A technical session in the programme of the virtual Euro PM2021 conference, organised by the European Powder Metallurgy Association (EPMA) and held October 18-22, 2021, focused on issues related to the processing of nickel-base alloys and refractory metals by Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing. Dr David Whittaker reviews four papers that address microstructure control, lattice optimisation and chemical post-processing parameters for IN718, and the AM of molybdenum. [First published in Metal AM Vol. 8 No. 1, Spring 2022]
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While Additive Manufacturing uses some powder characterisation methods similar to those used in conventional metal powder technologies, it is necessary to define additional properties critical for repeatable, reliable AM. ASTM International’s Dr Alexander Liu, Head of Additive Manufacturing Programs – Asia Region, Singapore, and Dr Rafi Khalid, Sr Lead, Additive Manufacturing Programs Development, Singapore, outline the key metal powder characteristics for AM and their significance, as well as discuss the industrial test methods and standards AM part makers rely on to maintain consistent quality. [First published in Metal AM Vol. 8 No. 1, Spring 2022]
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A collaborative study between Constellium SE, a global leader in aluminium materials headquartered in Paris, France, and a leading German AM research institute, has developed a new alloy which paves the way for cost-effective and high-performance AM components in series production. In this article, Constellium’s Dr Bechir Chehab and Syam Unnikrishnan present the company’s Aheadd® CP1 alloy, revealing cutting-edge productivity, very good mechanical properties, and the possibility to reduce Laser Beam Powder Bed Fusion (PBF-LB) processing costs by up to 65%. [First published in Metal AM Vol. 7 No. 1, Spring 2022]
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The control of powder feedstock characteristics is essential in metal Additive Manufacturing in order to guarantee the quality of built parts and reduce production costs. However, powder behaviour is influenced by a large number of particle properties, along with environmental conditions which can modify these properties. In the following article, Granutools’ Dr Aurélien Neveu reviews some of the current standards applicable to powder feedstock characterisation, and highlights how to make such procedures more robust, repeatable and meaningful for end-users with regards to real AM powders and process conditions. [First published in Metal AM Vol. 6 No. 3, Autumn 2021]
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If metal Additive Manufacturing is to compete with casting and other mass-production technologies, costs need to be reduced by a factor of ten. Optimising metal powder characteristics can get the industry halfway there, while anticipated improvements in equipment and processes will do the rest. Here, Equispheres’ Doug Brouse and Dr Martin Conlon discuss how the use of advanced aluminium powders can improve the build rate for Laser Beam Powder Bed Fusion (PBF-LB) by two to four times, as well as offering significant advantages for Binder Jetting (BJT) production. [First published in Metal AM Vol. 7 No. 1, Spring 2021]
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SAMOA, a European Union funded EIT RawMaterials project on ‘Sustainable Aluminium Additive Manufacturing for High Performance Applications’, investigated the processing of aluminium powders by Directed Energy Deposition. In this report, Himani Naesstroem, Joerg Volpp, Stefan Polenz, and Frank Brueckner review the effects of processing parameters and feedstock material age, as well as presenting an industrial case study. [First published in Metal AM Vol. 7 No. 1, Spring 2021]
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There is growing interest in the use of metal Additive Manufacturing for the production of jewellery and luxury watch components. This interest is driven not only by the potential design innovation offered by Additive Manufacturing, but also by the recognition of the environmental and economic advantages to be gained from it. In this in-depth report, Jochen Heinrich, Thomas Laag and Thierry Copponnex review the processing of platinum group metals by Additive Manufacturing. [First published in Metal AM Vol. 7 No. 1, Spring 2021]
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Hardmetals, also known as cemented carbides, have played a huge and often overlooked role in modern industrial development. From the first application in wire drawing dies in the 1920s, hardmetals are today universal and their application areas range from metal cutting and the machining of wood, plastics and composites to the production of glass bottles, aluminium cans and the ubiquitous ball-point pen tip. Can Additive Manufacturing make inroads into a market worth tens of billions of Euros in annual sales? Dr.-Ing. Johannes Pötschke reviews the fundamentals of hardmetal production and considers the most viable AM processes for this complex family of materials. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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Nickel-base superalloys are an important material group for components used in the gas turbine, aerospace and chemical processing industries. Many of the well-established superalloys available today do not, however, adapt well to processing by Additive Manufacturing. In this article, Dr Tatiana Hentrich and Dr Christina Schmidt, VDM Metals International GmbH, present an overview of nickel-base alloys with a focus on strengthening effects, mechanical properties and weldability, comparing production challenges by conventional production routes and Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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Whilst Additive Manufacturing is undoubtedly having a huge impact on the design and manufacture of rocket propulsion systems, most notably combustion chambers and nozzles, the Achilles’ heel of most AM processes is as-built surface finish. Whilst in many AM applications surface finish may be largely irrelevant to a component’s function or performance, when it comes to high-cycle fatigue properties, achieving the required level of smoothness is critical to performance. In this article, Justin Michaud, REM Surface Engineering, reports on advancements achieved in this area through a public-private partnership with NASA. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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A technical session at the Euro PM2019 Congress, organised by the European Powder Metallurgy Association (EPMA) and held in Maastricht, the Netherlands, October 13-16, 2019, focused on the impact of storage conditions, particularly exposure to humidity, on the characteristics and quality of powders used in Powder Bed Fusion Additive Manufacturing. Dr David Whittaker reviews selected papers presented during this session.
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At the 2019 Additive Manufacturing Users Group (AMUG) Conference in Chicago, Illinois, a panel was held to discuss requirements for Additive Manufacturing systems. Despite the late hour of the panel and depth in the week at which it was held, a formidable crowd organised themselves to hear Ryan Dehoff of ORNL, Filip Francqui of Granutools and John Barnes of The Barnes Group Advisors discuss the topic of powder in AM. In this article, the panellists explore in more detail the differences in powder requirements between AM systems.
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