Metal Additive Manufacturing Conference - MAMC 2022

Laser deposition processes such as laser metal deposition or direct energy deposition are additive manufacturing techniques that offer a great flexibility and efficiency compared to traditional subtractive manufacturing processes. However, the extreme thermal conditions during deposition and the rapid cooling times pose great challenges in the alloy design. This work illustrates how to...

By volume, most of the aluminum alloys used in additive manufacturing are either Al-Si based compositions or Airbus’s Scalmalloy. However, Al-Si alloys perform poorly and Scalmalloy is expensive due to the use of Sc. Other high strength aluminum alloys families, such as those of the 7xxx series, have been barely used due to their tendency to hot crack while printing. In this framework, a high...

Plasma Metal Deposition is an advanced manufacturing technique suitable for printing medium-to-large sized complex parts at high deposition rates while reducing material wastage and lead time. Aluminium alloys are one of the most commonly used metallic materials in manufacturing parts for aerospace and automotive applications due to their lightweight, excellent strength, and corrosion...

In this talk, two case examples of multi-parameter optimization is described, where parameter sets for multiple features such as surface roughness, downface integrity, mechanical performance or bulk density are optimized simultaneously using compact design of experiment. In the first case, a component with specific requirements on weldability, corrosion resistance and mechanical resistance led...

Recently NiTi based shape memory alloys (SMA) have been widely explored for the fabrication of complex parts through additive manufacturing (AM). Among the AM techniques, laser powder bed fusion (LPBF) is on the top and gaining momentum in reason of recent and remarkable advances. Using pre-alloyed NiTi powder as a feedstock, it was possible to correlate the processing parameters to the...

The manufacturing of high-speed steel (HSS) components using the laser powder bed fusion (LPBF) process could create an unprecedented combination of the materials' mechanical properties and the design freedom enabled by the process to unlock new applications, such as milling heads with functionally optimized cooling channels. However, the processing of HSS with the LPBF process shows high...

In the present research, we study the printing of an Fe-55%Ni alloy on a ductile cast iron substrate using the Wire and Arc Additive Manufacturing (WAAM) process. The macrostructural observations revealed that the interfacial region between the substrate and deposited alloy is divided in two subregions, including the heat-affected zone (HAZ) and the partially melted zone (PMZ). The...

Ti6Al4V the most widely used Alpha-Beta Ti-alloy for application in medicine, automotive and aerospace, known for its high strength and corrosion resistance, but also its high maximal operating temperature of around 420°C. Combined with its decent weldability under shield atmosphere it became a standard alloy for additive manufacturing processes, especially laser and electron beam based powder...

316L austenitic stainless steel is a commonly used alloy in a wide range of applications, including energy, petroleum, automotive, and medical industry. 316L has been a choice for combustion section components in steam and gas turbine engines. Owing to its low carbon content and extremely ductile austenitic matrix, 316L is one of the most commercially exploited steels for the laser powder bed...

Additive manufacturing (AM) has developed very dynamically in recent years and is becoming increasingly popular. For AM in metal, laser powder bed fusion (LPBF) is the most commonly used process and has been successfully applied in many industrial applications. It allows the fabrication of complex structures, but is time consuming, expensive and limited in build volume. To date, no AM...

In this work, the influence of the as-built microstructure of a Hastelloy X with modified chemistry, processed by power bed fusion-laser beam (PBF-LB), on the stress-rupture properties (816°C, 103 MPa) is studied. Further, the significant effect and underlying mechanisms of the minor and ppm alloying additions on the improvement of the high temperature creep strength of the material is...

Abstract
Selective Laser Melting (SLM) has already been used to manufacture of complex parts with high precision. However, the high cost for surface preparation is still a limiting factor for widespread of SLM parts in different industry branches. The high surface roughness and their resulting residual porosity influence the mechanical properties, especially dynamic ones. In this...

Electron Beam Melting (EBM) is nowadays well established as an additive manufacturing (AM) technology within Aerospace and Medical industry to produce components out of high-performance materials such as Titanium, Titanium Aluminides, Ni-based Superalloys and even pure Copper.

In comparison to other AM technologies, the hot EBM process leads in general to a low level of remaining residual...

NiTi based shape memory alloys (SMA) gained importance in the aerospace industry due to their unique shape recovery properties. Regardless of the great demand, the fabrication of SMAs is rather complex. For instance, forging and machining are limited due to the high strength and reactivity of NiTi alloys. Recently, additive manufacturing (AM) was disrupted as a feasible solution to mitigate...