3rd ‘Additive Manufacturing the Future’ Programme

Abstract: 

In just three years, our additive manufacturing team has grown into a dynamic hub of innovation, equipped with state-of-the-art infrastructure that spans the entire production lifecycle—from design and build preparation to manufacturing, post-processing, in-situ monitoring, and rigorous testing and characterization. Leveraging cutting-edge technologies like Powder Bed Fusion – Laser Beam (PBF-LB) and Directed Energy Deposition (DED), we operate across four key verticals: Processes, Materials, Design, and Digitization and Applications. Our industry-focused approach allows us to address specific pain points, driving advancements in additive manufacturing not only in the MENA region but also on a global scale. This talk will provide an overview of our current activities, highlighting how our integrated approach and technological expertise are contributing to the evolution of additive manufacturing, and setting new standards in the industry. 

Abstract: 

Additive Manufacturing is playing a major role in high-value applications across Aerospace, Defense, Medical, and Industrial sectors. In the Oil & Gas industry, it is widely used for maintenance and spare part production. In this talk, AMPOWER Partner Matthias Schmidt-Lehr will highlight the current market situation based on the AMPOWER Report 2024. Discover best practices from leading global users and learn how new technological approaches in Additive Manufacturing are creating opportunities to solve major production and maintenance challenges.

Abstract:

“Redefining the Final Frontier: How AM is Transforming Space Exploration” explores the revolutionary impact of additive manufacturing (AM) on the aerospace industry. This speech will delve into key areas, including material characterization, parameter development, topology optimization and systems integration, highlighting how advancements in these areas have redefined design and production capabilities for space exploration. By examining the successes of the U.S. Space Program and leading commercial space companies, the speakers will demonstrate how AM is enabling rapid innovation and pushing the boundaries of what is possible in space. From complex rocket engines to customized spacecraft components, AM is not just a tool but a transformative force driving the next era of flight.

Abstract:

Ensuring the quality of additively manufactured parts and components is extremely critical as AM technology adoption is becoming faster across multiple industry sectors. In the past couple of years, many international standards have been published that can be used to develop quality assurance framework within an organization in order to achieve third-party or regulatory certification. This presentation provides an overview of the needs and importance of research to standardization in delivering quality AM products. Many of existing standards can be mapped to the AM process chain for qualification while many gaps already exist in AM standardization. The major role of research community in closing the gaps and AM industrialization will be also highlighted.

Abstract: 

The adoption of 3D printing technology has revolutionized manufacturing, enabling rapid prototyping, mass customization, and complex geometries that were previously unattainable with traditional manufacturing methods. However, understanding the Total Cost of Ownership (TCO) in 3D printing is critical for organizations aiming to fully capitalize on its benefits while maintaining cost-effectiveness. TCO encompasses all costs associated with the acquisition, operation, and maintenance of 3D printing technology over its lifecycle. This includes initial capital expenditures on printers, software, and training, as well as ongoing costs such as materials, energy consumption, labor, maintenance, and potential downtime. 

The talk will cover the key components of TCO in L-PBF 3D printing, highlighting key components that goes unnoticed when calculating the in-famous Cost per part and how much of an impact scrap, failure and downtime could impact.

Abstract: 

Additive Manufacturing (AM) has become a mainstream technology in the lexicon of manufacturers, designers, and innovators as a method of producing high value components quickly and efficiently without the need for tooling. The benefits of 3D printing have centred around the ability to produce complex geometries and designs without the need for costly tooling and fixtures, opening the design space for product developers to unparalleled levels. In order to further enhance the capability of products, AM needs to continually move forwards, and this talk will give an overview of the multi-material / functional research that is being carried out at The University of Nottingham’s Centre for Additive Manufacturing, highlighting work in the development of electromagnetic materials, metallics and others, all with the goal of adding function to AM components.

ABSTRACT

In recent years, advances in additive manufacturing of metallic materials have revolutionized sectors such as aerospace, automotive and electronics, enabling new geometries and features that were impossible years ago using traditional methods. But one of the challenges facing this technology was manufacturing with highly reflective materials such as copper and aluminum. These materials, characterized by their high thermal and electrical conductivity, are essential in a wide range of industrial applications. However, their high reflectivity has posed major challenges in additive manufacturing, specifically in technologies such as Directed Energy Deposition (DED), where the use of traditional (IR) lasers is inefficient.

The arrival of Meltio's second-generation blue laser head has marked a turning point in this area. Its shorter wavelength allows for better energy absorption in highly reflective metals such as copper and aluminum, significantly improving process efficiency and the quality of the parts produced.

This paper explores recent advances Meltio has made in the manufacturing of high reflectivity materials using blue lasers in DED processes. Key improvements in accuracy, uniformity and defect reduction are discussed, as well as comparative studies between conventional laser technologies and the blue laser, highlighting their implications for the high-tech manufacturing industry.

Keywords: Blue, laser, Meltio, Directed Energy Deposition, Copper, Aluminum.

Abstract: 

Oxide dispersion strengthened (ODS) alloys such as ODS Ni alloys and ODS steels, provide an exceptional combination of resistance to deformation, creep, coarsening, oxidation, and corrosion. Despite these advantageous material properties, ideal for power generation and engine applications, the manufacturing of components using ODS alloys faces significant economic and technical challenges. Traditionally, powder metallurgy is considered the only viable method for
producing ODS alloys from powders, which are created by adding oxides through ball milling.
Conventional melting techniques result in the loss of oxide dispersoids due to processes such as coarsening, dissolution, agglomeration into inter-dendritic spaces, and slagging. The low machinability of these reinforced alloys has prompted interest in additive manufacturing (AM) as an alternative fabrication method, especially through rapid melting and solidification. Recently, there has been a growing focus on fabricating ODS alloys via laser-based powder-bed fusion (L-PBF) or laser direct metal deposition (DMD).

This presentation reviews research conducted over the past decade at Empa on the AM of ODS alloys. Various solid-solution and precipitation-strengthened Ni alloys [1-5], Al alloys [6], γ-TiAl and Ti alloys [7-9], and steels have been reinforced with nanometric oxides (Y 2 O 3 , HfO 2 , Al 2 O 3 ) and successfully fabricated using L-PBF and DMD. Key findings regarding microstructure formation during AM, microstructure stability during heat treatments, and the mechanical performance at elevated temperatures of selected ODS alloys will be presented. The main lessons learned from the AM fabrication of these alloys will also be discussed.

Key words: ODS alloys, laser powder bed fusion, microstructure stability, creep performance

REFERENCES:

[1] A. De Luca, C. Kenel, J. Pado, S.S. Joglekar, D.C. Dunand, C. Leinenbach, Thermal stability and influence of Y2O3 dispersoids on the heat treatment response of an additively manufactured ODS Ni–Cr–Al–Ti γ/γ′ superalloy, Journal of Materials Research and Technology. 15 (2021) 2883–2898. https://doi.org/10.1016/j.jmrt.2021.09.076.

[2] C. Kenel, A. De Luca, C. Leinenbach, D.C. Dunand, High-Temperature Creep Properties of an Additively Manufactured Y2O3 Oxide Dispersion-Strengthened Ni–Cr–Al–Ti γ/γ’ Superalloy, Advanced Engineering Materials. 24 (2022) 2200753.
https://doi.org/10.1002/adem.202200753.

[3] J.U. Rakhmonov, C. Kenel, A. De Luca, C. Leinenbach, D.C. Dunand, Effect of Y2O3 dispersoids on microstructure and creep properties of Hastelloy X processed by laser powder-bed fusion, Additive Manufacturing Letters. 3 (2022) 100069. https://doi.org/10.1016/j.addlet.2022.100069.

[4] C. Kenel, A. De Luca, S.S. Joglekar, C. Leinenbach, D.C. Dunand, Evolution of Y2O3 dispersoids during laser powder bed fusion of oxide dispersion strengthened Ni-Cr-Al-Ti γ/γ’ superalloy, Additive Manufacturing. 47 (2021) 102224.
https://doi.org/10.1016/j.addma.2021.102224.

[5] A. De Luca, C. Kenel, D.C. Dunand, C. Leinenbach, Effect of HfO2 dispersoids on the microstructure of a Ni-Cr-Al-Ti superalloy processed by laser-based powder-bed fusion, Additive Manufacturing Letters. 6 (2023) 100139.
https://doi.org/10.1016/j.addlet.2023.100139.

[6] J.A. Glerum, A. De Luca, M.L. Schuster, C. Kenel, C. Leinenbach, D.C. Dunand, Effect of oxide dispersoids on precipitation-strengthened Al-1.7Zr (wt %) alloys produced by laser powder-bed fusion, Additive Manufacturing. 56 (2022) 102933. https://doi.org/10.1016/j.addma.2022.102933.

[7] C.. Kenel, A.. Lis, K.. Dawson, M.. Stiefel, C.. Pecnik, J.. Barras, A.. Colella, C.. Hauser, G.J.. Tatlock, C.. Leinenbach, K.. Wegener, Mechanical performance and oxidation resistance of an ODS γ-TiAl alloy processed by spark plasma sintering and laser additive manufacturing, Intermetallics. 91 (2017) 169–180. https://doi.org/10.1016/j.intermet.2017.09.004.

[8] C.. Kenel, K.. Dawson, J.. Barras, C.. Hauser, G.. Dasargyri, T.. Bauer, A.. Colella, A.B.. Spierings, G.J.. Tatlock, C.. Leinenbach, K.. Wegener, Microstructure and oxide particle stability in a novel ODS γ-TiAl alloy processed by spark plasma sintering and laser additive manufacturing, Intermetallics. 90 (2017) 63–73. https://doi.org/10.1016/j.intermet.2017.07.004.

[9] C.. Kenel, G.. Dasargyri, T.. Bauer, A.. Colella, A.B.. Spierings, C.. Leinenbach, K.. Wegener, Selective laser melting of an oxide dispersion strengthened (ODS) γ-TiAl alloy towards production of complex structures, Mater. Des. 134 (2017) 81–90. https://doi.org/10.1016/j.matdes.2017.08.034.

Abstract:

Metal additive manufacturing (AM) offers significant advantages over conventional tooling methods, particularly in enhancing cooling performance. Despite these benefits, metal AM has yet to become a mainstream technology in mould manufacturing due to several challenges. In this presentation, we will share research and findings on the use of metal AM in mould production. The session will begin with an overview of the industry history and key applications for both polymer and metal AM. The focus will then shift to the transformative potential of metal AM in moulding processes and strategies for integrating this innovative technology into the established industrial production chain.

Abstract: 

Additive Manufacturing (AM) unlocks the possibility of creating next-generation alloys featuring properties unachievable by traditional manufacturing routes. Extending the current alloy portfolio is a top priority for accelerating the adoption of AM processes in established industrial sectors, such as aerospace and defence. The AM team at the Technology Innovation Institute (TII) is contributing to this industrial mission through the design, development, and industrialisation of aluminium pre-alloyed powders – AMALLOY3D – for Powder Bed Fusion Laser Beam (PBF-LB) manufacture. 

This work deployed alloy design based on CALPHAD principles to define a suitable chemical formulation and nanoparticle inoculant to achieve remarkable strength at room temperature paired with low hot crack sensitivity and high additive manufacturing productivity. The high- temperature variant of the alloy – AMALLOY3D-HT – demonstrated excellent strength in an environment heated up to 300 ºC due to a combination of novel precipitates and extreme grain refinement, outperforming the properties of commercial high-strength Al alloy grades available in the marketplace today. The talk also dives into the scale-up activities of TII’s proprietary alloys, from in-house ultrasonic atomisation to industrial powder production and PBF-LB manufacturing using pre-alloyed powder feedstock.