MIM SIS: Quality and Reliability of MIM

Session 5 – Monday 02 October – Time: 14:00 – 15:30

Chairs:
Dipl. Ing. ETH, MBA Georg Breitenmoser (Parmaco Metal Injection Molding AG, Switzerland)
Prof. Dr.-Ing. Frank Petzoldt (Fraunhofer Institut – IFAM, Germany)
Presentations:

Time 14:00 – 14:30

Author Bio: Dr. Hartmann studied Metallurgy at the RWTH in Aachen. He received his PhD for a Powder Metallurgy Thesis in 1989. For over 35 years Dr. Hartmann is engaged in the Simulation of Casting, Injection Molding, and Powder Metallurgy. In his professional career he was President of MAGMA Inc. in Chicago, General Manager of Simulation Sciences GmbH in Mannheim and for 10 years Managing Director of SIGMA Engineering GmbH. For 25 years Dr. Hartmann is Executive Manager of MAGMA GmbH in Aachen, Germany, with particular responsibilities for Strategic Business Development.

Abstract:

Virtual optimization of MIM/CIM processes has been practiced for over 20 years, aiming for component designs for robust manufacturing and manufacturing processes in the sense of “right first time”.
Manufacturing simulation means “model-based optimization”. In contrast, “data-based optimization” using AI techniques were introduced into manufacturing processes, at least if there is a clear relationship between manufacturing parameters and product qualities, both related to the individual part.
MIM and CIM do not belong to this group. A collection and evaluation of hundreds of production parameters are unthinkable today. The same applies to quality characteristics of each part.
In this contribution, “model-based” and “data-based” process optimization are first explained and classified. Using examples from MIM manufacturing, i.e. the injection molding process, mold thermal management, debinding and sintering, manufacturing parameters and their influence on product characteristics are then shown. Finally, the synergetic effects between model and data-based process optimization are discussed in detail.

Time 14:30 – 15:00

Author Bio: Dr. Alper Evirgen holds a PhD degree in Materials Science and Engineering and has 14 years of experience in materials research and development projects pursued in various research groups and industrial companies. His expertise covers material property – microstructure relationships on a wide range of alloys and new alloy development for various industries and applications.

Currently, Dr. Evirgen works as a Senior Materials Scientist for Additive Manufacturing in Oerlikon AM Europe GmbH since 2017. He manages new alloy development projects and also responsible for the management of the R&D laboratories in the company.

Abstract: High entropy alloys (HEAs) are interesting candidates for powder-based additive manufacturing (AM) since they exhibit an unusual combination of properties such as high mechanical performance, good corrosion and oxidation resistance. Among many, Al-Cr-Fe-Ni HEAs were shown to demonstrate improved mechanical properties as compared to simple duplex steels, owing to their nano-scale duplex microstructures obtained through conventional processing. Laser powder bed fusion (LPBF) processing of these novel HEAs, promises even further property improvements via microstructural refinement, making them promising materials for applications where high strength and good corrosion resistance are required such as impellers.

In this presentation, processing challenges and alloy development for AM, the alloy microstructure in as-built and heat-treated conditions, alloy mechanical properties by tensile testing after heat-treatment and comparison with duplex steels will be discussed.
At last, an outlook on the potential applications of the novel HEA and a demonstrator part built via LPBF will be presented.

Time 15:00 – 15:30

Author Bio: Frank Petzoldt will moderate this last slot in the seminar, involving all speakers and the audience in a discussion about the topic of Quality and Reliability of MIM. In fact, as also evidenced in the MIM Roadmap to 2030 prepared in previous events, MIM can, and should still evolve towards even better performance. The discussion will try to review what are the most promising routes to achieve this.

Abstract: Frank Petzoldt will moderate this last slot in the seminar, involving all speakers and the audience in a discussion about the topic of Quality and Reliability of MIM. In fact, as also evidenced in the MIM Roadmap to 2030 prepared in previous events, MIM can, and should still evolve towards even better performance. The discussion will try to review what are the most promising routes to achieve this.

EHQS SIS: Chemical Management, Standards and Sustainability for PM

Session 7 – Monday 02 October – Time: 14:00 – 15:30

Chairs:
Bruno Vicenzi (EPMA)
Kenan Boz (EPMA)
Presentations:

Time 14:00 – 14:30

Author Bio: Dr Simon Cook is a Materials Scientist with a degree and PhD from the University of Cambridge, UK. His experience includes 25 years working in industry in 2 large multinational companies (including 20 years in mining), and 4 years in the industry (metal) association space. His mining experience covered primary production but was more focussed on the main downstream uses of several commodities, including value-in-use and alternatives and substitutes. During the last 8 years, his focus has been on market access issues for metals – product stewardship and regulatory affairs – from the industry, the industry association, and the downstream user point of view. Simon joined the Eurometaux Chemicals Management Department in March 2021, to provide support on EU flagship regulatory developments such as the Chemicals Strategy for Sustainability.

Abstract: TBA

Time 14:30 – 15:00

Author Bio: Before founding Granutools, Filip has managed various businesses for the electronic microscopy subsidiary of Thermo Fisher Scientific known as FEI company. Filip started his career working for the Dutch semiconductor equipment manufacturer ASML in R&D in the Netherlands and then in customer facing roles in Japan. Filip holds a Master Degree in Applied Physics from the Free University of Brussels (Belgium) and an MBA from INSEAD (Singapore). He has numerous publications in scientific journals and holds multiple patents.

Abstract: Granutools introduces the classical tests like Hall and Hausner as well as their limitations. Most recent developments of powder flow measurements standards in metal AM are discussed. Spreadability measurements for various metal alloys inside printers will be shown and a link with intrinsic powder properties making use of a rotating drum.

Time 15:00 – 15:30

Author Bio: Kenan Boz has received his B.S. Degree in Electrical & Electronics Engineering in 1993 and MS degree in Systems & Control Engineering (Mechatronics) from Bosphorus University in 1995. He worked as technical manager and shareholder in various companies in the fields of design and production for components and assemblies in automotive and machine tools industry. After 2016, he has been involved in development of metal powders to be used in dental applications for additive manufacturing. Since 2019, he is the technical manager of European Powder Metallurgy Association (EPMA) based in France, working on Additive Manufacturing, Hot Isostatic Pressing and Hard Materials.

Abstract: TBA

MIM SIS: Sustainability of MIM

Session 12 – Monday 02 October – Time: 16:30 – 18:00

Chairs:
Dipl. Ing. ETH, MBA Georg Breitenmoser (Parmaco Metal Injection Molding AG, Switzerland)
Prof. Dr.-Ing. Frank Petzoldt (Fraunhofer Institut – IFAM, Germany)
Presentations:

Time 16:30 – 17:00

Author Bio: Studied physics at Swansea University and completed a PHD in the field of Material Science, using the Scanning Electron Microscope (SEM) based technique of Electron Back-Scattered Diffraction (EBSD) used to study Grain Boundary Engineering. Two years post-doc. research related to the fracture of ferritic steels used in the nuclear industry. Five years’ experience in steel industry working in the automotive and defence sectors. Employed by Sandvik Additive Manufacturing for more than 16 years in a technical & marketing sales capacity, specialising in the fields of powder metallurgy, with a particular focus on the applications of Metal Injection Moulding and Additive Manufacturing. Currently hold a strategic marketing position in the Powder Group. A committee member of EPMA MIM & AM sectors group. Represents the UK at ISO Standards committees for Additive Manufacturing.

Abstract: The sustainability of inert gas atomised metal powder production is a key factor in supporting the important message that Powder Metallurgy is a green technology. Especially, when applied as a raw material to the advanced manufacturing technologies of Metal Injection Moulding (MIM) and emerging sinter based Additive Manufacturing (AM) technologies. The principle process steps of inert gas atomised metal powder production are analysed, in terms of energy consumption and carbon foot print, while factoring efficiencies, to provide a sustainable low-impact production process. A powder production process that ideally utilises renewable energy sources and incorporates recycled raw materials, generates low levels of waste, with efficient use of resources & logistics modes that ultimately create efficient supply chains.

The principle of science based targets are embraced and environmental claims, especially for recycled content, are validated against recognised standards. The life cycle of metal powders are reviewed, from raw materials, through inert gas atomised powder production, to consolidated components in-service and at end of life. The development of sustainable materials, substituting elements with a high environment impact are presented including nickel free & light weight stainless steels and high-strength cobalt free maraging steels.

Time 17:00 – 17:30

Author Bio: Current work 06.2019: International Sales and Product Development Prokurist Carbolite Gero GmbH 01.2014: Project manager Carbolite Gero GmbH PHD: 2007 – 2014: PHD thesis: „A partly abberation corrected mass filter as additional element for a highly developed low voltage focussed ion beam“ SEM tutorials and operation TEM internship at the university of Tübingen PHD partly financed by Balzers company in Liechtenstein University and school 2002 – 2007: Study of Physics at the university of Tübingen 1993 – 2002: Isolde Kurz high school in Reutlingen Prize holder of the Deutsche Physikalischen Gesellschaft (DPG).

Abstract: The “Federal Climate Protection Act” increased carbon dioxide reduction targets on the path to climate neutrality. Thus, the carbon footprint is an essential element of sustainable business management and a valuable instrument for measuring the climate impact of products, services, and organizations. However, for most energy intensive manufacturing processes reliable and comparable data is not available yet. This study reports on the product carbon footprint (PCF) of a typical batch type metal injection moulding (MIM) process. The calculation of the carbon footprint includes the the (metal) injection moulding process of a typical MIM part, catalytic debinding as well as rest debinding and sintering in a batch type MIM furnace for two different kinds of materials.

Time 17:30 – 18:00

Author Bio: Sebastian Hein has studied chemistry at the Leibniz University of Hannover and a doctoral degree in inorganic chemistry. Since 2008 he is working at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Bremen, where he is currently manager of the department “Powder Technology”. He is working in the field of material development with a focus on novel functional materials and their shaping technologies based on powder technology (PIM, Extrusion, Additive Manufacturing). Aside from leading a R&D team of people with different scientific backgrounds, he is also co-responsible for the business field of medical technology at IFAM and has several years of project experience with material and process development of biocompatible and biodegradable materials, as well as their shaping processes. Furthermore, he is currently Co-Chairman of the sectoral group “Functional Materials” within the European Powder Metallurgy Association (EPMA).

Abstract: The production of parts using machining or casting requires a significant amount of energy and generates a large amount of waste. And although it is often stated that Metal injection Moulding (MIM) has a lower environmental impact than other manufacturing processes, it still has some negative effects on the environment. The production of metal powders and binders requires a significant amount of energy and generates a large amount of waste. In addition, the use of solvents and other chemicals in the manufacturing process can have a negative impact on the environment. To reduce the environmental impact of MIM, it is important to first analyse the energy consumption and waste generation in the manufacturing process and base improvement on that knowledge.

HIP SIS: Industrial Applications of HIP

Session 20 – Tuesday 03 October – Time: 08:30 – 10:00

Chairs:
Mr Jim Shipley (Quintus Technologies AB, Sweden)
Dr Ing Anke Kaletsch (RWTH Aachen University, Germany)

Presentations:

Time 08:30 – 09:00

Author Bio: Tomas Berglund works as R&D Manager at MTC Powder Solutions. He joined MTC Powder Solutions in 2012 and has worked in several roles in the company, all focused on R&D, application development and sales. Before joining Powder Solutions he worked at Sandvik Materials Technology R&D since 2007, where he as an R&D engineer worked in the areas of HIPed materials, HIPed compound solutions and HIP design. He has several approved patents and patents pending in the area of HIPed products. He got his M.Sc. mechanical engineering in 2003 and has prior to joining Sandvik worked with development in the area of high velocity compaction of metal powders and composite materials as well as metal injection molding sintering and heat treatment.

Abstract: In an industrial manufacturing environment of Powder Metallurgical HIPed Duplex Stainless Steels there are many potential pit falls. Examples of issues encountered in manufacturing of components are presented as well as issues deliberately created to simulate potential issues in different stages of the production process. The root causes of the are analyzed, discussed and limitations highlighted. This presentation highlights the complexity of manufacturing PM HIP DSS and the importance of material understanding and good process control when manufacturing these alloys. While some issues are unique to PM HIP material, many of them can also be found in conventional wrought materials e.g., sigma and nitride precipitation.

Time 09:00 – 09:30

Author Bio: TBA

Abstract: TBA

Time 09:30 – 10:00

Author Bio: TBA

Abstract: TBA

AM & HIP SIS: Benefits of combining AM & HIP

Session 28 – Tuesday 03 October – Time: 11:00 – 12:30

Chairs:
Dr Ing Anke Kaletsch (RWTH Aachen University, Germany)
Dipl-Ing Claus Aumund-Kopp (Fraunhofer – IFAM, Germany)

Presentations:

Time 11:00 – 11:30

Author Bio: 1992 – 1997 Chalmers University of Technology MSc, Engineering materials
2018 – 2019 Stockholm School of Economics
Since September 2021, Business Development Manager at Quintus Technologies

Abstract: Clean HIP processing is an innovative solution that significantly enhances the surface quality and performance of components processed through Hot Isostatic Pressing (HIP), reduces or eliminating the need for time-consuming and expensive pre- and post-processing methods. Designed to achieve a minimum oxygen content in the HIP atmosphere, this advanced approach resolves a major industry challenge: surface oxidation and alpha case formation of parts during the HIP process. We present how the adaptation of a novel toolbox, including best practices, hardware/software improvements and getter cassettes, enables the production of oxide free complex surface structures and narrow media channels in a cost-effective and environmentally friendly way. Moreover, added benefits from this method are less oxidation corrosion rate of HIP furnace components and improved performance of part surface treatment methods when these are mandatory and/or necessary for the specific application. This presentation aims to provide better insight and understanding of the user benefits that can come from using this novel capability for hot isostatic pressing.

Time 11:30 – 12:00

Author Bio: Global Materials Engineer at Bodycote
2005 – 2007 University of Birmingham – Engineer’s Degree, Advance Aerospace and related materials Engineer’s Degree (DIPEngD), Advance Aerospace and related materials
2002 – 2005 The University of Manchester – Bachelor’s Degree (BSC), Materials Sciences

Abstract: Most parts built by additive manufacturing (AM) processes require secondary treatments to render them suitable for the intended critical purpose. Even with the most robust techniques, metal powder fusion processes still create small internal voids during the build cycle. The effect of post-build hot isostatic pressing (HIP) was evaluated on Ti 6/4 (titanium – 6% aluminum – 4% vanadium). Advanced characterization techniques such as computed tomography (CT) scanning x-ray, scanning electron microscope (SEM) fractography, and fatigue analysis were used to evaluate the effects on properties. Results demonstrate the removal of defects and the corresponding improvement in mechanical properties. This is especially important for critical components in industries such as nuclear, aerospace, medical, and subsea applications where fatigue is a major cause of premature failure. Additional work will concentrate on optimizing HIP parameters where minimized grain growth is desired.

Time 12:00 – 12:30

Author Bio: TBA

Abstract: TBA

AM SIS: Overview of the Evolution of AM Technologies

Session 35 – Tuesday 03 October – Time: 14:00 – 15:30

Chairs:
Mrs Adeline Riou (Aubert&Duval, France)

Dipl-Ing Claus Aumund-Kopp (Fraunhofer – IFAM, Germany)

Presentations:

Time 14:00 – 14:30

Author Bio: Ian Gibson is a full professor within the Design, Production and Management department as well as Director of the Fraunhofer Innovation Platform for Advanced Manufacture at the University of Twente in the Netherlands. He has been involved in 3D Printing or Additive Manufacturing since the early 1990s, when it was largely known as Rapid Prototyping. He co-established the first academic journal on the topic, the Rapid Prototyping Journal, in 1994. He also co-wrote the most successful text on the topic, Additive Manufacturing Technologies, published by Springer, which is now in its 3rd edition and has been read by more than 6 million people. His research interests are connected to many aspects of AM, but his main interests are now focused on helping the technology transfer effectively to mainstream industrial production.

Abstract: AM technology in general is experiencing a transition where industry is switching from ‘if’ it is a suitable technology to add to their process chains to ‘how’ and ‘when’ it should be added. This is backed up by many AM technology providers providing shopfloor ready technology rather than systems more suitable for the laboratory. Proposed enhancements to AM machines and other support technologies indicate that the mid-term future is also likely to significantly be affected. We will discuss these topics during this presentation, particularly focusing on laser-based powder-bed fusion additive manufacturing for metal parts.

Time 14:30 – 15:00

Author Bio: Alex Hardaker is an advanced research engineer with 6 years experience in Additive Manufacturing (AM), with a focus on powder bed fusion – laser based (PBF-LB) equipment. Developing understanding across the whole manufacturing process chain. His interests include large/multi laser PBF-LB, copper AM processing, and novel applications.

Abstract: As machine vendors release PBF-LB systems with larger build envelopes that enable industry to manufacture larger components, the challenge of managing quality and build risks increases. Some of this risk is associated with the addition of new features such as multiple lasers to reduce build time for example, that could lead to detrimental effects to part quality if not managed in a controlled manner. Therefore, it is critical to understand the characteristics and challenges of these with these new machine strategies in order to fully utilise their capabilities and enable industrialisation of large scale LB-PBF.

Time 15:00 – 15:30

Author Bio: Dr. Amin Molavi-Kakhki has been with Rio Tinto Metal Powder for 6 years as a Research Engineer. Amin has a specialization background in powder metallurgy, with a sustained engagement in the additive manufacturing research and development space for water atomized ferrous alloys.

Abstract: Industrial application of Additive Manufacturing (AM) is recently getting more attention, as the printing technologies are evolving towards a faster printing speed and eventually lower manufacturing cost. Choosing the right part and application and an optimum set of printing parameters along a wise selection of low-cost feed material will help to extend the real industrial use of AM. In this work, ATOMET 1025, a water atomized low carbon steel powder, produced by Rio Tinto Metal Powder was evaluated as the feed material for low to medium series production of industrial parts via a high-speed Laser Powder Bed Fusion (LPBF) method, developed by Brose Group. A series of different types of heat treatment was
studied on the printed samples to achieve the target mechanical properties. The results confirmed that this combination of material, printing process and post processing can lead to the properties equivalent or better than the conventional counterparts.

FM SIS: Amorphous Metals by Powder Metallurgy

Session 36 – Tuesday 03 October – Time: 14:00 – 15:30

Chairs:
Dr Sebastian Hein (Fraunhofer IFAM, Germany)
Mr Peter Kjeldsteen (Sintex a/s, Denmark) & Dr Moritz Stolpe (Consultant, Germany)
Presentations:

Time 14:00 – 14:30

Author Bio: Ralf Busch began studying physics at the Georg-August-Universität Göttingen after graduating from high school in 1983. He received his PhD in Göttingen in 1992 with a thesis on “Analytical field ion microscopy of the reaction in Zr-Co bilayers”. In 1993, he went to the California Institute of Technology in Pasadena (USA) as a Feodor Lynen Fellow of the Alexander von Humboldt Foundation. There he started to work in the field of Bulk Metallic Glasses. In 1999, he accepted an Assistant Professorship in Materials Science in the Department of Mechanical Engineering at Oregon State University and became an Associate Professor there in 2004. He accepted a professorship in Metallic Materials at Saarland University in 2005

Abstract: This presentation gives an overview of recent advances in additive manufacturing of amorphous metals. These metals are multicomponent alloys that do not crystallize but freeze into a metallic glass when cooled from the melt. Therefore, laser powder bed fusion is a very suitable means to additively manufacture parts of amorphous metals. The requirements for the particular alloy system, the quality of the powder a well as the processing conditions to obtain fully amorphous parts are discussed. Of particular interest is the heat management during the layer by layer manufacturing, since crystallization in the heat affected zone has to be suppressed.

Another important factor is the impact of impurities like oxygen from the powder or the manufacturing environment on the properties of the processed alloy. Examples on Zr-, Ti-, Ni- and Fe-based alloys will be given, in which either the unique mechanical or soft-magnetic properties of the amorphous alloys are exploited.

Time 14:30 – 15:00

Author Bio: Fazal is the Co-founder & CEO of Phaseshift Technologies. PhaseShift is a Canadian startup focusing on accelerating the design novel high performance alloys using Machine Learning and Computational Materials Science.

Abstract: This research presents a new method for discovering high-performance alloys with optimized glass-forming ability, mechanical properties, and soft-magnetic properties. The approach combines machine learning and multi-scale simulations to predict and validate the properties of candidate alloys. Machine Learning algorithms and Simulations synergistically work together to produce the best Metallic Glass with the best balance of all the properties, i.e. Pareto Optimal Compositions. The results demonstrate the potential of the methodology for accelerating the discovery of superior alloys for various applications.

Time 15:00 – 15:30

Author Bio: B.Sc. in Mechanical Engineering – University of Maryland, College Park, USA. M.Sc.in Mechanical Engineering at Technical University Eindhoven, Netherlands.

Abstract:

Fe-based soft magnetic bulk metallic glasses (BMGs) have shown unprecedented magnetization saturation and coercivity values and are thus envisioned as potential candidates to increase the efficiency of electromagnetic components. Laser powder bed fusion (LBPF) allows to manufacture relatively large BMG parts while retaining an amorphous microstructure due to high local cooling rates. However, in practice, the thermal cycles generated in the layer-wise LBPF process tend to cause undesired crystallization. To date, finding optimum LPBF processing conditions that yield, simultaneously, high densities and high fractions of the amorphous phase, which give rise to the desired mechanical and magnetic performance, remains a challenge.

This work provides a thorough study of the effect of processing parameters on the resulting (micro)structure and properties of a commercial Fe-based amorphous alloy. The relationship between internal defects, mechanical properties and soft magnetic behaviour is established, defining guidelines for the successful additive manufacturing of Fe-based BMGs LPBF.

FM SIS: Sustainability of Critical Raw Materials by PM

Session 44 – Tuesday 03 October – Time: 16:30 – 18:00

Chairs:
Dr Sebastian Hein (Fraunhofer IFAM, Germany)
Mr Peter Kjeldsteen (Sintex a/s, Denmark)

Dr Martin Bram (Forschungszentrum Juelich GmbH Inst Of Energy & Climate Research, Germany)

Presentations:

Time 16:30 – 17:00

Author Bio: Research Group Leader Materials Processing and Sustainability

Abstract: Grinding sludge is a coproduct generated during the machining process and typically consists of a mixture of metallic and non-metallic particles, binder material from the grinding wheel, and cooling lubricant. Separating the grinding chips from the sludge can enable their reuse as starting material for powder metallurgical processes. This study investigates the utilization of recycled grinding chips as starting material for powder metallurgy processes. In this work, four different processing techniques, including electro-discharge sintering (EDS), hot isostatic pressing (HIP), supersolidus liquid phase sintering (SLPS), and field-assisted sintering (FAST), are used to process the recycled grinding chips. The effect of each technique on the microstructure formed and the associated properties of the sintered material are evaluated. Based on the results, the utilization of separated grinding chips for powder metallurgical processes shows great potential for sustainable material usage and reduced environmental impact in the manufacturing industry.

Time 17:00 – 17:30

Author Bio:

Abstract: Being a hotspot in materials research and engineering for decades, thermoelectric (TE) power generation are still lack of large scale applications in industry. One of the limiting factors are the scarceness of Tellurium (Te), one of the raw elements in the current thermoelectric devices. Tellurium is rarer than Gold on earth, and only concentrated in a few countries. The short of Te has led to a sky-rocketing of the price of TE materials, especially after the geographical conflicts in Easten Europe since 2022. Independency of critical raw materials has become one of the key issues for the European Union. Developing Te-free thermoelectric materials and identify large-scale applications for TE generation are at the core of the mission of the START project.

Time 17:30 – 18:00

Author Bio: Project Manager

Abstract: Nowadays, diamond segments and wires are commonly used for sawing natural stone, concrete and ceramics. The cutting section of the tool consists of synthetic diamond crystals embedded in cobalt based metallic matrix, obtained using powder metallurgical (PM) routes. Cobalt is considerer a CRM (Critical raw material) due to the supply chain risk. Furthermore it is also considered highly toxic and subjected to REACH regulation. The present work has a twofold objective: from one side the substitution of cobalt by other non-toxic elements, and at the same time, the development of a diamond injection moulding process to allow obtaining more complex shape parts (thus improving their performance) and increasing the process productivity.

HM SIS: A 100 years development of Hard Materials – I

Session 51 – Wednesday 04 October – Time: 08:30 – 10:00

Chairs:
Raquel de Oro Calderon
Dr Jose Garcia

Presentations:

Time 08:30 – 09:00

Author Bio: TBA

Abstract: WC-Co cemented carbides discovered in Germany in the early 1920’s are an example of a successful commercial project for the development, patenting, and implementation of fundamentally new materials. Patenting WC-Co materials in the USA, Germany and Great Britain and classifying ‘know-how’ leaded to their great commercial success, so the price of 1 g cemented carbide was as high as the price of 1 g gold in the early 1930’s.
Synthetic diamonds were first obtained at ultrahigh pressures at ASEA (Sweden) in 1953, but all the results were kept secret. In this regard, the priority of their invention went to General Electric (USA), where synthetic diamonds were produced a year later, since the results were patented and then published in the NATURE journal.
Diamond films were first obtained by chemical vapor deposition at low pressures in the USSR in the 1960’s, but all the results were kept secret at that time, so the priority in this field of research is still disputed by Russian, American and Japanese scientists.

Time 09:00 – 09:30

Author Bio: After a training as a furniture maker alongside secondary school, Walter Lengauer studied technical chemistry at TU Vienna. He completed his studies in 1984 with a diploma and in 1987 with a doctorate. After habilitation in 1993, Walter has been studying hard materials, hardmetals and cermets together with his research group. Focus on these materials was fundamental properties as well as production and application. He was a post doc at the University of Geneva, visiting professor at the University of Rennes and supervisor of 57 academic theses at TU Vienna. Walter can prove many cooperations with international companies, has more than 150 scientific journal papers, about 80 conference contributions with more than 90 lectures, is co-inventor of 13 patents and serves as a reviewer for more than 20 scientific journals. Walter retired from the TU Vienna in September 2023 and now works for TUTEC GmbH, Vienna, as a consultant for hardmetals, cermets and ceramics for applications in machining and electronics industries.

Abstract: Cermets are a class of composite materials which are competitive to hardmetals but do not contain free hexagonal tungsten carbide but a face-centred-cubic hard phase. They were first synthesised only seven years after hardmetals appeared. In their early days Cermets were fabricated by using carbides as a hard phase only. However, in the 1970s nitrogen was introduced into cermet systems which substantially widened their field of application. Today we are able to prepare Ti(C,N)-based cermets using a huge variety of high quality carbide, nitride and carbonitride starting powders. The wide homogeneity ranges of these multi-component compounds further multiply the possibilities of establishing certain overall compositions, resulting in an immense area of research. The present contribution gives a short overview on the historic development and the current status on science and application of industrial cermet grades.

Time 09:30 – 10:00

Author Bio: TBA

Abstract: TBA

P&S SIS: Improving Sustainability and Cost in Pressing and Sintering – Part 1

Session 52 – Wednesday 04 October – Time: 08:30 – 10:00

Chairs:
Dr Caroline Larsson (Höganäs AB, Sweden)
Dr Cèsar Molins (AMES SA, Spain)

Presentations:

Time 08:30 – 09:00

Author Bio: M.Sc. Materials Physics from Royal Institute of Technology, Stockholm. Worked for Höganäs since 1998; product development, marketing, sales and training platforms. Today, product portfolio management.

Abstract: We are now in one of the most dramatic reinventions of the automotive industry, where sustainability is transforming end user demands, and electrification is booming. While most nations progress towards a greener future, the majority remain far from having clear policies in place. Still, OEM:s like Mercedes has launched Ambition 2039, to make their entire fleet of new vehicles net carbon-neutral along the entire value chain and over the vehicles’ entire life cycle by 2039. Other OEM and Tier X have similar targets, already becoming as important a factor as quality and price. To meet these demands, our solutions need to be developed here and now. In 2035, internal combustion engines (ICE) is forecast to decline to 50% of the 2019 level, whereas battery electric vehicles (BEV) are growing fast.

As an industry, both threats and opportunities await us ahead. Our core PM powertrain business is soon becoming obsolete. However, if we as an industry can prove ourselves to offer a lower CO2 footprint than competing metal forming techniques, we have a great opportunity to become a part of the solution towards these sustainability goals, both in automotive as well as in non-automotive applications.

Time 09:00 – 09:30

Author Bio: Sales Area Manager Metals

Abstract: The ability of producing high density components offers manufacturers a greater capability to answer today’s market needs, changed due to factors such as the electrification of cars and the continuous demand for cost reduction.

In this perspective SACMI, TFM, K4SINT and the University of Trento have been collaborating within the European project LIFE16 ENV-IT-000231 and successfully implemented a solution through the lubrication of the mold that allows the production of high-strength and high-density sintered components. Parts with green density up to 7.50 g / cc and green resistance over 60MPa, that makes also possible functional mechanical processing before sintering, have been successfully produced.

During the presentation main results and advantages of the solution will be presented.

Time 09:30 – 10:00

Author Bio: Johannes Gediga owns a Diploma in aeronautical engineering and a PhD in Chemical Engineering (Dr -Ing.). He currently holds the position of Director Sustainability Consulting Mining and Metals. Johannes’ expertise is based on 28 years work in product and corporate sustainability in the mining and metals industry. His experience includes Life Cycle Assessment (LCA), product and corporate carbon footprint, Carbon reduction roadmap development and other sustainability framework projects with many commodity associations and companies.

Abstract: Sustainable development is a development that meets the needs of the present without compromising the ability of future generations to meet their own needs [Brundtland Report 1987].
The Intergovernmental Panel on Climate Change (IPCC) issued its third part of the Sixth Assessment Report which highlights the importance of society, industries and companies to focus on carbon minimization and transition from fossil fuels to renewables. The UN body advocates for this approach over blind trust in future climate mitigating technologies, warning that climate change is accelerating much faster and climate impacts and their corresponding social, structural and economic implications are being realized earlier than scientists had anticipated.
Data driven decision making for decarbonisation can be supported by Life Cycle Assessment (LCA), which is a valuable methodology for evaluating environmental impacts across a product value chain.
It also supports to identify and avoid potential shifts of burden within the value chain.
With increasing pressure for Corporation to respond to climate change Life Cycle Thinking supports Sustainable Development Goals like SDG 3, 9, 12 and 13.

HM SIS: A 100 years development of Hard Materials – II

Session 59 – Wednesday 04 October – Time: 11:00 – 12:30

Chairs:
Dr Alexandra Kusoffsky
Prof Walter Lengauer

Presentations:

Time 11:00 – 11:30

Author Bio: Education:
• B.Sc. Physical Metallurgy and Science of Materials, University of
Birmingham 1973
• M.Sc. Physical Metallurgy and Science of Materials, University of
Birmingham 1976 Research and Thesis on SiAlON ceramics
• MBA University of PiHsburgh 1986
Work Experience:
• Lucas Industries 1973-1978: Research and development of SiAlON
ceramics
• UK Atomic Energy Authority 1978-1981: Research and
development of SiC ceramics
• Kennametal Inc. 1981-2014: Research, development, engineering,
and commercialization of ceramics, cemented carbides, hard
coatings, steels, and superhard materials for metalcuttng and
other products.
• North Technical Management, LLC 2015-present: Project
management and technical consulting, advisory boards, technical
writing.

Abstract: TBA

Time 11:30 – 12:00

Author Bio: Martina Lattemann is Specialist and Technology Area Manager for Modeling and Simulations at Sandvik Coromant. She obtained her Ph.D. at the Karlsruhe Institute of Technology in Germany and was Post.-Doc. and Assistant Prof. at Linköpings Universitet, before she started as a group leader at the Technical University Darmstadt, Germany. She received an ARC International Followship which she spent at the University of Sydney developing new plasma process for surface modification and as visiting scientist at Curtin University in Perth, where she also was offered an Adj. Assoc. Prof. position. Her main research area is within materials science ranging from thin film technologies, advance materials characterization, and computer simulations. Lately, her focus lies on multiscale modeling for the development of hard metals.

Abstract: Hard metals have been used in the cutting industry for the last 100 years with its main constituent WC and Co being still the same. Over the decades, performance improvements could not be achieved anymore solely by varying the grain size and binder volume fraction and new ways such as adding grain growth inhibitors had to be found. Computational methods are a vital part within R&D of hard metals ranging from first-principles and atomistic simulations to Finite Element Analysis and thermo-dynamical modeling as well as computation fluid dynamics and statistical modelling. In this talk, we will give an overview on how computer simulations have been applied to support the efforts in developing of hard metals.

Time 12:00 – 12:30

Author Bio: 1986 – 1991 Studies of Materials Science, University Erlangen-Nürnberg, Germany
1991 – 1996 PhD “Fatigue of cemented carbides…”, University Erlangen-Nürnberg, Germany
07/96-10/98 Material Analysis, KENNAMETAL Inc., Latrobe PA, USA
11/98-02/20 Manager Research & Development, Cutting Tools, CERATIZIT Austria GmbH
03/20 – now Director Research & Development, CERATIZIT Austria GmbH

Abstract: Hard metals based on tungsten carbide have unique material properties regarding specific types of stress such as wear, tensile/compression and impact stress, thermal and mechanical fatigue, and hardness. Therefore, they have been continuously improved since their introduction in technical applications about one hundred years ago and are therefore used very successfully for wear-active applications, mining and especially for cutting tools in metalworking.

Here, the demands on the powder metallurgically produced material system are increasing, driven by complex component geometries, new types of materials to be processed, cost and efficiency pressure in production as well as increasing quality requirements. In addition, closed material flows, the use of secondary raw materials and holistic sustainability are becoming increasingly important. For about sixty years, the coating of the cemented carbide has also been a decisive factor in the development speed of industrial applications. Modern, analytical methods allow ever better insights into this material and the associated coatings down to the atomic level and thus enable, also with the support of simulation, the tailor-made design and development of outstanding material properties regarding specific applications. This presentation is intended to recall scientific achievements, present actual developments, and discuss sustainability aspects.

P&S SIS: Improving Sustainability and Cost in Pressing and Sintering – Part 2

Session 60 – Wednesday 04 October – Time: 11:00 – 12:30

Chairs:
Dr Caroline Larsson (Höganäs AB, Sweden)
Dr Cèsar Molins (AMES SA, Spain)

Presentations:

Time 11:00 – 11:30

Author Bio: Oliver Schenk received his master’s degree in mechanical engineering at Wuppertal University, Germany in 2020 and works on simulation of powder metallurgical manufacturing processes in the Institute for Materials Applications in Mechanical Engineering (IWM) at RWTH Aachen University, Germany. His research interests include the multiscale modelling of powder compaction and sintering.

Abstract: The powder metallurgical (PM) process chain has long been an established route for the production of precision parts for automotive applications, such as powertrain components for internal combustion engines. In the course of transition of automotive industry and due to the increasing demand for sustainable solutions in the production, the PM industry is facing new challenges, including both new technical applications and new materials, such as soft-magnetic alloys. The targeted use of numerical methods can enable the efficient development and improvement of the entire process chain while maintaining competitiveness. In this lecture, a digital twin of the PM process chain will be presented that provides information on both dimensional changes and effective properties. Practical examples on its application to powder compaction, sintering and secondary operations will show the potential of this digital twin in terms of efficiency and sustainability.

Time 11:30 – 12:00

Author Bio: Education: Dr. rer. nat. at Westfälische Wilhems Universität Münster (Germany) – Dep. of Physics (1981). Work: Head of Corporate R&D, Quality, Health and Safety at Krebsöge Group / Sinter Metals Inc. / GKN Sinter Metals (1987 – 2002); VP Global Advanced Engineering / R&D. at GKN Sinter Metals (2002 – 2012); Consultant (after retirement, 2012 – today) with Powder Metallurgy Solutions (own company). Started in professional PM in 1981 at Sintermetallwerk Krebsöge, Germany; former member of the board of DGM (German Society of Materials) and of Board and Council of EPMA; from end of 2015 to end of 2016 acting as Executive Director of EPMA; Technical Chairman of World PM1998 (EPMA, Granada) and Co-chairman of World PM2002 (MPIF, Orlando); Skaupy Award (1998, Fachverband, Germany) and Distinguished Service Award (2012, EPMA).

Abstract: Pressure on continuous improvement of sustainability combined with improved cost of all industrial products and processes is growing in the near future. Parallel, driven by the latest developments in new energy technologies, former commodity materials became strategic. Nickel and copper, classical alloying elements in PM, are now becoming critical metals with potential risks of availability and price increases.
The latest developments of powders with reduced Cu / Ni content or without these elements and respective adapted sintering processes will give PM industry new tools to further improve the competitive edge against other forming technologies. The latest results with focus on the combination of sustainability, properties and cost are presented and discussed in this presentation.

Time 12:00 – 12:30

Author Bio: Caroline holds a M.Sc. in Metallurgy and Materials technology from the Royal Institute of Technology in Stockholm.
She has been working for Höganäs AB, since 1988, and has held several managing positions in Product development, Technical sales & marketing, Production strategies, Business development and Market communication as well as Product management.

Abstract: Improving sustainability in all processes, including Press&Sinter, is a win-win situation when it can be done while simultanously reducing costs. This happens especially when efficiency is increased, creating positive effects in both directions. Caroline Larsson of Höganäs AB is going to moderate the final discussion of the two SIS sessions, involving the speakers and the audience.