https://orcid.org/0000-0002-0209-2629
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ABSTRACT
The combination of Additive Manufacturing (AM) and Hot Isostatic Pressing (HIP) offers great potential for industrial applications. Skilfully connecting AM and HIP creates a manufacturing process that unites the advantages of the two approaches. We demonstrate a production route for composite components by combining AM and HIP: a HIP capsule made of corrosion resistant steel is additively manufactured using Powder Bed Fusion with Laser Beam (LPBF). Before LPBF, the distortion and shrinkage of the capsule due to HIP is compensated by optimising the capsule’s geometry using Finite Element (FE) simulation of the HIP process. The capsule is filled with steel powder and manufactured by a conventional powder HIP. After HIP, the capsule remains as an outer layer on the component, so that a functional net-shape composite component is produced. Subsequent investigations show that a complex extruder screw segment can be successfully produced with a geometrical deviation smaller than 1.5%.
Acknowledgements
The authors would like to thank Dr. Bengt Hallstedt for contributing valuable DICTRA calculations to this work, the European Powder Metallurgy Association (EPMA) for highlighting this work at Euro PM2018, the Forschungsgesellschaft Stahlverformung e. V. (FSV) for supporting the research, and the Arbeitsgemeinschaft industrieller Forschungsvereinigungen ‘Otto von Guericke e.V. (AiF) for the funding.
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No potential conflict of interest was reported by the author(s).
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Notes on contributors
Sebastian Riehm
Sebastian Riehm studied mechanical engineering at RWTH Aachen University, majoring in design & development. Subsequently, he conducted research in the field of powder metallurgy at the Chair and Institute for Materials Applications in Mechanical Engineering at RWTH Aachen University. In several research projects he addressed the material specific effects of Additive Manufacturing and Hot Isostatic Pressing on steels and TiAl alloys. He completed his research with a PhD thesis on the fabrication of near-net-shape composite components produced via a combined process route using computer simulation, Additive Manufacturing and Hot Isostatic Pressing. After completing his PhD studies, he is now working in the ceramic industry.
Vera Friederici
Vera Friederici studied material science at the Technical University Darmstadt in Germany. In cooperation with the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Bremen she wrote her diploma thesis before starting working as a research assistant in 2008 first in the department of microfabrication and later in the department of biomaterial technology. In 2011, this department was absorbed by the Powder Technology department. She was involved in research projects on the topic of implants, in particular with powder technology issues relating to the material titanium. Later, in addition to metal powder injection moulding also PBF-LB. Since September 2019, she has been working at the Leibniz Institute IWT as a research associate in the Materials Technology Department and is working on fatigue failure of steels.
Sandra Wieland
Sandra Wieland studied material science at Technical University Dresden and is working at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) since her graduation in 2014. Besides her occupation as a project manager, she pursued her doctoral thesis on sintering of magnetocaloric LaFeSi-alloys, which was completed in 2019. Curently, she is the head of the Functional Materials and Components group in the Powder Technology department at Fraunhofer IFAM.
Yuanbin Deng
Yuanbin Deng received his master's degree in materials engineering at RWTH Aachen university in 2015 and works on simulation of powder metallurgical manufacturing processes in the Institute for Materials Applications in Mechanical Engineering (IWM) at RWTH Aachen University. He is currently the head of the Process Simulation group in the Powder Technology department of IWM. His research interests centre around the macroscopic modelling and simulation of sintering and hot isostatic pressing process, geometry optimisation for near net shape manufacturing.
Simone Herzog
Simone Herzog studied Materials Science with the support by the Deutschlandstipendium at RWTH Aachen University and was winner of the Hans-Walter-Hennicke lecture competition in 2012. She graduated in 2013 with honors and was awarded with the SpringorumDenkmünze before starting her doctoral studies in the field of high-temperature brazing of ceramic-metal composites as a research assistant in the Powder Technology department at IWM. She has been a groupleader in the Process Technology group since 2015, which analyses powder technology manufacturing processes, starting from the powder up to the component. The research focus lies on the understanding of the effects of process parameters or different manufacturing processes on the microstructure, the mechanical properties and the reliability of components.
Anke Kaletsch
Anke Kalestch is head of the division Powder Technology at the Institute for Materials Applications in Mechanical Engineering (IWM) at RWTH Aachen University. Besides, she is the deputy head of the Institute of Applied Powder Metallurgy and Ceramics (IAPK), which is an associated institute of RWTH Aachen University. Anke Kaletsch studied Mechanical Engineering in Aachen and received her doctoral degree from RWTH Aachen University in 2016.At IWM and IAPK she coordinates research activities and projects in the field of powder metallurgy and ceramics. The main research areas in her department are additive manufacturing (AM), hot isostatic pressing (HIP) and sinter simulation for different production processes like HIP, FAST/SPS or sintering of parts, produced by binder jetting. Her own scientific focus is the combination of additive manufacturing technologies with hot isostatic pressing.
Christoph Broeckmann
Christoph Broeckmann worked with the Institute of Materials Science at Bochum until 2000 after finishing his studies in Mechanical Engineering at Ruhr-University Bochum, Germany, in 1990. He got his PhD in 1994 on a thesis on the fracture of carbide rich steels. As senior scientist he established a research group on creep related problems at Bochum University. In 2000 Christoph Broeckmann got his lecture qualification (habilitation) based on a work on creep of particle reinforced materials. In 2000 he moved to the machine factory Köppern GmbH &Co. KG in Hattingen where he first was responsible for material and design related research and development. Since 2003 he became managing director of “KöppernEntwicklungs GmbH” a subsidiary dedicated to the development, production and delivery of large, powder metallurgically produced wear parts. he joined RWTH Aachen University as a professor in 2008. Since 2009 he is head of the Institute for Materials Application in Mechanical Engineering.