
ue c
hain
s fo
r Eur
ope
Sant
iago
Cue
sta-
Lope
z
D10
– In
vite
d:Ad
vanc
ed In
term
etal
lic T
itani
um
Alu
min
ides
- D
evel
opm
ent
Stat
us a
nd A
pplic
atio
nsH
elm
ut C
lem
ens
E10
– In
vite
d:
The
Inte
rnet
of T
hing
s (Io
T) fo
r Ca
stin
g w
ith 3
D P
rinte
d Sa
nd
Mol
dsEr
ic M
acD
onal
d
10:3
0A
11Th
erm
ally
Indu
ced
Poro
sity
(TIP
) in
Add
itive
ly M
anuf
actu
red
(AM
) A
lSi1
0Mg
Allo
yEi
nat S
trum
a
B11
Char
acte
rizat
ion
of M
olyb
denu
m
Proc
esse
d by
Equ
al C
hann
el
Ang
ular
Pre
ssin
gYu
ri Kh
optia
r
C11
The
Conc
ern
of C
ritic
al R
aw
Mat
eria
lsM
aria
Lui
sa G
rilli
D11
Influ
ence
of N
anop
artic
les
Am
ount
on
Eros
ive
Wea
r Pr
oper
ties
of Z
A-2
7 A
lloy-
base
d D
ual-s
ize
Com
posi
tes
Ale
ksan
dar V
encl
E11
GE
Addi
tive
- Fro
m P
roto
typi
ng
to P
rodu
ctio
n w
ith S
pect
ra P
atrik
Sjö
öqui
st
10:5
0A
12U
ltras
onic
Cha
ract
eriz
atio
n of
Add
itive
ly M
anuf
actu
red
AlS
i10M
g U
sing
Tim
e of
Flig
ht
and
Att
enua
tion
Calc
ulat
ions
Tom
er S
ol
B12
Inno
vatio
ns in
twin
-rol
l cas
ting
tech
nolo
gies
for m
agne
sium
st
rips
and
wire
sU
lrich
Pra
hl
C12
The
Effec
ts o
f Hea
t Tre
atm
ents
on
the
Phys
ical
Pro
pert
ies
of
NiT
i20H
f Sha
pe M
emor
y A
lloy
Mic
hal K
eret
Kla
iner
D12
AAT
iD c
onso
rtiu
mD
evel
opm
ent o
f Adv
ance
d Te
chno
logi
es fo
r3D
Prin
ting
of T
itani
um A
ero-
stru
ctur
esLi
or Z
ilber
man
E12
An
Effec
t of D
MLS
Pro
cess
Pa
ram
eter
on
Surf
ace
Roug
hnes
s an
d D
imen
sion
al A
ccur
acy
Of
CL50
WS
Mat
eria
lH
iren
Gaj
era
Hal
l A
Hal
l A
15
11:1
0A
13Tu
ngst
en A
dditi
ve
Man
ufac
turin
g–Te
chni
cal
Asp
ects
Dov
Cha
iat
B13
Elec
tro
Chem
ical
Mac
hini
ng, a
n Eff
ectiv
e M
etho
d fo
r Pro
cess
ing
Mat
eria
ls u
sed
in E
xtre
me
Wor
king
Con
ditio
nsZo
ran
Pand
ilov
C13
Tem
pera
ture
Effe
cts
on h
igh
stra
in ra
te b
ehav
iour
of a
Tu
ngst
en A
lloy
Ezio
Cad
oni
D13
Lig
ht-W
eigh
ting
in M
etal
Add
itive
Man
ufac
turin
g U
sing
Topo
logi
cal O
ptim
izat
ion
Dan
Tho
ma
E13
Sur
face
mod
ifica
tion
of A
M p
arts
usi
ng p
lasm
a el
ectr
olyt
icpo
lishi
ngH
enni
ng Z
eidl
er
11:3
0A
14M
etal
s Ad
ditiv
e M
anuf
actu
ring
from
Hig
h-en
d Te
chno
logy
to
Com
mod
ityJe
rem
y M
adow
B14
Ana
lytic
al a
nd E
xper
imen
tal
Inve
stig
atio
n of
Pas
sive
Gra
nula
r M
ediu
m-b
ased
Tub
e Pr
ess
Har
deni
ngH
ui C
hen
C14
Rece
nt D
evel
opm
ents
in th
e Re
sear
ch o
f BCC
Ref
ract
ory
Hig
h En
trop
y A
lloys
Eyal
Esh
ed
D14
SLM
prin
ted
stee
l con
form
al
cool
ed in
sert
for e
xtru
sion
die
s w
ith a
nti-w
ear b
earin
gsIv
an To
daro
E14
Lase
r Ass
iste
d Sy
nthe
sis
of
Hig
h En
trop
y A
lloy
Coat
ing
on A
lum
inum
: Trib
ocor
rosi
on
Beha
vior
Sam
eeha
n Jo
shi
11:5
0A
15Im
plem
enta
tion
of
Ther
mog
raph
ic M
etho
d fo
r D
LMD
Pro
cess
Mon
itorin
gA
nton
ella
Riz
zo
B15
Char
acte
rizat
ion
of In
terf
ace
Stre
ngth
Obt
aine
d by
Hot
Ro
lling
: A C
ompu
tatio
nal S
tudy
Va
lidat
ed b
y Ex
perim
ents
on
Al
1050
and
Al 6
061
Elad
Prie
l
C15
Surf
ace
Cont
amin
atio
n an
d Ca
rbid
e Fr
ee Z
one
Form
atio
n du
ring
Hot
Isos
tatic
Pre
ssin
g of
Su
pera
lloy
IN10
0D
raga
n Ra
jnov
ic
D15
Addi
tive
man
ufac
turin
g in
nova
tions
in Is
rael
Udi
Gal
un
E15
Prop
ertie
s of
Wire
and
Arc
Ad
ditiv
e M
anuf
actu
red
Mat
eria
lsFl
ipo
Bert
rand
12:1
0 Lu
nch
13:3
0Pl
enar
y Se
ssio
n #6
– D
r. A
lex
King
– R
epla
cem
ent o
f cri
tical
raw
mat
eria
l
14:0
0Pl
enar
y Se
ssio
n #7
– U
niv.
Pro
f. D
r. Le
opol
d W
eber
– C
ritic
alit
y of
Min
eral
s: M
yth
or T
ruth
?
14:3
0O
pen
disc
ussi
on (P
anel
): Cr
itica
l raw
mat
eria
ls re
plac
emen
t - c
urre
nt s
tate
and
futu
re c
halle
nges
(A
lex
King
, Leo
pold
Web
er, P
eter
Sac
hsen
mei
er, M
aria
Lui
sa G
rilli
, And
reas
Bar
tl)
Mod
erat
or: D
r. Sa
ntia
go C
uest
a Lo
pez
15:0
0Co
ffee
brea
k
Hal
l A
Hal
l A
Hal
l A
16
Para
llel S
essi
ons
– In
dust
rial
Inno
vati
ons
Add
itive
man
ufac
turi
ng V
II -
Elec
tron
Bea
m M
eltin
gM
etal
s pr
oces
sing
IV
Allo
ys a
nd C
ritic
al M
etal
s IV
App
licat
ions
IV –
A
dditi
ve M
anuf
actu
ring
VII
- New
mat
eria
l and
pro
cess
de
velo
pmen
tH
all A
Hal
l BH
all C
Hal
l EH
all D
Chai
rN
oam
Elia
zIv
an To
daro
Ezio
Cad
oni
Men
ache
m B
ambe
rger
Eric
Mac
dona
ld
15:3
0A
16 -
Invi
ted:
Map
ping
the
Tray
of E
lect
ron
Beam
Mel
ting
(EBM
) Ti-6
al-
4v S
ampl
es -
Prop
ertie
s an
d M
icro
stru
ctur
eEi
tan
Tife
ret
B16
– In
vite
d:
Met
al-c
oate
d Ce
nosp
here
s vi
a M
agne
tron
Spu
tter
Coa
ting
Rout
e - A
New
Pre
curs
or fo
r M
etal
Mat
rix S
ynta
ctic
Foa
ms
Vjac
esla
vs L
apko
vski
s
C16
– in
vite
d:St
rate
gies
for D
evel
opm
ent
of N
ovel
Mat
eria
l Sys
tem
s an
d Co
atin
gs fo
r Ext
rem
e En
viro
nmen
tsRo
bert
Piti
cesc
u
D16
– in
vite
d:Li
thiu
m a
s a
A k
ey A
ctor
in
Glo
bally
Dec
arbo
nize
d M
obili
ty/
elec
tron
ics
and
Futu
re E
nerg
y M
arke
d: A
Circ
ular
Eco
nom
y A
sses
smen
tRo
bert
o Ig
lesi
as
E16
- inv
ited:
Impr
ovem
ent o
f Gas
Ato
miz
atio
n Pr
oces
sing
Effi
cien
cy a
nd P
owde
r Q
ualit
y to
Ben
efit A
dditi
ve
Man
ufac
turin
gIv
er A
nder
son
16:0
0A
17M
icro
n-sc
ale
Mon
te C
arlo
Si
mul
atio
ns fo
r Add
itive
M
anuf
actu
ring
Proc
ess
usin
g El
ectr
on B
eam
Itzha
k O
rion
B17
Spar
k Pl
asm
a Si
nter
ing
Met
hod
for R
ecyc
ling
of T
ungs
ten-
Cont
aini
ng C
ompo
site
Mat
eria
lsVj
aces
lavs
Lap
kovs
kis
C17
Miti
gatio
n of
Met
als
Corr
osio
n in
Ene
rgy
Gen
erat
ion
Plan
ts b
y T
heir
Surf
ace
Prot
ectio
n w
ithCo
atin
gsSi
lviy
a Bo
yche
va
D17
Revo
lutio
nary
Al-a
ir Ba
tter
y Te
chno
logy
Dan
ny G
elm
an
E17
Dev
elop
men
t of a
Ni-b
ase
Supe
rallo
y fo
r Add
itive
M
anuf
actu
ring
Iver
And
erso
n
16:2
0A
18In
Situ
Neu
tron
Diff
ract
ion
of
Addi
tive
Man
ufac
ture
d Ti
6Al4
V U
nder
Tens
ile S
tres
sYa
ron
Gan
or
B18
Com
pres
sion
Cre
ep o
f Cop
per
unde
r Ele
ctric
Cur
rent
Stu
died
by
a S
park
Pla
sma
Sint
erin
g (S
PS)
App
arat
us
Bar
ak R
atzk
er
C18
Cata
lytic
act
ivity
of n
icke
l aft
er
corr
osio
nM
ayta
l Cas
pary
Toro
ker
D18
Al-C
o-Cr
-Fe-
Ni h
igh
entr
opy
allo
y: n
ovel
feat
ures
and
un
ders
tand
ing
Loui
sa M
eshi
E18
Solid
ifica
tion
durin
g Se
lect
ive
Lase
r Mel
ting
of C
o-29
Cr-6
Mo
Allo
yZh
an C
hen
16:4
0A
19Effi
cien
t Man
ufac
ture
of T
itani
um
Airc
raft
Par
ts b
y Li
near
Fric
tion
Wel
ding
Bert
rand
Flip
o
C19
The
Effec
ts o
f The
rmom
echa
nica
l Tr
eatm
ents
on
a N
ew F
e-ric
h D
ual-p
hase
Com
plex
Co
ncen
trat
ed A
lloy
(CCA
)M
arcu
s You
ng
D19
SPD
pro
cess
ed m
ater
ials
for
ener
gy a
pplic
atio
nsRi
mm
a La
povo
k
E19
Num
eric
al a
naly
sis
of in
take
m
anifo
ld a
nd i
ts m
anuf
actu
ring
in a
dditi
ve m
anuf
actu
ring
Seba
stia
n Ko
wal
czyk
17:0
5Cl
osin
g of
TIM
E201
8 an
d To
war
ds T
IME2
020
June
1st 2
018
09:0
0 –
15:0
0G
ener
al A
ssem
bly
of C
OST
act
ion
“CRM
-EXT
REM
E” a
t the
Tec
hnio
n
Hal
l A
Hal
l A
17
Abstracts
Additive Manufacturing I
New Material and Process development
A1
10:30
State-of-the-art and Experiences of New Material and Process
Development for EBM
Andrey Koptyug (Invited)
Main beneficiaries of Additive manufacturing (AM) in metallic materials today
include automotive and aerospace industry, and orthopedics. Having certain
advantages over more traditional metal works AM cannot yet provide needed
range of industrially available materials. Thus one of the main research directions
related to AM today is developing new materials and processes. Suggsted
presentation will discuss specifics of the powder bed EBM process and issues
related to the development of new materials: needed modifications to industrial
equipment, powder- related issues and test procedures, basing on the examples
of successful tests and EBM material development for new steels, amorphous
metal and permanent magnets. It will also present a vision for the systematic
approach to the new material development for EBM. A discussion of the issues
related to the technology transfer from the laboratory environment to industry will
be using an example of the stainless steel 316L process development.
A2
11:00
Real-time monitoring of AM process with EOSTATE OT and MPM
Milovanov Vyacheslav
A3
11:20
Advanced Manufacturing of Near-Net-Shape Parts from Functional
Materials: 3D Printing of Porous Ni-Mn-Ga Magnetic Shape Memory Alloys
C. Virgil Solomon
Ni-Mn-Ga magnetic shape memory alloys are known for producing large
reversible strains in the presence of magnetic fields. These strains are reported in
single crystal samples, which are challenging to produce. Furthermore, Ni-Mn-Ga
alloys possess limited ductility, inherently limiting plastic deformation processing.
Recently, it has been reported that porous polycrystalline Ni-Mn-Ga has produced
18
strains similar to the single crystals. In this work, parts with complex geometries
and hierarchical porosity have been produced by means of 3DP via binder jetting
technique using three Ni-Mn-Ga prealloyed powders with distinct morphologies.
The part porosity depends on the packing rate of the Ni-Mn-Ga powder and the
sintering conditions of the green part. All sintered parts show reversible
martensitic phase transformation, irrespective of the initial powder morphology.
Mechanical properties of the printed parts have been investigated using
compressive testing and nano-indentation techniques. A reversible magnetic-
field-induced strain (MFIS) of 0.01% was observed in thermo-magneto-
mechanically trained parts.
A4
11:40
3D Printing of Fe77Ni5.5Co5.5Zr7B4Cu1 High Temperature Magnetic
Powders
C. Virgil Solomon
In this study, Fe77Ni5.5Co5.5Zr7B4Cu1 magnetic powders prepared by ball milling
from melt spun ribbons were evaluated for 3D printing using binder jetting
technique. Seven different powders have been prepared in three different ball
milling systems (ZrO2, WC, and YSZ) under various milling conditions. Powder size,
size distribution, and powder morphology were investigated in order to optimize
binder jetting parameters, such as printing layer thickness and binder saturation.
Chemical homogeneity of the powders was also investigated since it affects the
printed part quality. Three powders were determined to be suitable for 3D
printing, and one was selected for part manufacturing. Simple geometry parts
have been obtained by binder jetting of selected powder followed by subsequent
processing of the green parts by binder curing and powder sintering. Parts printed
from these high temperature magnetic powders might be used in the
development of smaller and more efficient power convertors and magnetic filters.
19
Additive manufacturing III
Directed energy deposition
A5
15:30
Microstructural Evolution and Defect Control in Al-Si-Mg Components
Fabricated via Directed Energy Deposition (DED)
Noam Eliaz
The influence of processing parameters on microstructure, defects, and
mechanical properties in Al-Si-Mg components, fabricated using laser engineering
net shaping (LENSŽ), a directed energy deposition (DED) additive manufacturing
(AM) technique, was investigated. Our results underscore the finding that
microstructure evolution in the fabricated Al-Si-Mg components is complex and
critically influenced by two phenomena that are active in the melt pool: turbulent
fluid flow and rapid solidification. The microstructure of the LENS deposited
material was studied and compared to that of wrought Al alloys. SEM, EBSD and
TEM were used to investigate the microstructural evolution, while X-ray computed
tomography (X-CT) was used to precisely analyze the formation of pores and their
spatial distribution in the DED fabricated alloys. Furthermore, the evolution of
microstructure of deposited Al-Si-Mg during DED is discussed in the context of
related thermal phenomena in an effort to provide fundamental insight into the
mechanisms that govern defect formation.
A6
16:00
Multi-Materials and Multi-Functionality Enabled by Hybrid Additive
Manufacturing
Brett Conner
The combination of directed energy deposition (DED) additive manufacturing
integrated with a multi-axis machining center enables new products with multi-
material geometries and surface finishes not available to additive processes alone.
Hybrid manufacturing is demonstrated of monolithic and functionally graded
materials (FGMs). DED of compositionally graded combinations of M300 and 316L
steels are explored for applications requiring a significant change in material
hardness. Results from parameter development of deposited monolithic steels are
contrasted with graded steels. An iterative FGM design approach combined rapid
fabrication, computational analysis, and characterization. Additionally the utility of
integrating disparate non-metal deposition capabilities along side metal
20
deposition capabilities into a single hybrid CNC is explored. This endeavor paves
the path toward a practical means of adding discrete disparate multi-material
features in conjunction with graded structures in a single build for the first time
and serves to expand the hybrid approach along both system architecture and
materials axes.
A7
16:20
A Comparative Study of Laser Surface Melted and LENSTM Deposited Gray
Cast Iron
Rajarshi Banerjee
Gray cast iron (GCI) is a classical material well known for its damping properties.
However, it suffers from a low surface hardness and thus, inferior tribological
properties. Therefore, the current work focuses on improving these surface
tribological properties using laser-based strategies. The commercially obtained
GCI was subjected to a surface melting treatment using a 3 kW Nd:YAG laser. The
rapid thermal changes during laser treatment led to a surface microstructure
consisting of two distinct zones: a melted zone and a heat-affected zone
underneath, leading to different microstructures. As a result, a marked
improvement in hardness and surface wear resistance was achieved. Similar
observations were noted in an additively manufactured (AM) samples which were
processed via LENS™. In case of AM samples, the microstructure showed gradual
variation from bottom to the top of the sample because of different extents of
reheating and cooling.
A8
16:40
Micron-scale Additive Manufacturing Using Laser Transfer of Metals
Zvi Kotler
Laser induced forward transfer (LIFT) is a digital, non-contact printing technique
which has been used for printing of micron-scale metallic structures. Versatility in
controlling droplet size in the 100's of femto-liters range and a choice of metallic
print materials, allows for the design and fabrication of functional metal micro-
structures. We will demonstrate high speed LIFT printing technology along with
examples of its use for the fabrication of high resolution electric circuitry and
printed metal MEMS.
21
A9
17:00
Enabling material development for complex applications
Kirill Volchek
3D printing introduces endless material technology benefits, but yet companies
are still struggling on how to incorporate the technology into their product
development and manufacturing processes. The presenter will review the different
challenges and obstacles we face today inn the product development life cycle,
from having a digital model all the way to a printed physical model and how some
of these challenges are met today with the help of innovative approach for having
an agile material development that allows implementing new manufacturing
strategies and business models.
Additive manufacturing V
Advancements in Powder Bed Fusion
A10
10:00
Mechanical Properties of AlSi10Mg Specimens Fabricated by Additive
Manufacturing Using Selective Laser Melting (AM-SLM)
Naor Uzan (Invited)
Materials fabricated by AM technology requests in-depth investigation of a wide
range of mechanical properties. In the present study mechanical properties
(fatigue, tensile and creep) of an AM-SLM AlSi10Mg alloy were investigated. The
results revealed that the as-built machined and polished specimens displayed the
highest fatigue limit, stress relief and hot isostatic pressing decrease the yield
strength, hardness and fatigue limit. Surfaces polished before shot-peening or
following removal of about 25-30μm from the surface after shot-peening by either
mechanical or electrolytic polishing showed improved fatigue limit. The elastic
modulus, yield stress and the ultimate tensile stress values continuously
decreased, while values of elongation rose with increasing temperature. The creep
parameters, namely stress exponent and apparent activation energy indicate that
the creep mechanism at play is related to dislocation creep controlled by core
diffusion. The fine microstructure of specimens is responsible for improved
mechanical properties, but leads to decreased creep resistance.
22
A11
10:30
Thermally Induced Porosity (TIP) in Additively Manufactured (AM) AlSi10Mg
Alloy
Einat Strumza
AM process rapidly developed in the past decades is now serving the needs of
industries for fast production of samples with complex geometries. The most
common printing method is Selective Laser Melting (SLM) of AlSi10Mg. The main
disadvantage of this technique is formation of porosity. In this study, the thermal
expansion and conductivity of AlSi10Mg were measured in two directions parallel
to the printing direction (Z) and perpendicular (X). In both directions, the sample
shows abnormal thermal expansion and conductivity compared to the cast alloy.
After heat treatment, the samples were analyzed using SEM and micro-CT and the
TIP phenomenon was evident. It was established that the TIP was more dominant
in Z direction compare to the X samples. HIP'ed (Hot Isostatic Press) AM samples
were measured as well, to solve the porosity problems. The reasons behind this
phenomenon may be related to the printing strategy as will be discussed.
A12
10:50
Ultrasonic Characterization of Additively Manufactured AlSi10Mg Using
Time of Flight and Attenuation Calculations
Tomer Sol
Additive manufacturing is a novel method for the production of different materials
and alloys. With the increasing development in additive manufacturing, a demand
for quality control has risen as well. Ultrasonic examination, a non-destructive
evaluation (NDE) method, can be used for qualitative and quantitative
measurements of defects common to additive manufacturing. In this research,
Specimens were additively manufactured with notches marking degrees around
the perimeter. The samples, three of which were heat treated prior, were examined
using the Archimedes method and pulse echo ultrasonic methods. Longitudinal
and transverse (angle depended) Time Of Flight measurements were performed,
as well as Frequency Depended Attenuation calculations.The transverse TOF
measurement revealed a clear anisotropy of the material in all samples, as well as
an increase in the attenuation coefficient slope as the heat treatment temperature
increase.
23
A13
11:10
Tungsten Additive Manufacturing–Technical Aspects
Dov Chaiat
Materials well suited for selected laser sintering (SLS) are regularly adapted
by balanced properties of melting point, thermal conductivity, surface
tension and viscosity. With state-of-the-art laser based equipment and the
so far developed processing strategies/parameters the titanium alloys and
stainless steels are defined as "typical easy-to-fabricate materials", whereas
tungsten is still considered "difficult-to-fabricate". Tungsten high melting
point of 3410oC means high cohesive energy and high surface tension. This
fact drives the shaping of the melted tungsten toward a minimum energy
state. It creates a tendency of stopping the merging of melt pools along
the scan tracks and forming individual tungsten spherical drops. This result
is defined as the "balling phenomenon".The paper will touch several
technical aspect of processing tungsten base material by additive
manufacturing.
A14
11:30
Metals Additive Manufacturing from High-end Technology to Commodity
Jeremy Madow
Today's metal 3D printing includes complicated and long procedures which
dramatically affect the efficiency of the process and on the final product cost
(Working with dedicated and costly powders, explosion proof facilities etc.). While
metals 3DP is becoming more and more common, its production systems today
are still expansive and complicated. In order to bring forwards the supply to match
the growing demand DesktopMetal Inc. has been developing a wide range of
technological solutions. This presentation will discuss the state of developments in
terms of new solutions to combine traditional (MIM – Metal Injection Molding)
and additive methods (FDM – Fused deposition Modeling) with their challenges
and limitations. The realization of an office friendly platform to produce metal
end-use parts requires a safe and simple working environment to overcome the
current large technological gap between the designer of the metal part and the
ability to manufacture it. In addition to the metallurgical production process
developed we will also discuss the technologies, materials, resolution and
accuracy. The presentation will also describe the following commercial solution
that will reduce the part cost from 100s of dollars to only a few.
24
A15
11:50
Implementation of Thermographic Method for DLMD Process Monitoring
Antonella Rizzo
The aim of this work is to assess a method to monitor the temperature field that
was produced during the DLMD process, analyze its variation with some process
parameters and study its effects on the presence of pores and cracks, on clad
geometry and on dilution with the substrate. Temperature monitoring was carried
out using a thermal camera with cooled detector and high acquisition frequency,
capable of detecting temperatures up to 2500 °C. Some custom algorithms were
implemented in order to identify some thermal indexes, such as Tmax, heating
and cooling rate, able to provide information about the efficiency of the
deposition process in terms of quality of the repaired part.A number of
experimental tests were designed for the deposition of both single clads and
deposition strategies of a Nickel superalloy powder on an AISI 304 stainless steel
substrate, using an Ytterbium fiber laser source.
Additive manufacturing VII
Electron Beam Melting
A16
15:30
Mapping the Tray of Electron Beam Melting (EBM) Ti-6al-4v Samples -
Properties and Microstructure
Eitan Tiferet (Invited)
We present a study on the dependency of physical properties (density,
elongation, tensile strength and fatigue limit) and microstructure on the
geometrical location in a tray of powder bed EBM. It was found that the
mechanical properties slightly depend on the order of melting. It seems that
when applying high percentage (above 50%) of melted surface, there are density
variations and the mechanical properties deteriorate near the edges of the tray.
Nevertheless, upon applying HIP (Hot Isostatic Pressure) post process, samples
can reach higher density accompanied by higher elongation with uniform
strength and fatigue limits.
25
A17
16:00
Micron-scale Monte Carlo Simulations for Additive Manufacturing Process
using Electron Beam
Itzhak Orion
Electron-beam for additive manufacturing process for metal 3D printing is one of
two alternatives, as the second one is based on Laser beam. Electron energy
deposition in the metal powder is subjected to the way electrons transport in
matter. Simulating variety of energy and flux will enable better optimization of
the AM process.
We describe a Monte Carlo method simulation designed to evaluate the
feasibility and utility of generating realistic particle-scale powder-bed
configurations. For this purpose full simulation details were introduced into the
EGS5 Monte Carlo code. A titanium solid body of 50 micron radius in front of a
wide beam, at 60 keV kinetic-energy, was defined. Energy deposition into the
body, scattered electrons energy and angular distribution were tallied.
Several visual electron-track analyses were demonstrated as well.
From the simulations a new viewpoint to AM process was obtained, and the
momentum transfer from electron to metal bodies was formulated.
A18
16:20
In Situ Neutron Diffraction of Additive Manufactured Ti6Al4V Under
Tensile Stress
Yaron Ganor
Additive Manufacturing (AM) of Ti6Al4V alloy by Electron Beam Melting (EBM)
yields unique microstructures characterized by micron and sub-micron grains.
Phase content is primarily α-phase and residual β-phase. For the research of
mechanical properties of AM Ti6Al4V, specimens in the as built (AB), heat
treatment (HT), and hot isostatic pressing (HIP) conditions were subjected to
tensile stress in-situ neutron diffraction in the SMARTS facility in Los Alamos.
Specimens loaded until certain stress in the elastic region then unloaded, while
measurements took place at selected stresses during loading and unloading.
After reaching yield stress, specimens underwent strain-controlled stressing with
in-situ measurements during stressing. No hysteresis was detected in all samples
in the elastic or plastic regimes. Another specimen underwent a HT at
1000\\176C, increasing β-phase content and larger grains.
Results will be presented and discussed. Further study is required to understand
why AM EBM Ti6Al4V samples are not prone to hysteresis.
26
A19
16:40
Efficient Manufacture of Titanium Aircraft Parts by Linear Friction Welding
Bertrand Flipo
New composites aircrafts require many titanium alloy parts. Aerostructures are
often machined from oversized ingots, forgings or extrusions. For titanium alloys,
this is expensive due to the large amount of wasted material, and their slow
machining. Already known for the production of latest aero engines compressor
Blisks, Linear Friction Welding (LFW) is a disruptive technology capable of
producing aerostructure parts by joining smaller workpieces to produce a
preform, machined to the desired dimensions, reducing lead times and using
material efficiently.Metallographic examinations carried out on a large series of
Ti-6Al-4V trials revealed high integrity welds free from contaminants and oxides
at the weld interface. As-welded joints and post-weld heat-treated joints were
tested under tensile and alternating fatigue conditions, showing properties
directly comparable to the parent material. A techno-economic assessment was
conducted on a demonstrator part, and demonstrated that LFW can be
economically implemented for the aerostructure industry.
Metals Processing I
B1
10:30
Seamless Flowformed Tube Made of Wire Arc Additive Manufacturing
Amnon Shirizly
Flowforming is a metal forming technique for production of axisymmetric
cylindrical workpieces starting from hollowed thick-walled. Generally, a hollowed
pre-formed geometry of seamless axisymmetric extrudes or deep-drawn parts are
used. In this work, the preformed tubes were produce using Wire WALM method
where metal wires are used as raw material for GMAW robot. The preformed tubes
were manufactured adding layer by layer of molten material. The flexibility of
WALM process allows quick change from one geometry to another. However,
material and process parameters such as tool path, welding variables, materials
and other machine properties are critical to the process success. In this work, two
near-net-shape geometries were built from ST37 and SS316L and tested: A close
tube and an open cylinder for forward and backward spinning.The mechanical and
27
metallurgical properties of the wires, preformed tubes and the final flowformed
tubes were examine and compared to the standard requirements.
B2
11:00
Influence of Shielding Gas Composition on Microstructure and Mechanical
Properties of Wire and Arc Additive Manufactured Inconel 625
Matija Bušic
Wire and Arc Additive Manufacturing (WAAM) becomes increasingly important
process for manufacturing complex geometry components. It is especially used for
products made from expensive metals such as Inconel 625. Shielding gas used for
protecting molten pool is one of the key process parameters due to its significant
impact on microstructure and mechanical properties of final product. In this
experiment four samples have been made using different shielding gas mixtures.
Due to its high productivity MIG/MAG welding process has been used. Process
stability and productivity rate were main criteria in determination of the optimal
range of welding parameters. Geometrical characteristics were measured as each
layer has been deposited during the process. Finally, non-destructive and
destructive tests have been conducted on the test specimens and the data was
analysed. The influence of the shielding gas composition on microstructure and
mechanical properties has been determined and the conclusions were drawn.
B3
11:20
Overview of Additive Manufacturing in Metal Forming at the IUL
Ramona Hölker-Jäger
Additive manufacturing processes develop progressively from prototype
manufacturing to component manufacturing and are a complement and/or
alternative to conventional manufacturing technologies like metal forming. The
major advantage of additive manufacturing, i.e., the geometrical freedom of the
components to be produced, is faced by the big disadvantage of a long
manufacturing time. In contrast to many forming technology processes, additive
manufacturing processes are, despite machine and process specific developments,
still not yet suitable for mass production. Therefore, at the Institute of Forming
Technology and Lightweight Components, the approach of an integration of
additive manufacturing processes into the traditional forming technology is
pursued in order to combine the advantages of both technologies. An overview of
the application of additive manufacturing in metal forming at the IUL are given.
28
B4
11:40
Mechanical Properties of EB-welded AM-SLM AlSi10Mg Alloy
Moshe Nahmany
Difficulties in building large AM-SLM modules may hinder using of the SLM-parts
in a wide range of structural applications. An attractive way to resolve this issue is
to produce large composite modules by joining AM-SLM components, by a high-
quality welding method. The electron beam (EB) welding method was used. EB
welding of 2.5-5mm thick AlSi10Mg AM-SLM material have been successfully
conducted. After the welding, weld sheets were cut in pieces for microstructural
examination and mechanical testing. Microstructural characterization of the joint
was performed using optical and scanning electron microscopy. The
macrostructure of the base metal consists of approximately half-cylindrical
solidified melt pools. The weld metal consists of columnar dendrites originating
from the fusion line and equiaxed grains in the center. Tensile properties of joints
were determined by testing flat transverse tensile specimens at room temperature
with machining the weld profiles. The correlation between tensile properties and
microstructure will be discussed.
Metals Processing II
B5
15:30
Improvements in Welding Properties through the Use of Interlayer
(Invited)Timothy Pasang
This paper presents recent results from fusion welding of titanium alloys using
various types of interlayer. Without an interlayer, CP Ti would typically result in
comparable hardness across the weld and base material (BM). However, for α
alloys, near-α alloys and α+β alloys the fusion zone (FZ) and heat-affected-zone
(HAZ) show high hardness compared with the BM. Inversely, β alloys have FZ and
HAZ with lower hardness compared to BM. Under loading, the presence of areas
with higher or lower hardness comparatively to the BM could affect the load
distribution across the weldments. Post welding heat treatment (PWHT) is
sometimes employed to minimise or avoid this situation. However, for large-size
components, PWHT is not practical. In this investigation, we show that by selecting
a proper interlayer the above issues can be minimised or avoided, hence, PWHT
may not be necessary which will lead to cost reduction and process efficiency.
29
B6
16:00
Wear Properties of Friction Stir Processed Aluminium-Magnesium Alloy
Sebastian Balos
Friction stir processing (FSP) emerged as a process similar to friction stir welding
(FSW), but aimed at increasing the surface properties of mainly aluminium alloys. In
this work, the influence of FSP parameters including tool geometry, rotational and
translational speeds, as well as the influence of tool tilt were evaluated. The main
goal was the reduction of magnesium content in aluminium alloys, as the macro
and wear properties of processed AA5754 containing 3 % of magnesium was
compared to the unprocessed AA5083 alloy with 4.5 % Mg. It was shown that the
most influential parameters are tool geometry and tilt angle. The optimized
specimens had the eliminated linear defect of the tunnel type, as well as increased
wear properties. The increase in wear was due to the combination of grain
boundary strengthening effect.
B7
16:20
Manufacturing of Functionalized Surfaces for Influencing the Tribological
Behavior of Metallic Parts by Cutting Operations
Andreas Schubert
Metallic parts are often used in machinery. In many cases they have to bear
tribological loads. With respect to resource efficiency and lightweight design, the
specific loads are increasing in various applications. This can be considered
concerning sliding bearings, where minimum size and minimized friction is of
interest. Specific surface structures help to improve the surfaces to enable high
load and low friction. On the other hand for friction-locked connections of metallic
parts also microstructured surfaces can help to increase the transferable forces or
torque.For both kinds of application it is necessary to have machining technologies
to achieve the needed surface structure within short and reliable process chains.
The presentation shows possibilities to achieve dedicated functional surface
structures manufactured by ultrasonic assisted turning and turn-milling operations
as well as their influence on the tribological functionality of the surfaces.
30
B8
16:40
Laser and Electron Beam Welding of Additive Manufactured and
Conventional Ti-6Al-4V Parts
Benny Tavlovich
In recent years, the use of powder bed additive manufacturing (AM) increases
rapidly. The current AM production systems are size limited. In many cases the
required parts are larger than the chamber size, and therefore there is a need to
produce sub-parts and weld them together. According to product’s complexity it
can be produced either by AM or by conventional manufacturing methods.In this
study Ti-6Al-4V parts were produced separately by conventional and by AM
processes, and later were joined together using two welding methods: laser or
electron beam welding. Weld properties of conventional to conventional, AM to
AM, and of AM to conventional manufactured parts were examined. The properties
were analyzed and compared in terms of weld bead profile, tensile strength, micro-
hardness, macro examination, and nondestructive testing. The results indicated that
it is possible to achieve sound welds of AM to AM, and of AM to conventional Ti-
6Al-4V parts.
B9
17:00
Moderated discussion – 100,000Ton press project –potential, needs,
collaboration and requirements -
Marina Oksenhandler
Metals Processing III
B10
10:00
Burnishing of AISI 4140 alloy steel surface using diamond matrix composite
tools
Magdalena Szutkowska (Invited)
New, two diamond matrix composites with 10 wt.% Ti3GeC2 and 10 wt.% TiB2
bonding phases were used. The diamond powder of 3-6 ľm (MDA, De Beers) was
mechanically mixed with the Ti3GeC2 phase and separately with TiB2nano phase.
Ti3GeC2 phase was produced by self-propagating high temperature synthesis
(SHS). Compacts were sintered at pressure of 8.0 GPa and temperature of 2235K
using the Bridgman type high pressure apparatus. The mechanical properties were
determined: Vickers hardness HV1, Young’s modulus, compressive radial strength,
fracture toughness and wear resistance. Microstructure studies using scanning and
31
transmission electron microscope, X-ray and electron diffraction phase analysis
were used. To improve the final quality of the AISI 4140 alloy steel, balls of
diamond new-composites were incorporated into burnishing tools. For selected
ball diameter the influence of burnishing parameters, such as burnishing force and
feed on surface geometry parameters were measured and profilograms of the
surface roughness was recorded.
B11
10:30
Characterization of Molybdenum Processed by Equal Channel Angular
Pressing
Yuri Khoptiar
Equal Channel Angular Pressing (ECAP) induces severe plastic deformation in
metals, resulting in very fine (usually sub-micron) grain size. It has been
successfully employed to various metallic materials, however limited data is
available on ECAP of molybdenum. In this work we report on successful ECAP
processing of molybdenum 30 mm rods. For this purpose, special ECAP die was
designed and manufactured. High purity Mo rods were preheated to 900-1000°C
prior to pressing. ECAP process was employed using "C" route. The microstructure
and the mechanical properties of ECAPed molybdenum before and after
subsequent heat treatment will be presented based on HRSEM, EBSD and tensile
testing.The ECAP process was also investigated using a coupled thermo-
mechanical finite element model that was validated by comparison to
experimental observations.
B12
10:50
Innovations in twin-roll casting technologies for magnesium strips and
wires
Ulrich Prahl
B13
11:10
Electro Chemical Machining (ECM), an Effective Method for Processing
Materials used in Extreme Working Conditions
Zoran Pandilov
Electro-Chemical Machining (ECM) is a generic term for a different electro-
chemical processes. ECM is used to machine work pieces made from electro-
conductive metals and metal alloys irrespective of their hardness, strength or
32
thermal properties, through the anodic dissolution, in different industries, like
Energy, Transportation and Machinery manufacturing. The Electro Chemical
Machining is particularly suitable for machining materials used in extreme
conditions like high temperature, loading, friction and wear. Basic principles,
application for processing different materials, achievable tolerances and
advantages of the Electro-Chemical Machining are presented. Prof. Dr. Zoran
Pandilov Faculty of Mechanical Engineering, University "Ss. Cyril and Methodius"-
Skopje, Republic of MACEDONIA, E-mail: [email protected] of the WG 1
and Management Comitee Member from the Republic of MACEDONIA for the
COST Action CA 15102
B14
11:30
Analytical and Experimental Investigation of Passive Granular Medium-
based Tube Press Hardening
Hui Chen
In response to the demand of lightweight design and increased safety
requirements, press hardening has become the standard manufacturing process in
producing side-impact components such as B-pillars of cars. The use of granular
material as forming medium in tube hydroforming can enable press hardening of
tubes for directly producing hollow components that need not only provide
strength but also stiffness. However, the non-hydrostatic and frictional properties
of granular media, unlike conventional hydroforming fluids, cause limitations in
part complexity. An enhancement of granular medium-based tube press
hardening is to not actively pressurize the granular material but have it passively
build up pressure as a reaction to the movements of outside forming punches. To
analyze the technology, the physical background is described deriving an
analytical process model. Experimental investigations show the feasibility of the
new process to produce hollow profiles with complex geometries and high tensile
strengths up to 1500 MPa.
B15
11:50
Characterization of Interface Strength Obtained by Hot Rolling: A Computational
Study Validated by Experiments on Al 1050 and Al 6061
Elad Priel
Multi-layered aluminum alloy sheets are commonly used in the aerospace and
automotive industry. Hot roll bonding is an effective approach for manufacturing
multi-layered sheets but the exact relation between the thermo-mechanical fields
33
which develop during hot rolling and bonding strength is still an open question. In
the present study, a novel configuration of bi-layered specimens was used to
generate interface bonding through hot rolling in Al 1050/Al 1050, Al 6061/Al
6061 and Al 1050/Al 6061 pairs. Three point bending (3PB) experiments were
conducted on the rolled specimens in order to examine the interface strength.To
quantify the thermo-mechanical conditions which develop at the interface during
the roll bonding experiments, a coupled thermo-mechanical finite element model
was developed. To model interface debonding in the 3PB experiments a cohesive
zone approach was utilized. The obtained characterization of the interface
strength and its dependence on the experimental parameters will be presented
and discussed.
Metals Processing IV
B16
15:30
Metal-coated Cenospheres via Magnetron Sputter Coating Route - A New
Precursor for Metal Matrix Syntactic Foams
(Invited)Vjaceslavs Lapkovskis
The four types of composite powders (CP) comprising of the ceramic hollow micro
spheres with particle size 50-125 痠, (average particle size d50 is 75 痠) and
metals: Cu, stainless steel (SS), Ti and double layer Ti-TiN film coatings were
obtained and discussed in current work. The CPs, coated with meals were
obtained by plasma vapour deposition (PVD) using a magnetron sputtering
system. By varying the sputtering rate, the coating thicknesses varied in the range
of 0.4-2.5 痠 for Cu films and 0.2-0.8 痠 for SS films. A series of Al matrix
composite syntactic foam (SF) cylindrical shape samples were fabricated by spark
plasma sintering (SPS), using constant pressure – 9,5 Mpa, 60 and 120 sec of
sintering time. Obtained samples of SF has apparent density 0.9-1.2 g/cm3 range.
Obtained samples has apparent density 1.1 -1.9 g/cm3 range and compressive
strength from 30 to 130 MPa.
B17
16:20
Spark Plasma Sintering Method for Recycling of Tungsten-Containing
Composite Materials
Vjaceslavs Lapkovskis
Tungsten as a critical raw material for the European Union is mainly used in the
34
manufacturing of hard metals and abrasives, as well as in the aerospace industry
in form of composites. Current work proposes an effective approach for such
composite materials recycling where particles or filaments of metallic tungsten are
distributed in the mass of composite matrix such as aluminium or copper.
Application of spark plasma sintering approach facilitates bonding between
tungsten and matrix material producing new composite materials with enhanced
properties.
B18
16:40
Compression Creep of Copper under Electric Current Studied by a Spark
Plasma Sintering (SPS) Apparatus
Barak Ratzker
The spark plasma sintering (SPS) apparatus, typically used for powder
consolidation, utilizes simultaneous application of uniaxial pressure and elevated
temperature, generated by a current flow that passes through graphite tooling. In
principle, the SPS apparatus is a high-temperature dilatometer and can be
employed as a creep testing device. Moreover, one can employ two different
testing configurations for conductive materials, which determines whether the
sample is isolated from the current or not. This allows to study the effect of an
electric current passing through the sample on creep behavior and electro-plastic
deformation (EPD) of conductive materials, which might be important for metal
shaping and forming. In the present study, the influence of an electric current
) on the creep behavior of pure copper during 27 A/mm-(density of ~6
compression creep in the 400-600蚓 temperature range was investigated. The
nature of the electro-plasticity and the experimental results will be discussed.
Seminar – Israel Innovation Authority
Alloys and Critical Metals I
C1
10:30
Governmental support of industrial innovation in Israel (Hebrew)
Malka Nir
35
C2
11:00
International frameworks for R&D funding
Nili Mandelblit
C3
11:20
Review of goals and results of Horizon2020 NOVAMAG project -
Development of non-rare-earth and rare-earth-lean permanent magnets
PopovVladimir
In suggested presentation will be demonstrated research and development of
high performance permanent magnets and technologies in the framework of
European project NOVAMAG. The novelty of this project is the use of theoretical
modelling tools to discover/develop advanced rare earth-free/lean permanent
magnets. Among the main objectives, NOVAMAG aims to develop an automated
large computational screening followed by experimental screening of new and
novel intermetallic compounds with uniaxial structures (with high saturation
magnetization, magneto-crystalline anisotropy and Curie temperature), which can
be used for the rapid development of high performance permanent magnets
without the use of critical raw materials (CRM). The newly found compounds with
either no CRM (MnAl, FeNi, FeCo) or significantly reduced CRM like in the RFe12
alloys with the tetragonal 1:12 structure and R=Ce, Nd, Sm will be presented.This
project has received funding from the European Union’s Horizon 2020 research
and innovation program under grant 686116.
C4
11:40
Accelerated Development of Substitutes for Rare-Earth Permanent Magnets
Thomas Lograsso
The Critical Materials Institute has developed a multi-pronged approach to finding
substitutes for permanent magnets including materials discovery, application of
advanced manufacturing methods and substitution at the system level to improve
overall motor performance. An integrated computational experimental
methodology for materials discovery allows for rapid screening of both intrinsic
magnetization properties as well as quickly identifying those systems that can
develop extrinsic coercivity required for a hard magnet. This effort has rapidly
identified both high performance magnets with reduced RE content and RE-free
magnets that exceed the performance of existing non-RE magnets. Alternatively,
application of advance manufacturing methods such additive manufacturing,
36
magnets can be fabricated into unique configurations that can concentrate flux
not possible with conventionally processed magnets. When coupled with
advanced motor design, overall motor performance can be improved with
reduced magnet sizes and with significant less manufacturing scrap losses.
Alloys and Critical Metals II
C5
15:30
Roughness toughness correlation and design parameters of future alloys
Shmuel Osovski (Invited)
As materials science and technology continues to evolve, the possibility of fine-
tuning materials’ parameters and microstructures per specific application is
becoming a reality. The complexity of the various achievable microstructures and
their effect on the overall performance of the material calls for an integrated
computational experimental approach. The lack of understanding of how complex
microstructures interact with one another, as well as with the applied loading (e.g.
stress state, loading rate etc.) is impeding their future development, when
considering issues related to damage accumulation and fracture, the knowledge
gaps are even more apparent. Here, we will demonstrate how a combined
experimental-numerical effort can lead to design guidelines for future alloys, while
emphasizing the role of the different microstructural constituents on damage
accumulation and crack growth.
C6
16:00
Facts and Myths of Niobium Recycling:
Andreas Bartl
It is well known that the supply of certain raw materials is essential for
technologically-advanced economies. In 2017 a third list of 27 CRM’s was
published by the European Commission which, among others, contains Niobium.
Niobium is believed essential for emerging technologies such as ferroalloys or
micro capacitors. The supply risk for Niobium is extremely high as 90 % originates
from Brazil. Recycling of Niobium is extremely important. The reported recycling
rates vary from zero up to 56 %. As Niobium is predominately used for alloys in
concentrations below 1 %, recycling of Niobium is based on a separate processing
of Niobium containing steel which are remelted into the same (or a similar) alloy.
In practice, Niobium containing steel grades are commingled with other steel
37
grades and Niobium is heavily diluted. Niobium undergoes a “non-functional”
recycling which means that it does not exhibit any function and is de facto lost.
C7
16:20
Graphene as an Effective Support for Nickel Nanoparticles as a Catalyst for
Methanol Electro-oxidation in Alkaline Medium
Figen Kadirgan
Although Pt-based alloys have been considered most active for methanol
oxidation, the cost price and limited supply of Pt constitute a major barrier
to the development of direct methanol fuel cells (DMFCs) based on Pt.
Therefore investigations on low cost non-noble metals for electrocatalysis
of the methanol oxidation reaction are increasing. In this work, graphene
surface is decorated by nickel nanoparticles using a simple electro-
deposition method. Nickel nanoparticles (NP) are deposited on the surface
of glassy carbon electrode (GCE) which was previously treated by reduced
graphene oxide (RGO). The electro catalytic activity of the Ni catalysts
toward methanol oxidation in alkaline medium are investigated by cyclic
voltammetry, chronoamperometry, Tafel plot and electrochemical
impedance spectroscopy. It is found that the methanol is oxidized on
Ni/RGO/GCE electrode with higher rate, low activation energy and over-
potential. Beside of higher catalytic activity of Ni on graphene, it shows
better stability in comparison with Ni/GCE.
C8
16:40
Nanostructure analysis of PCBN and PCD composites
Alexander Anokhin
C9
17:00
Graphene as an Effective Support for Nickel Nanoparticles as a Catalyst for
Methanol Electro-oxidation in Alkaline Medium
Figen Kadirgan
Graphene oxide (GO) and its functionalized - modified - reduced derivatives take
important place in a variety of technological applications because of their unique
electrical conductivity properties and excellent mechanical properties which
intrinsically come from two dimensional, sp2 bonded carbon honeycomb crystal
38
structure of graphene and its high specific surface area (~2600 m2.g-1). Having
this large surface area allow graphene to be homogeneously dispersed in polymer
matrix, thus it can be used to fabricate advanced nanocomposites which can be
integrated in energy storage systems, physical and biological sensors, flexible
electronics and many other applications. In this work, a novel nickel oxide (NiO)
functionalized graphene oxide (GO) - polyacrylamide (PAAM) nanocomposites,
(NiO-GO)n/PAAM fabricated by in situ polymerization method will be explained.
Their structural properties, mechanical properties, electrical properties and self-
healing abilities will be discussed. The optimum concentration of (NiO-GO) and
other important parameters were given for each property.
Alloys and Critical Metals III
C10
10:00
Critical Raw Materials and their influence in the key present and future
technological and industrial value chains for Europe
Lopez-Santiago Cuesta
Key sectors like the Energy production, aerospace, transportation,
communications, components, tools and manufacturing, representing more than
80% of the EU economical activity, rely on the use of strategic materials. A clear
example are refractory metals, the core of technology/materials for components
and materials working under extreme conditions. In the case of Energy
production, the particular case of refractory (i.e Nb, W) and other Critical Raw
Materials (CRMs) like Lithium (Energy storage), Cr and ODS steels used for
Concentrated Solar Power, or advanced materials for future Nuclear systems will
be examined. Alloys and superalloys used in the aerospace sector constitute a
technological challenge to ensure the non-dependence of CRMs. Present barriers
and technology advances towards substitution will be presented to the
audience.Moreover, substitution and recyclability analysis, as well as raw materials
flow for the above mentioned value chains, will be discussed and analyzed,
presenting the last recommendations for different cases of relevance.
39
C11
10:30
The Concern of Critical Raw Materials
Maria Luisa Grilli
There is a growing concern about securing access to metals and minerals needed
for economic production. Raw materials are, in fact, at the basis of Europe’s
economy. This work offers a survey of critical raw materials (CRMs) used in energy,
transportation and machinery manufacturing. Understanding of the role of CRMs
and a careful evaluation of environmental and health impacts are key factors in
materials’ substitution, when searching for alternatives able to maintain the
performance of components and products.Some of the on-going EU activities in
the field of CRMs are described. Insights into a possible reduction, substitution or
recycling of certain CRMs in advanced engineering materials are given.
C12
10:50
The Effects of Heat Treatments on the Physical Properties of NiTi20Hf
Shape Memory Alloy
Michal Keret Klainer
The unique properties of shape memory alloys (SMAs) allow technological
applications in various fields. The shape memory effect is related to phase
transformation that can be induced by a temperature change. As a consequence,
heat transport is a key process for the function of the shape memory effect.This
research focuses on the effect of heat treatments on the physical properties of the
novel NiTi-20Hf alloy. Its transition temperature is in a range of 120-200ºC,
making it an attractive candidate for high-temperature actuators. In designing an
SMA-based actuator, various physical properties must be taken into consideration:
density, latent heat, specific heat, thermal conductivity and sometimes electrical
conductivity. These properties, measured in samples of NiTi20Hf rod and sheet,
will be presented in comparison to binary NiTi. The knowledge and the ability to
control physical properties of Niti-20Hf SMAs will endorse their use in the high
temperature aerospace applications in the future.
C13
11:10
Temperature Effects on High Strain Rate Behaviour of a Tungsten Alloy
Ezio Cadoni
Tungsten alloys are often used in machinery and in other industrial sectors.
40
Tungsten is one of the Critical Raw Materials that are the object of the Cost
Action CA15102 “Solutions for Critical Raw Materials Under Extreme
Conditions (CRM-EXTREME)”. The extreme conditions object of this paper is
the high strain rate and the combined effect with the temperature. The aim
of this paper is the description of the mechanical characterization of a
tungsten alloy under extreme conditions of temperature and loading. The
experimental results in extreme conditions of high strain rate and high
temperature of a tungsten alloy are presented.The temperature ranges
from room temperature to 1100°C while the high strain rate is between
1000 and 2000 s-1. Temperature of 400°C induce an increment of ductility
in the alloy. The strain rate provokes an enhance of strength and modulus
of toughness.
C14
11:30
Recent Developments in the Research of BCC Refractory High Entropy
Alloys
Eyal Eshed
High Entropy Alloys (HEAs) are a class of equimolar alloys incorporating at least
five elements and exhibiting a single, configurationally disordered, solid solution
rather than multiple intermetallic compounds. In recent years, this new class of
metallic materials has been extensively studied with the purpose of understanding
phase formation in them and finding high-performance applications for them in
advanced engineering. 2nd and 3rd generation HEA samples have been produced
by vacuum arc melting from elemental metallic pieces which were subsequently
heat-treated at various temperatures. The microstructures of the as-cast and the
heat-treated samples were investigated by means of scanning electron
microscopy combined with electron probe micro analysis and x-ray diffraction.
The mechanical properties were also evaluated.The effect of different elements on
the microstructural and mechanical behavior of HEAs was determined. The
obtained results will be presented and discussed with the aim to clarify future
directions in applicative research of HEAs.
C15
11:50
Surface Contamination and Carbide Free Zone Formation during Hot
Isostatic Pressing of Superalloy IN100
Dragan Rajnovic
The HIP process is of great importance for superalloy castings due to the almost
complete elimination of micro-porosity by a combination of plastic deformation,
41
creep and diffusion. However, during the HIP a contaminated surface layer and a
carbide free zone are formed. To study these surface errors differently grinded
and polished samples made of superalloy IN100 were used. The thickest
contaminated layer occurs for the grinded samples (1,728 µm), while the lowest
layer thickness was in case of polished samples (0,888 µm). The contaminated
layer is consisted of oxides, carbides and nitrides formed due to the diffusion of
chemical elements from metal matrix and their reaction with impurities in HIP
atmosphere. Consequently, a carbide free zone is formed with depth of 100 and
48 µm for grinded or polished samples, respectively. Finally, in order to minimize
surface errors during the HIP process a smoother part surface is preferable.
Alloys and Critical Metals IV
C16
15:30
Strategies for Development of Novel Material Systems and Coatings for
Extreme Environments
Robert Piticescu (Invited)
The objective of this review is to make a critical analysis of the existing
methodologies and strategies to develop materials systems and coatings to be
used in extreme environments. Understanding that extreme or harsh conditions
encompass a large variety of solicitations in service such as: extreme temperatures,
friction and/or radiation in aerospace or aeronautic parts or structures,
microelectronic components, industrial facilities and vehicles as well as corrosion
and erosion conditions or shock waves due to marine environment affecting the
off-shore infrastructures due to wind, etc. An overview of the deposition
techniques to achieve surface protection and modification, with selected examples
of materials systems and protective coatings aiming to reduce the use of CRMs
are revealed. Acknowledgments: H2020 Grant Agreement TWINNING 692216 The
virtual Center for sustainable development of Advanced Materials operating under
extreme conditions"- SUPERMAT -COST Action CA 15012“Solutions for Critical
Raw Materials under Extreme Conditions”- Ministry of Research and Innovation,
RDI Program for Space Technology and Avanced Research - STAR, project number
528 –Androtech.
42
C17
16:00
Mitigation of Metals Corrosion in Energy Generation Plants by Their Surface
Protection with Coatings
Silviya Boycheva
Stainless steels (SSs) are the main constructional material in energy generation
plants because of their excellent corrosion resistance due to the formation of a
protective oxide layer acting as an intermediate boundary with contact media.
Therefore, SSs are structural materials for critical components to be used in
contact with reactor cooler, saturated and superheated steam. The unique
properties of SSs are governed by adding critical raw materials (CRMs), as Cr, Mo,
Si, V, W, Mn, Mg, Nb, Co, Be, etc. The prolongation of time of life of these key
constructional materials by improvement of their corrosion resistance will provide
CRMs saving. Stronger protection of SSs can be ensured by building up of an
additional anti-corrosion coating with high chemical, thermal and erosion
resistance.
C18
16:20
Catalytic activity of nickel after corrosion
Maytal Caspary Toroker
Metals are often used as catalysts for the oxygen evolution reaction which is of
significant importance for water splitting as an alternative energy source energy.
However, metals may corrode to have hydroxyl terminations and even allow
diffusion of hydrogen atoms whose positions are not fully determined
experimentally. In order to understand how hydrogen diffusion affects catalytic
efficiency, we use Density Functional Theory+U (DFT+U) calculations that model
oxygen evolution reaction catalysis for pure and doped metal oxide materials. Our
calculations reveal that hydrogen diffusion is possible in some doped cases. This
could provide insights on the duality of proton and charge transfer at the surface
of reactive materials.
C19
16:40
The Effects of Thermomechanical Treatments on a New Fe-rich Dual-phase
Complex Concentrated Alloy (CCA)
Marcus Young
A new approach for alloy development involving so-named high-entropy-alloys or
complex-concentrated-alloys has opened endless opportunities for the
exploration of novel structural alloys. This new approach utilizes the
43
thermodynamic balance between high configurational entropy and Gibbs phase
rule to explore complex systems of 4-5 elements or more. The main difference
from traditional alloys is that no base element is required and the composition is
usually equiatomic or near-equiatomic. The outcome of highly concentrated
atomic mixtures results in unique properties of the crystal structure, e.g. a highly
distorted lattice. Complex concentrated alloys (CCAs) are less restrictive, allowing
for one or more elements to be more dominant in the mixture. In this study, we
present a novel Fe-rich CCA, Fe30Cr19Ni19Co19Al11Ti2 (atomic %), which
combines a dual – phase FCC/BCC structure with some age-hardening capabilities.
Applications I
D1
10:30
Titanium in Chemical Industries and Medical Applications: Laboratory
Research and Industrial Performance
Michael Schorr (Invited)
The use of titanium (Ti) and its alloys, as materials for the manufacture of chemical
equipment, for production of orthopedic implants; in aircraft and aerospace
vehicles, military missiles is expanding due to improvement in production, a
steady reduction in price, availability and fabrication technology. This work
presents the experience of the authors in laboratory investigation and industrial
development, in two fields: a. application of Ti in the fabrication of corrosion-
resistant equipment for fertilizers, minerals and chemicals in innovative production
plants in Israel and b. The advancement of a Ti6Al4V alloy, modified with TiO2
nanotubes, which was developed for antibacterial and antifungal activity; and
development of a Ti orthopedic implant coated with hydroxyapatite, in laboratory
research in Mexico and Israel. The results and illustrations of these industrial
performances and laboratory investigations, of the collaborating countries: Mexico
and Israel, will be presented and discussed.
D2
11:00
Studying the Combinatorial Effect of Platinum Group Metals and Rare
Earths for Catalytic Performance Enhancing for Automotive Applications
Iakovos Yakoumis
The use of ceramic materials that exhibit redox properties or lattice oxygen ion
44
mobility and/or electronic conductivity at intermediate and high temperatures, as
catalysts support has been significantly enhanced over the last decades. In this
study, the effect of oxygen storage capacity of various ceria-zirconia oxides on the
catalytic activity has been investigated. A Pt/CexZr1-xO2 catalyst has been
synthesized at two different loadings, and tested for the gas phase C3H8 oxidation
reaction. Three CexZr1-xO2 oxides, corresponding to different oxygen storage
capacity values have been used. The results reveal the important role of lattice
oxygen on the gas phase oxidation and have been interpreted in terms of: i. the
metal work function modification when strongly adsorbed O-ions are present on
its surface, ii. the electron transfer through the oxide, and iii. the oxygen vacancies
present on the oxide support surface in the proximity of the three phase
boundaries.
D3
11:20
Mixed Light Inspection: A Novel Technique to Enhance Fluorescent Dye and
Magnetic Particle Inspections
Geoff Diamond
Currently, penetrant Inspection (PI) and Magnetic Particle Inspection (MPI)
requires ambient lighting conditions to be very low which often limits deployment
to darkened rooms or under covered awnings and tents. The extra time and
resources necessitated by operating under low light conditions can cause
production bottlenecks, be expensive in terms of manpower and increase
downtime. The system presented here eliminates these production bottlenecks
and significantly increases throughput rates at inline inspection points. We present
a novel technique that can extract fluorescent signals less than 20-lux, from
background light levels of over 100,000-lux. This advance is a step-change
improvement in reducing processing times and raising standards and consistency
of quality audits when using PI and MPI techniques. Additionally, machine vision
software automatically detect defects and identifies regions of interest for the
operator by overlaying falso colours on visual images of the inspected part. All
images (pass or fail) are permanently stored to provide a 100% Quality Audit.
Technicians can be used in lieu of more fully trained inspector and the
productivity of a qualified inspector can be greatly increased by enabling them to
inspect remotely via telemetry, supervising/reviewing the work of technicians on
the ground in multiple geographically separated sites.
45
D4
11:40
Perspectives of XCT for Nondestructive Studying of Metallic Micro and
Nano Structures
Ehrenfried Zschech
High-tech products or their internal components often have geometrical
dimensions or microstructure features in the micro- and nanometer range. High-
resolution 3D characterization of these metallic materials and structures is needed
for materials development, process control and quality assurance. X-ray computed
tomography (XCT) is a versatile tool for nondestructive 3D characterization of
materials and structures also in the sub-micrometer range. Novel laboratory X-ray
sources, e. g. using micro-structured anodes, and novel focusing optics, e. g.
multilayer Laue lenses, will enable spatial resolutions down to 0.3 m and 10 nm
for sub-micro XCT and nano XCT, respectively [1]. In addition, multilayer Laue
lenses allow to extend laboratory nano XCT to photon energies > 10 keV.
Examples for high-resolution X-ray imaging will be shown: Metallic parts
fabricated using additive manufacturing, crack propagation in composites and
failure localization in metal interconnects for 3D-stacked microchips.
Applications II
D5
15:30
Closed Cell Aluminium Foam Applications
Norbert Babcsan (Invited)
The success of an innovation depends on the market needs. Closed cell
aluminium foams are mainly used as structural materials. Besides the light
weight of the closed cell aluminium foams there are three main properties
as aesthetics, mechanical energy absorption and specific stiffness which are
driving three industrial groups as 1. design and building industry, 2.
defence and safety industry, 3. mobility and machinery, respectively. The
paper discusses our products, prototypes and their properties developed
from different aluminium foam materials.
46
D6
16:00
Comparison of Various Properties of Ti Alloys for Implant Making
Raj Soni
The paper deals with the review of work being carried in the field of biomedical
alloys. Lot of work is going on around the world for making implants with
Titanium (Ti) as the base metal. The paper focuses on several Ti alloys comparison
considering various properties such as Young’s modulus, density, microstructure,
corrosion, wear, fatigue, cytotoxicity, osseointegration etc. for suitability to make
implants. Currently used implant material like Ti6Al4V contains adversity due to
Al- and V- contents and also high Young’s modulus which is the reason for Stress
Shielding, suggesting to discover alternative materials. The paper also includes
process adopted to make Ti-Ta alloy by arc melting and its microstructure
evaluation by SEM and XRD. It reveals the microstructure characteristics of Ti-
30%Ta and Ti-70%Ta. Former contains α’ (HCP) structure and the later contains β
(BCC) structure which is very promising for biomedical application.
D7
16:20
Influence of Low Temperature on Impact Energy and Microstructure of
Unalloyed ADI Material
Dragan Rajnovic
The Austempered Ductile Iron (ADI) is obtained by austempering heat treatment
of ductile iron and it possess a unique microstructure of ausferrite - a mixture of
ausferritic ferrite and carbon enriched retained austenite. Depending on the
microstructure obtained, the ADI have a wide range of mechanical properties,
especially a remarkable combination of high strength and toughness. However, at
low temperatures ausferritic ferrite and retained austenite have different behavior,
as they have body centered or face centered cubic structure, respectively. For that
reason, in this paper impact energy and microstructure of unalloyed ADI with
different starting amount of retained austenite have been studied in temperature
range from +24 to 196°C. It was found, that after cooling the stable retained
austenite, becomes thermally unstable and depending on carbon content
transform trough diffusionless decomposition into metastable austenite, bainite or
even martensite, hence causing brittleness of the ADI material.
47
D8
16:40
Heat Treated Cast Iron as Ballistic Protection
Sebastian Balos
Heat treated cast irons are attractive engineering materials due to their relatively
good cost effectiveness. Their low cost is related to their good castability and ease
of machining, making them ideal for replacing certain types of steel. However,
their main drawback is their lower ductility, which limits their application field or
must be overcome by design of the product. A typical such product are perforated
plates which can be used for ballistic protection as an applique armor for armored
vehicles. In this paper, the ballistic performance of heat treated ductile and
vermicular cast iron are presented. It was shown that by the optimization of
geometry and heat treatment parameters, a full ballistic protection of the
perforated plate-homogenous basic plate armor system can be attained.
D9
17:00
Infiltration of molten metals into porous SiC preform : industrialization and
applications of CMC
Itzhak Mutzary
Applications III
D10
10:00
Advanced Intermetallic Titanium Aluminides - Development Status and
Applications
Helmut Clemens (Invited)
Intermetallic TiAl alloys based on the gamma-TiAl phase are already used as
engineering lightweight high-temperature materials in aircraft and automotive
engines. Thereby, they partly substitute the twice as heavy Ni-base superalloys.
The processing technologies comprise casting, forging as well as additive
manufacturing. All the applications mentioned above require balanced mechanical
properties, i.e. certain ductility at room temperature as well as defined creep
strength at elevated temperatures. In the framework of this presentation the alloy
design rules, which have been applied for the development of TiAl alloys will be
explained. Besides the considerations which have led to the selected alloying
elements, the heat treatments conducted subsequent to conventional hot-forging
48
are discussed. In this context it will be shown that a combination of computer-
aided alloy design and novel characterization techniques, e.g. in-situ high-energy
X-ray and neutron diffraction, has accelerated both alloy and process
development sustainably.
D11
10:30
Influence of Nanoparticles Amount on Erosive Wear Properties of ZA-27 Alloy-
based Dual-size Composites
Aleksandar Vencl
The ZA-27 alloy is a casting alloy, frequently used for sliding bearings intended for
high load/low speeds. Copper in the alloy is often replaced with silicon, which is
classified as one of the critical raw materials, in order to improve the wear
resistance. Similar effect can be obtained by addition of nano- and microparticles
instead of silicon. The role of nanoparticles is to improve the matrix in terms of
fracture strength, toughness and hardness, and the role of microparticles is to
additionally increase hardness and to reduce wear. The main issue in production
of nanocomposites is the low wettability of nanoparticles by molten metal.
Nanoparticles are prone to form clusters, losing their capability to homogeneously
disperse throughout the matrix. Composites are produced through a relatively
low-cost technique, i.e. compocasting process with mechanical alloying pre-
processing (ball milling), in which the metal chips of the matrix is mechanically
alloyed with nanoparticles.
D12
10:50
AATiD consortium Development of Advanced Technologies for 3D Printing
of Titanium Aero-structures
Lior Zilberman
D13
11:10
Light-Weighting in Metal Additive Manufacturing Using Topological
Optimization
Dan Thoma
Metal additive manufacturing (AM) techniques such as Direct Metal Laser
Sintering (DMLS) and Directed Energy Deposition (DED) allow for complex
geometry fabrication of metal parts, a capability that is of special interest from a
design point of view. Design of light-weight structures is considered one of the
49
most promising advantages of complex geometries, and AM can fully utilize both
topological optimization and lattice structures to reach light-weighting objectives.
In this work, we characterize the mechanical properties of additively
manufactured, optimized, load-bearing functional parts. Design and optimization
is done using Pareto software, developed at UW-Madison. These designs are later
manufactured using a DMLS system and a DED system. For validation of the
models, mechanical tests are performed to quantify each design and to identify
the existing trade-offs in terms of performance versus weight. Topological
optimization of 316L stainless steel AM components will be compared to Al 6061.
D14
11:30
SLM printed steel conformal cooled insert for extrusion dies with anti-wear
bearings
Ivan Todaro
Additive Manufacturing (AM) allows great degree of freedom in components
design without geometrical constraints of other manufacturing processes. This
made the process fitting for extrusion dies and inserts production. Indeed
conformal cooling channels, whose realization is possible through AM processes,
allow an efficient utilization of liquid nitrogen as cooling media. In this way it is
possible to increase the process performances in terms of production rates, profile
quality and die lifespan. In this context a multi-die is proposed in which the
expensive AM part, the insert with cooling channels, is integrated into an H13
steel housing. Finite Element simulations of the extrusion process were performed
to predict thermal field gradient, die stresses under the process thermomechanical
loads and multistate fluid-dynamics.. The first AM inserts were manufactured in
H13 steel and 3D printing parameters were optimized to get the right balance
between density and crack tendency of the material.
D15
11:50
Additive manufacturing innovations in Israel
Udi Galun
50
Applications IV
D16
15:30
Lithium as a Key Actor in Globally Decarbonised Mobility, Electronics and
Future Energy Markets: A Circular Economy Assessment
Roberto Iglesias (Invited)
Although as of 2017 lithium isn’t considered a critical raw material, its eventual
scarcity raises concern, since its economic importance continues to burgeon, while
the concentration of producers may put supply at risk. As the leading element for
energy-storage technologies, the ever-growing fabrication of high-capacity
batteries for electronics and the unstoppable electric car transition will soon take
Li to criticality. Climate change drives efforts to develop clean sources to supply
increasing energy demand. Nuclear fusion presents advantages, namely, high
energy efficiency, reliable power, plentiful fuel and increased safety. One of the
main concerns in the ongoing programs is the design of the breeding blanket,
responsible for production of the essential albeit scarce tritium. Liquid lithium-lead
blankets stand out as promising candidates. Success in fusion energy production
will enormously increase Li demand. Evaluation of immediate needs and supply
chain of lithium to circumvent criticality issues seems crucial for the energy sector.
D17
16:00
Revolutionary Al-air Battery Technology
Danny Gelman
The ever-growing demand for portable electric power has been pushing battery
technologies to extreme. In order to provide more energy in lighter weight,
smaller volume batteries InEnSto is focusing on the high potential Aluminum-Air
(Al-air) technology. Implementation of Al–air batteries as a sustainable energy
storage device up until recently has been hampered by severe hurdles. Al anode
high corrosion rate in aqueous alkaline solution is of major concern in terms of Al
usage and safety. In non-aqueous electrolytes adverse Al surface activation
substantially limits any power output.
D18
16:20
Al-Co-Cr-Fe-Ni high entropy alloy: novel features and understanding
Louisa Meshi
51
D19
16:40
SPD processed materials for energy applications
Rimma Lapovok
The advanced technological applications set the targets for material performance
at a level that is difficult to achieve with conventional materials. Common
approaches for improving material characteristics, for example, by alloying or
thermomechanical processing are reaching their limits. In many cases, the set of
the required microstructures and associated properties cannot be achieved in one
particular material.
Additive manufacturing II
Emerging Technologies
E1
10:30
Solid-state additive manufacturing and post-processing of the Al/Ti system
Aslan Miriyev (Invited)
Ultrasonic additive manufacturing (UAM) allows to create 3D-structures by joining
thin metal layers on top of each other using ultrasonic vibrations along with
compressive normal force. UAM utilizes temperatures much lower than the
melting temperature of raw materials, allowing AM of dissimilar materials.
Characteristics of the interface region between the layers determine the
mechanical properties of the UAM-fabricated parts. Thus, achieving continuous
and strong interfacial bonding is of a crucial importance in UAM. In the Al/Ti
UAM-parts, the interfacial bonding is based on mechanical interlocking between
the Al and Ti layers, resulting in poor shear strength. Post-treatment of the Al/Ti
system for only 1 minute in the spark plasma sintering (SPS) apparatus increased
the interface strength of the Al/Ti parts to beyond that of aluminum due to
intermetallic layer, which evolved by Al diffusion through 3formation of a thin TiAl
) grain boundaries.3/TiAl3the (TiAl
52
E2
11:00
Material Developments in Binder Jet 3D Printing
Andrew Klein
As binder jet 3D printing continues to transition from a prototyping process to a
production process for metals, increasing the availability of materials is key for
increasing adoption of the technology. With the ability to spread standard MIM
powders, binder jet 3D printers are able to print an increasingly wide range of
materials. Printhead improvements have enabled finer feature resolution and
surface finish. This presentation will highlight the current state of the art for binder
jet 3D printing, discuss the development process for new alloys, and present the
material properties and microstructures of the newest available materials.
E3
11:20
Lithography-based Additive Manufacturing of Metal-based Suspensions
Gerald Mitteramskogler
The presented lithography-based additive manufacturing process is suitable for
the processing of metals. Being an indirect AM method, it uses a photoreactive
metal suspension, which is cured by selective exposure to light. The photoreactive
suspension is loaded with a commercially available 316L powder up to a solids
loading of 50 vol%. After printing the green parts, an additional thermal treatment
is required for the parts to gain their final metallic properties. This thermal
treatment—similar to the thermal treatment used for Metal Injection Molding
(MIM)—eliminates the polymer binder and is referred to as debinding. After the
debinding stage, the structure can be sintered up to 98.5 % of the theoretical
density of 316L. Using the LCM process, highly complex parts made of 316L could
be manufactured showing a good geometrical accuracy and very low surface
roughness. Also the mechanical properties of the AM structure are comparable to
conventionally manufactured 316L.
E4
11:40
Methodology for Maturity Evaluation of Powder Bed Additive
Manufacturing Based on MRL and NDE
Ori Yeheskel
Manufacturing Readiness Level (MRL) methodology goes hand in hand with
53
Technology Readiness Level (TRL). The equipment for Additive Manufacturing
(AM) is in a maturity level of TRL 8 where growing number of machines are sold
yearly worldwide. However, the maturity of 3D printed metal objects is lower
sometimes as low as MRL 5. In the current talk we shall describe a methodology
that is being developed to expedite and verify the maturity of 3D printed metal
objects (e.g. Ti6Al4V, AlSi10Mg). The methodology includes verifying quality of
personnel, raw materials, work procedures, and continuous study of the "powder-
processing-microstructure-properties-performance", PP-M-PP, relationships.
Some properties are measured using ex-situ non-destructive evaluation (NDE) but
in-situ NDE like LayerQam will also be implemented. Current NDE is based on
analyzing the interaction of sound waves with the microstructure which is studied
by fractography, metallography, and neutron diffraction at the Los Alamos
National Laboratory (LANL).
Additive manufacturing IV
AM Applications and Technology
E5
15:30
Additive Manufacturing of Ti6Al4V (ELI) Medical Implants
Willie du Preez (Invited)
Over the past years the production of customised medical implants through
additive manufacturing by the CRPM in South Africa has grown significantly. While
satisfactory results have been obtained and the quality of life of many patients
have been improved, further research is required to enable the production of
qualified components. This paper shares the growing acceptance of additive
manufacturing, as well as the establishment of a South African Additive
Manufacturing Strategy. An overview of the progress made by the Collaborative
Programme in Additive Manufacturing is presented. The scope of the metals
research performed towards the qualification of additive manufacturing of Ti6Al4V
medical implants is discussed. Examples are given of internationally leading work
on utilising these implants, which were additively manufactured under an ISO
13485 system, in maxillo-facial reconstructive surgery. Lastly, the development of
an affordable polyurethane artificial heart valve is presented as a different type of
medical implant.
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E6
16:00
Application of Additive Manufacturing for Veterinary Medical Implants
Gary Muller
Additive Manufacturing Center at Technion is the first Israeli institution certificated
by ISO13485:2003 - manufacturing medical devices by electron beam melting
(EBM). EBM is a specific additive manufacturing process that runs in high vacuum
and high temperature conditions providing superior mechanical properties of
manufactured parts. This fact made EBM an irreplaceable technique for medical
implants production.In the current research are presented different cases of
veterinary implants manufacturing. Such manufacturing is specific and sometimes
even more complicated than human implants production, because of thinner
tissue covering. Was examined the functional integration between bone and
implant for different loading conditions and was investigated efficiency and
strength of implants lattice structures.
E7
16:20
Laser Additive Processing of a Functionally Graded Internal Fracture
Fixation Plate
Srinivas Aditya Mantri
Although bone fracture-fixation devices are crucial for fracture-site stability,
undesirable stress-shielding at locations further away from the fracture-site, are
problematic due to the stiffness-mismatch between the bone and fracture-fixation
device. This issue can be efficiently addressed by fabricating a stiffness-graded
(compositionally-graded) titanium alloy fracture-fixation plate, with low elastic
modulus at the ends, comparable to the bone modulus; and higher elastic
modulus at the center, close to the site of the fracture. Additive manufacturing
processes such as laser engineered net shaping (LENS™), can be used to fabricate
such functionally-graded alloys. This study will present the results from a novel
LENS™ deposited fracture-fixation plate for use in orthopedic surgery. The
gradation has been achieved between a low modulus Ti-35Nb-10Zr (wt. %) alloy
and the higher modulus, commercially pure Ti near the center of the plate. Site-
specific investigations of the microstructure, mechanical behavior, corrosion, and
cyto-compatibility along the compositional gradient will be presented.
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E8
16:40
3D Bioprinting of Hybrid Materials for Regenerative Medicine
Implementations in Innovative SMEs
Robert Piticescu
Small and medium-sized enterprises (SMEs) are the backbone of Europe's
economy. They represent 99% of all businesses in the EU.In the past five years,
they have created around 85% of new jobs and provided two-thirds of the total
private sector employment in the EU. The European Commission considers SMEs
and entrepreneurship as key to ensuring economic growth, innovation, job
creation, and social integration in the EU. Generally, AM is a must-have capability.
It is just not smart to go to market without sufficiently iterating and refining a new
design, and 3D printing can absolutely help.We present some original results on
the high pressure synthesis of hybrid nanomaterials based on hydroxyl-apatite
and commercial polymers and their use in 3D bioprinting of personalized
implants.
E9
17:00
Biological transformation influencing manufacturing of metal components
using AM technologies
Rafael Wertheim
Biological transformations are considered today as a new emerging frontier in the
industrial revolution (Industry 4.0). The thevolution of the digitalisation and 4
principles of biologically inspired and biological intelligent manufacturing is
proposed as a driver and an influencing factor on the development of new
materials, design concepts, processes and equipment as well as for the
manufacturing system. The potential of using biological transformations in
manufacturing can be considered for innovation of industrial products and for the
complete manufacturing system, mainly by using, inspiring or imitating biological
and botanic elements, solutions, phenomena, materials, or living objects. The
combination of biological principles with digitalization, new technologies and new
processes, like Additive Manufacturing, presented here, provide an excellent tool
for sustainable and efficient production. Examples of research and development
directions as well as industrial products are presented and discussed in the paper.
Few examples of molds and dies with optimized and efficient cooling channels,
inspired by the dicot leave structure, were designed and produced, including
Additive Manufacturing.
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Additive manufacturing VI
AM Tooling, Surface Control
E10
10:00
The Internet of Things (IoT) for Casting with 3D Printed Sand Molds
Eric MacDonald (Invited)
Process interruptions of additive manufacturing have been leveraged to
robotically place additional functionality within complex structures. Sand casting
stands to be transformed as binder jetting can create sand molds with
unprecedented geometric complexity as well as with the integration of sensing
capabilities. Printed sand molds can enable lattice structures and light-weighting;
however, with increasingly intricate designs and larger cavity surface area, the
complexity of both the thermodynamics and chemistry of the casting process
requires reliance on high-fidelity simulations. One potential solution is to leverage
the design freedom of CAD-based solid modeling to introduce cavities specifically
for inserting sensors (Internet of Things) to enable the collection of a diversity of
data to validate and optimize simulations. This presentation will discuss
preliminary data from unprecedented levels of process monitoring with both
wireless and wired sensors placed at strategic locations throughout printed mold
and internal cores.
E11
10:30
GE Additive - From Prototyping to Production with Spectra
Patrik Sjööquist
Arcam EBM provides Additive Manufacturing solutions for production of metal
components, using Electron Beam Melting (EBM). The technology has been
available since the late 1990s with constant development. Since the launch of the
Q-series machines Arcam has focused EBM towards industrialization and
reliability. With the acquisition of Arcam EBM and ConceptLaser by GE and the
formation of GE Additive, the Industrialization of the AM business is expected to
accelerate significantly.
As the EBM and DMLM Technologies develop it is clear that they complement
each other in many ways. With its high power and magnetic control of the
electron beam the EBM Technology enables a industrialized process for bulky
designs and hot materials like Titanium Aluminized and Inconel which is
precedence whereas DMLM has finer unfinished surface and the ability to design
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for internal passages. GE Additive is alone in having both offerings.
With Arcam in its portfolio, GE Additive can leverage its large engineering network
to further develop the capabilities of the EBM Technology. The future has exiting
new possibilities
E12
10:50
An Effect of DMLS Process Parameter on Surface Roughness and
Dimensional Accuracy Of CL50WS Material
Hiren Gajera
DMLS can be made customized tooling insert, die and mould with cooling channel
which is also known as conformal cooling. Die, mould or tooling insert are widely
used in injection moulding industries. Thus, worse dimensional accuracy and
surface roughness of die and mould affect number of parts or products that make
huge losses to industries. Thus, dimensional accuracy and surface roughness of
die or mould is very significant parameter for injection moulding industries.
Hence, this study carried out for the same. In this study, the relationship between
input parameters of DMLS (laser power, layer thickness, scan speed and hatch
distance) and performance characteristic (Dimensional accuracy and Surface
roughness) have been discussed. From study, it can be seen that Layer thickness
and laser power are most affective parameter for mentioned characteristic.The
obtained result was validated and that optimum result have good agreement with
performed regression result.
E13
11:10
Surface modification of AM parts using plasma electrolytic polishin
Henning Zeidler
Plasma electrolytic Polishing (PeP) is based on a high DC voltage applied between
a metallic part and an aqueous electrolyte and the following creation of a plasma
envelope around the part. There, electrochemical and plasma reactions take place,
ablating material and reducing surface roughness. The process does not require a
shaped tool and has the capability of achieving surface quality of Ra ≤ 0.02 µm.
PeP is well suited for deburring, shining and polishing of complex shaped parts.
PeP is a suitable process to finish macro- as well as micro parts and contributes to
a tight tolerance chain. Furthermore, applied on AM parts, it is allowing to push
the design of complex parts further towards general industrial use. The paper
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presents the current state and application scenarios as well as ongoing research
topics.
E14
11:30
Laser Assisted Synthesis of High Entropy Alloy Coating on Aluminum:
Tribocorrosion Behavior
Sameehan Joshi
Al-Co-Cr-Fe high entropy alloy coatings were additively produced on aluminum
substrate with the aid of laser surface engineering. Primary microstructural
observations indicated formation of metallurgically bonded hundreds of micron
thick coating for various laser fluences (16.9-21.2 J/mm2). The coatings consisted
of a mixture of high entropy and intermetallic phases, resulting in marked
improvement in hardness as compared to the aluminum substrate. Coating
corresponding to higher laser fluences showed an improvement in corrosion
resistance over the aluminum substrate in 0.6 M NaCl solution. As a result,
superior wet-wear resistance and lower friction coefficients were observed in 0.6
M NaCl solution for the coatings relative to the base material. However, amongst
the coating samples, an incremental amount of dilution as a function of laser
fluence led to a decrease in wet-wear resistance at higher applied loads. The
coating processed through an intermediate laser fluence of 19.1 J/mm2 exhibited
the best tribocorrosion behavior.
E15
11:50
Properties of Wire and Arc Additive Manufactured Materials
Flipo Bertrand
This presentation takes a look at the different manufacturing methods for Wire
and Arc AM of 500 x 300 x 30mm test samples in low alloy steel, 316L stainless
steel, Inconel 625 alloy and Aluminium alloy A356. Basic properties such as tensile
performance, impact toughness and fracture toughness are tested, and for the
IN625 and A356, the effect of a post deposition heat treatment is considered. The
results are compared to a nearest equivalent conventional material and
conclusions drawn.
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Additive manufacturing VII
New material and process development
E16
15:30
Improvement of Gas Atomization Processing Efficiency and Powder Quality
to Benefit Additive Manufacturing
Iver Anderson (Invited)
Several technical challenges for powder feedstock must be solved to allow full
development of additive manufacturing (AM) to be achieved and to enable
sufficient build microstructure control to be established for high performance
applications. Many certified feedstock powders have excessive cost and limited
availability due to the narrow powder size distribution and high powder quality
that is optimal for each specific AM process. For example in new experimental
alloys, off-size powder (perhaps 80-90%) produced in typical atomization
processes necessitates careful size classification work and excess inventory,
resulting in unacceptable costs. The powder quality challenges include spherical
shape with minimal powder “satellite decoration” to promote flowability, along
with elimination of internal porosity and reduced powder surface oxides to
improve as-built microstructure quality. Progress on gas atomization process
research to mitigate these issues for Ni and Ni-based alloy powders will be
reported. Supported by USDOE-EERE-Advanced Manufacturing Office through
Ames lab contract DE-AC02-07CH11358.
E17
16:00
Development of a Ni-base Superalloy for Additive Manufacturing
Iver Anderson
Additive manufacturing (AM) is permeating the manufacturing community as a
processing method to form complex net-shape parts and components. The
benefits of AM to the aerospace industry is two-fold as new geometries become
possible and material waste of expensive alloys is dramatically reduced, thus
providing higher temperature, light-weighting, and cost advantages. However,
many high temperature and extreme environment alloys of interest (e.g. Mar-M-
247) show cracking and defects when AM processed due to their low weldability.
This work will describe iterative alloy modifications to mitigate these issues using
both thermodynamic modeling and experimental verification, characterization of
modified alloy powders within the Ni-base superalloy family produced in-house
60
via high pressure gas atomization, and AM builds produced from these modified
powders. This work was performed in collaboration with Oak Ridge National
Laboratory’s Manufacturing Demonstration Facility and funded by the U.S.
Department of Energy’s - Energy Efficiency and Renewable Energy - Advanced
Manufacturing Office.
E18
16:20
Solidification during Selective Laser Melting of Co-29Cr-6Mo Alloy
Zhan Chen
As microstructures of metallic parts are important for their mechanical
performance, their formation needs to be understood. In this work, using F75 Co-
29Cr-6Mo alloy, modes of solidification during SLM have been studied. It will be
shown that epitaxial growth with two possibilities of <100> crystallographic
orientations and cellular growth without a plannar zone are not affected by laser
power. This is because the shape of track did not change sufficiently as P varies.
No equiaxed grains have been observed although grain growth direction can
readily change. P does not affect cell size suggesting that P does not affect
significantly the temperature gradient (G). The determined values ranged 0.4-0.8
microns are within the range found in many alloys processed by SLM. G and
cooling rate (dT/dt) will be determined and will be compared to those determined
by simulation and based on an emperical relationship from literature.
E19
16:40
Numerical analysis of intake manifold and its manufacturing in additive
manufacturing
Sebastian Kowalczyk
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