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Technical Program

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Status: 18 April, 2025
Wednesday, 4 June, 2025

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08:30 PRO12-A 1
Optimizing microstructure through carbon control with Push-Pull gas cycling in Hard Metals
Chicinaș H.1, Westermann H.2, Schön A.2
1Technical University of Cluj-Napoca, Romania
2Gühring KG, Germany
Abstract
This study explores the push-pull gas cycling technique using both inert and reactive gases to optimize the sintering atmosphere for hard metals, aiming to reduce carbon content and improve microstructure. The push-pull method alternates between vacuum and gas exposure during sintering, focusing on lowering carbon activity to prevent graphite formation. Key parameters including magnetic saturation (Ms), coercivity (Hc), Vickers hardness (HV30), and fracture toughness (K1c) were measured to evaluate the mechanical and magnetic properties of the samples. Optical microscopy was used to assess microstructural changes, particularly in grain size and phase distribution. The results indicated that this technique effectively flushes physically trapped carbon bearing compounds, as well as chemically, when using reactive gases, leading to improved carbon control. Additionally, the alternating "breathing" effect of the push-pull method enhances temperature uniformity throughout the oven. This approach led to a more refined microstructure and enhanced mechanical and magnetic performance, demonstrating the push-pull technique’s potential to improve the quality of sintered hard metals.
08:50 PRO12-A 2
Impact of laser ablation on tungsten carbide 3D objects after extrusion (MEX)
Oliveira G.1, Rodrigues P.1, Vieira T.1
1University of Coimbra, Portugal
Abstract
3D objects manufactured from powder by Material Extrusion (MEX), have a distinct surface topology depending on the building strategy selected. For some applications, such as machining tools, carbide surfaces require the lowest surface roughness, not achievable by MEX. To avoid an expensive post-processing, laser ablation on the green surface becomes the alternative, to achieve better surface roughness of 3D objects after sintering. Tungsten carbide filament was home produced and used on a commercial 3D printer, to shape green 3D objects. The surface treatment was performed using a fiber laser (50 W), adopting different strategies and parameters (power, speed, frequency, line distance, number of passages). After laser ablation, debinding, and sintering, the 3D object surface roughness and the main mechanical properties, were evaluated. For the optimized laser parameters, it was possible to attain, on 3D objects, half of the untreated surface roughness values, without damaging the underlayers.
09:10 PRO12-A 3
Liquid Phase Migration and Shape Distortion of WC-Co Cemented Carbides during Sintering
Takeshi S.1, Yasuharu F.1, Taichi K.1, Terasaka S.2
1Kyoritsu Gokin Co., Ltd., Japan
2Tohoku University, Japan Fine Ceramics Center, Japan
Abstract
WC-Co cemented carbides are manufactured by powder metallurgy and liquid phase sintering. In the industrial products of cemented carbides, the quality of the shape after sintering is as important as the quality of the material property. However, sintered cemented carbides can exhibit shape distortion that cannot be explained by the non-uniformity of the green density or the effects of gravity. In this study, the deformation of cemented carbide during sintering was investigated in detail in relation to liquid phase migration. As a result, it was found that when a temperature gradient or carbon concentration gradient occurs in the sintered compact during cooling, the liquid phase migrates, and the sintered compact exhibits the shape distortion. The mechanism of the liquid phase migration during cooling is also discussed.
09:30 PRO12-A 4
About the effect of composition on the solid state sintering of cemented carbides with alternative binders
Missiaen J.-M.1
1Université Grenoble Alpes, France
Abstract
Cemented carbides usually consist of hard WC grains embedded in a tough Co based binder. They offer a wide range of applications as drilling and cutting tools or wear materials. The use of cobalt as a binder is however questioned, due to the recent evolution of the European regulation on chemicals. The effect of alternative binders on the microstructure and mechanical properties has been widely investigated in the last decades. However, analysis of the effect of the binder composition on the different sintering steps, and especially on the early stage of solid state sintering is still incomplete. Solid state spreading of the binder and consequently solid state sintering of the composite is delayed with a Fe-rich binder, as compared to a Co- or Ni-rich binder. This delay is by many aspects similar to what is observed when moving from a W-rich to a C-rich composition for a given metallic binder. These results are discussed in terms of variation of the solubility in the binder and of the interfacial energy with the binder composition.
09:50 PRO12-A 5
Microstructure and mechanical properties of WC-Co cemented carbides prepared by hot oscillatory pressure sintering
Liu J.1, Zhao K.1, Wang K.2, An L.2
1Southwest Jiaotong University, China
2Dongguan University of Technology, China
Abstract
WC-Co cemented carbides were prepared by hot oscillatory pressure sintering (HOP), and the effect of sintering temperature and oscillatory pressure on the densification, microstructure and mechanical properties was investigated. The results show that the dense samples can be prepared by the HOP process at the solid-phase sintering temperature (< 1350 oC), revealing a significant reduction in the sintering temperature compared with conventional hot pressing. The ultra-fine WC grains are obtained in the HOP samples, and the distribution of Co phase is more uniform compared to conventional hot pressed samples. In addition, more fcc-structured Co phase and Σ2 low-energy grain boundaries are observed in the HOP samples, which exhibits Vickers hardness of ~22 GPa and fracture toughness of ~12 MPam1/2. It indicates that oscillating pressure accelerates particle rearrangement, plastic deformation, and grain boundary diffusion. This work demonstrates a new approach to prepare high-performance cemented carbides.

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10:30 PRO12-B 1
Evaluating additive manufacturing technology for cemented carbide with industrial applications
Wang Z.1, Bonidie M.1, Schmid D.2, Miyanaji H.1, Prichard P.3
1Kennametal Inc., USA
2Kennametal Shared Services GmbH, Germany
3Oak Ridge National Laboratory, USA
Abstract
Additive manufacturing (AM) exhibits significant economic advantages compared to traditional manufacturing in the fabrication of highly complex components with short lead times. Due to these advantages, AM has shown promise in the manufacturing of customizable cemented carbide components for metal cutting and aggressive wear applications. In this work, the feasibility of the various AM technologies for cemented carbide applications is quantified based on cost, quality, scalability and technical maturity. For Binder Jet Printing, one of the most widely adopted technologies, various implementations have been examined for their ability to print cemented carbides. Key differences between manufacturers will be discussed showing the benefits and challenges when printing these materials in achieving a uniform microstructure with acceptable properties. The paper concludes by showing an example of how the customers can benefit from the deployment of this innovative manufacturing technology through enhanced design, improved lead times and reduced secondary finishing operations in reaming and endmilling applications.
10:50 PRO12-B 2
Additive manufacturing of WC-Co ceramic/metal composites using binder jetting: the link between microstructure, defects and mechanical properties
Erwan Marciano E.M.1, Olivier D.2, Xavier B.1, Sébastien D.3, Alexis B.4
1insa lyon, France
2Université Lyon 1, France
3Evatec Tools, France
4CEA LITEN Grenoble, France
Abstract
Cemented carbides, traditionally composed of tungsten carbide and cobalt, are manufactured by powder metallurgy and must reach full density. Today's environment is prompting us to find ways of saving the materials needed to manufacture industrial products, through the use/development of innovative processes such as additive manufacturing.
However, major technological and scientific hurdles remain : understanding the link between printing parameters, physico-chemical properties of powders, microstructures of printed parts and mechanical properties of sintered parts.
The debinding/sintering cycle was set and several mechanical tests were carried out to highlight the differences in mechanical behavior between pressed and printed parts using Metal Binder Jetting (MBJ). A link was established between the defects caused by MBJ and the choice of printing parameters, taking mechanical properties into consideration. The role of microstructure has also been evaluated, notably by studying the impact of grain size homogeneity. In this purpose, a number of mechanical tests (hardness, toughness, bending test) and observations (SEM, EDS) have been carried out to answer previous questions.
11:10 PRO12-B 3
Direct ink writing of cemented carbides: Processing – mechanical integrity correlation
Cabezas L.1, Jiménez-Piqué E.1, Vleugels J.2, Huang S.2, Llanes L.1
1UPC, Spain
2KUL, Belgium
Abstract
Additive Manufacturing has emerged as an alternative to conventional processing routes for shaping materials based on a 3D CAD model layer-by-layer part production. In this regard, Direct ink writing (DIW) is a flexible and cheap method which was already successfully applied to diverse ceramic systems. It is based on a simple hydrogel-based slurry whose behaviour is defined by the ceramic filler content, morphology and particle size. However, reports on DIW of cemented carbides are scarce. The main reasons are challenges linked to their metal-ceramic nature as well as concerns associated with the mechanical integrity of the intrinsic layer-assemblage, particularly considering the stringent service-conditions encountered in cemented carbide applications. In this context, the objective of this contribution is two-fold, i.e. to find optimal composition and printing parameters for DIW of WC-12 wt.%Co, and to evaluate the fracture behaviour of printed and sintered bending bars. In doing so, an extensive and systematic study combining processing and mechanical characterization are combined. The results are compared with equivalent samples manufactured by conventional press and sintering and Binder Jetting.
11:30 PRO12-B 4
Microstructural Evolution of Direct-Ink Writing Produced WC-12Co/Mo (wt%) Cemented Carbide
Mphasha N.P.1, Genga R.2, Vleugels J.3, Huang S.3, Sacks N.4, Polese C.5, Janse van Vuuren A.6
1School of Chemical and Metallurgical Engineering, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg, South Africa, South Africa
2Academic Development Unit (ADU), University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg, South Africa; ARUA CoE-MEN, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg, South Africa, South Africa
3Department of Materials Engineering (MTM), KU Leuven, Kasteelpark Arenberg 44/bus 2450, Leuven, Belgium, Belgium
4Department of Industrial Engineering, Stellenbosch University, 145 Banghoek Rd, Stellenbosch, South Africa, South Africa
5School of Mechanical, Industrial and Aeronautical Engineering, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg, South Africa; ARUA CoE-MEN, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg, South Africa, South Africa
6CHRTEM, Nelson Mandela University, University Way, Gqeberha, South Africa, South Africa
Abstract
In this study, the evolution of WC-8.4Co-3.6Mo (wt%) microstructure produced by Direct-Ink Writing (DIW) was investigated. Molybdenum (Mo) was added as a partial replacement of the cobalt (Co) binder to improve the mechanical properties and high-temperature performance of WC-based composites. Key parameters, including ink solid loading, extrusion pressure, layer thickness and strand width, were systematically varied to assess their influence on the resulting microstructure, density and hardness. Decreasing the layer height (from 49 µm to 19 µm) and strand width (from 67 µm to 28 µm) resulted in a more homogeneous microstructure, improved packing density and reduced shrinkage. The combined effect of lower layer height and narrower strand width significantly enhanced both the density and hardness of the consolidated samples, leading to a marked reduction in microstructural defects, such as voids and cracks. Higher solid loading (92.4 wt%) also contributed to denser compacts, thereby reducing porosity. Additionally, the study examined the effect of controlled humidity drying conditions on the microstructure. Higher humidity levels (49.7 %rh) facilitated more uniform drying, reducing the formation of cracks and thus improving the overall structural integrity of the samples.

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13:00 PRO04-A 1
Functional Principle and Mechanical Properties of an Molybdenum Alloy Designed for Powder Bed Fusion
Braun J.1, Kaserer L.1, Stajkovic J.1, Singer P.2, Distl B.2, Mayr-Schmölzer B.2, Kestler H.2, Leichtfried G.1
1University of Innsbruck, Austria
2Plansee SE, Austria
Abstract
The requirements for the alloy design of refractory metals differ significantly between powder metallurgically (PM) manufacturing by sintering and additive manufacturing by laser-based powder bed fusion (PBF-LB). The rapid solidification process inherent to PBF-LB presents a challenge in the reduction of impurities, such as oxygen. Nevertheless, it allows for the introduction of higher alloying contents, which would result in embrittlement in PM processes. In this study, we present the results of a Mo-0.45 wt.% C alloy manufactured by PBF-LB. The rationale behind the necessity for such elevated carbon contents is discussed, and the resulting mechanical properties are presented. These include room temperature (RT) and hot tensile and bending strength. Additionally, the influence of heat treatments on the microstructure and resulting fracture toughness of the samples is elucidated. The findings demonstrate that molybdenum manufactured by LPBF can compete with PM alloys, such as TZM and MHC, in hot tensile strength and exhibits sufficient fracture toughness at room temperature for end-use applications.
13:20 PRO04-A 2
Controlling the Tungsten Laser Powder Bed Fusion Process: Pyrometry-Driven In-Situ Parameter Optimization on the timescale of Microseconds
Stajkovic J.1, Braun J.1, Kaserer L.1, Distl B.2, Leichtfried G.1, Rispler C.1, Kahl M.1, Mayr-Schmoelzer B.2
1University of Innsbruck, Austria
2Plansee SE, Austria
Abstract
The geometry of the cross-sectional vapor capillary in laser powder bed fusion (PBF-LB) is critical for process optimization, particularly when processing refractory metals like tungsten. Despite its importance in medical and nuclear fusion applications, fabricating complex structures using PBF-LB remains challenging due to the lack of reliable process control strategies. Identifying a single parameter set capable of achieving high quality across varying conditions—such as bridging and thin-walled structures—is both experimentally costly and potentially infeasible. Recent studies suggest that pyrometric signals provide insights into laser penetration depth and vapor capillary geometry while also offering the potential for real-time feedback control of laser power. This capability enables in-situ adaptation to changing local conditions, maintaining the vapor capillary geometry within a desired range. This study translates these theoretical concepts into a practical workflow by implementing pyrometric feedback control in the production of tungsten sample cubes, evaluating their quality through Archimedes density measurements. The results demonstrate that pyrometric feedback loops in PBF-LB can enhance process stability and ensure consistently high build quality.
13:40 PRO04-A 3
3D Printing of Tungsten Heavy Alloys: An Approach with the MoldJet Process
Teuber R.1, Weißgärber T.2, Riecker S.1, Herzer N.1, Handtrack D.3, Mayr-Schmölzer B.3
1Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM Dresden, Germany
2Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM Dresden; TUD Dresden University of Technology, Germany
3Plansee SE, Austria
Abstract
The present study investigates the processing of tungsten heavy alloy in sinter-based additive manufacturing. A process chain has been developed for the processing of a Densimet 185 (97% W, rest Ni, Fe) metal powder into a paste and its subsequent 3D printing using the MoldJet process. The MoldJet process is a novel, sinter-based additive manufacturing technology, which enables the production of a wide range of geometries without the need for support structures. The high productivity of up to 1600 cm³/h also enables series production of components. The development process of a metal suspension and the challenges posed by the printing process are described. The printing and demolding process is explained, as well as the subsequent steps of debinding and sintering. The resulting microstructures and properties of the material are presented in terms of their chemical and mechanical properties. Finally, a general outlook on the applicability of the process for WHA products is given. This comprehensive approach allows understanding the challenges and requirements of the process and classifying the results achieved.
14:00 PRO04-A 4
Additive Manufacturing of High Temperature Mo-Si-B-Ti Alloys
Perepezko J.H.1, Lu L.1, Wood L.1, Thoma D.J.1, Rankouhi B.1, Haque N.U.1, Zhang F.2, Zhang C.2
1University of Wisconsin-Madison, USA
2Computherm LLC, USA
Abstract
With the drive to increase the operating temperature of gas turbine engines beyond the limits of Ni base superalloys refractory metal alloys are receiving increased attention. In order to achieve the enhanced performance an alloy must be designed to satisfy several challenging requirements involving mechanical properties and a number of thermophysical properties as well as environmental resistance at 1300℃. To address these challenges an effective design has been established based upon additive manufacturing (AM) utilizing a reactive synthesis of component powders of Mo, Si3N4, BN and Ti where a high throughput synthesis and characterization are employed together with guidance from computational thermodynamics to identify promising alloy compositions. The selected Mo-3.3Si-4.5B-10Ti alloy includes Ti for both density reduction to 9.2 g/cm3 and to limit the Si solubility in Mo and the associated embrittlement effect of Si. The alloy design exhibits a high compressive strength of about 1.6 GPa and ductility above 20% at room temperature. With AM and optimized processing parameters turbine blades have been produced at full scale.
14:20 PRO04-A 5
Abstract: Additive Manufacturing of Tungsten Heavy Alloy (WHA)
DuMez T.1, Ohm S.1, Stawovy M.1
1Elmet Technologies, USA
Abstract
Tungsten heavy alloy (WHA) is a machinable, high-density metal with mechanical properties equivalent to other common engineering materials.  Traditional manufacturing methods for WHA, such as powder metallurgy and metal injection molding have geometric complexity limitations.  Additive manufacturing (AM) offers an alternative for the fabrication of WHA components, enabling the creation of intricate geometries and customized designs. This technical report explores the feasibility and advantages of using AM techniques to produce WHA components. Various AM processes, including powder bed fusion (PBF), direct energy deposition (DED), and binder jetting, are discussed in terms of their suitability for WHA manufacturing. The challenges associated with AM of WHA, such as process parameters, and part quality control, are also addressed. The report presents experimental results on the AM of WHA, including microstructure characterization, mechanical properties and dimensional control. The potential applications of AM-produced WHA components in industries such as aerospace, defense, medical and nuclear energy are discussed. Overall, this report provides valuable insights into the current state of AM for WHA and highlights the future prospects of this emerging technology.

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13:00 SE13-A 1
alpha-Al2O3 coatings grown by moderate temperature CVD process
Höhn M.1, Stiens D.2, Manns T.2
1Fraunhofer Institute IKTS, Germany
2Walter AG, Germany
Abstract
CVD alpha-Al2O3 layers are one of the most important components in modern coating systems for cutting tools. These layers are usually deposited at substrate temperatures of 1000°C and higher. In this work Al2O3 layers were deposited in a moderate temperature process (MT-CVD) using a precursor system containing AlCl3-H2O-H2(-H2S) at substrate temperatures between 700°C and 900°C and at a deposition pressure between 1 and 6 kPa. The obtained coatings were characterized with respect to phase composition, crystal structure, hardness, adhesion and wear behaviour. In dependence of the deposition pressure and precursor ratio alpha-Al2O3 layers are formed with a hardness up to 2700 HV[0.01].
The wear behaviour of MT-CVD alpha-Al2O3 coated cutting tools was tested in milling steel 42CrMo4. A high performance of the MT-CVD alpha-Al2O3 coatings was observed. MT-CVD alpha-Al2O3 coated inserts showed at least a comparable lifetime to state-of-the-art CVD alpha-Al2O3.
The performed work demonstrates the possibility to reduce the coating temperature to produce alpha-Al2O3 coatings by modifying the precursor system. The MT-CVD alpha-Al2O3 coatings have comparable properties to state-of-the-art CVD alpha-Al2O3.
13:20 SE13-A 2
Alumina-based Nanocomposite Coatings by Chemical Vapor Deposition
Liu Z.1, Banerjee D.1
1Kennametal INC, USA
Abstract
Nanocomposite is a multiphase solid material where one of the phases has the size of less than 100 nanometers (nm) in at least one dimension, or structures having nano-scale repeat distances between the different phases that make up the material.  Nanocomposite coating represent a new generation of materials exhibiting completely new properties with respect to the conventional used materials. In this work, we demonstrate a couple of potential Al2O3-based nanocomposite systems deposited by CVD process directly using multilayer concepts with well-controlled deposition conditions to maintain the deposited “thin film” at nanoscale in either continuous layer or nanoparticle states.  Ultimately, a nanocomposite coating can be formed with improved wear resistance and metal-cutting performance. The ability to process nanocomposite by direct nucleation and growth of ceramic materials via CVD technique should provide new technical opportunity on the advanced materials development and applications.
13:40 SE13-A 3
Phase and texture formation in H2O-based moderate temperature Al2O3 chemical vapor deposition processes cancelled
Böőr K.1, Bäcke O.2, Kümmel J.1, Manns T.1, Kiefer D.1, Halvarsson M.2, Stiens D.1
1Walter Tools, Germany
2Chalmers University of Technology, Sweden
Abstract
Dense, crystalline, and hard Al2O3 coatings can be deposited at moderate temperatures (MT; ≤ 850 °C) using H2O and AlCl3 precursors in ultralow pressure chemical vapor deposition (ULP CVD) processes. The deposition is feasible in an industrial scale reactor as well [1].

In the presented study Al2O3 coatings were deposited in MT CVD processes onto the combinations of various coatings – such as Ti(C,N) on TiN – and bonding layers. The microstructure, the crystalline phases, and the texture evolve differently than in the processes at high temperatures (HT; 1000 °C) that utilize the water-gas shift reaction. Similarly to the HT CVD processes, the mentioned coating properties are influenced by the underlying coating layer, too.

The current understanding of the phase and texture development during growth will be presented, based on characterization results from imaging and diffraction techniques (SEM, EBSD, TEM, XRD).

[1] Höhn, M., Stiens., D, Gardecka, A.; Janssen, W.; Manns, T., Moderate Temperature CVD Alpha Alumina Coating (2021), Patent Application WO2023088866A1
13:40 SE13-A 4
Tailoring microstructure and crystal texture of titanium carbonitride Ti(C,N) thin hard coatings grown by chemical vapor deposition
El Azhari I.1, Valle N.2, José G.3, Stiens D.4, Manns T.4, Jenifer B.5, Christoph P.5, Flavio S.5, Luis L.6, Frank M.5
1University of Saarland, Germany
2LIST, Luxembourg
3Sandvik Coromant, Sweden
4Walter, Germany
5Saarland University, Germany
6Universitat Politècnica de Catalunya, Spain
Abstract
Titanium-based phases are broadly utilized in multilayer protective hard coatings for metal cutting tools. Especially in the context of chemical vapor deposition (CVD), Ti(C,N) is one of the most frequently used materials providing strong resistance to abrasive wear. This work focuses on a detailed study of coatings with different structures and preferential crystallographic orientations. Ti(C,N) was deposited on WC-Co substrates in an industrial hot wall reactor through a moderate temperature CVD process (MT-CVD), varying deposition parameters such as temperature, total pressure and reactant partial pressures. Correlative microscopy of high-resolution secondary ion mass spectrometry imaging (nano-SIMS) and Electron Backscatter Diffraction (EBSD) was used to investigate the compositional variations inside single crystals and segregation at the grain boundaries correlated to crystal shapes and orientation. Changing the texture from <211> to <110> not only influences the type of crystal shapes but also alters the chemical composition at the grain boundaries (segregation/complexions), and the distribution of contaminants within the crystals, affecting the mechanical properties of the coating. The results of this work can be used to optimize the properties of hard coatings produced by CVD.
14:00 SE13-A 5
Investigation of the impact of cooling crack-free CVD coatings on notch wear initiation
Sirtuli L.1, Boing D.2, Bushlya V.1, Norgren S.3
1Lund University, Sweden
2Sandvik Coromant, Sweden
3Lund University, Sandvik, Sweden
Abstract
CVD (chemical vapor deposition) coated tools typically exhibit cooling cracks due to the mismatch in thermal expansion coefficients (CTEs) between the cemented carbide and the coating. These cracks have been shown to act as weak points in the coating during machining, leading to accelerated notch wear formation. To study the notch formation without the influence of the cooling cracks, we have matched the CTEs of the coating and the substrate by using a cermet substrate, which resulted in a crack-free CVD coating. Two coated cermet tools: i. textured (0001) α-Al₂O₃/Ti(C,N) and ii. nanolayered κ-Al₂O₃-TiN/Ti(C,N) were investigated. During AISI316Ti turning, the κ-Al₂O₃-TiN/Ti(C,N) coating delaminated entirely at notch region after 0.3 m of cutting, exposing the cermet.  On the other hand, the α-Al₂O₃/Ti(C,N) coated tool exhibited localized flaking of the Al₂O₃ layer, while the underlying Ti(C,N) remained intact. This result differs from previous observations of the α-Al₂O₃/Ti(C,N) coating on cemented carbide, where cooling cracks led to exposure of the substrate. These findings suggest that the suppression of cooling cracks on α-Al₂O₃/Ti(C,N) coating retards the notch wear progression.

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15:00 PRO04-B 1
Alloying Concepts for AM of Tungsten using Powder Bed Fusion-Laser Beam - KEYNOTE
Kaserer L.1, Braun J.1, Distl B.2, Mayr-Schmoelzer B.3, Singer P.3, Kestler H.3, Leichtfried G.1
1University of Innsbruck, Austria
2Plansee SE, Austria
3PLANSEE SE, Austria
Abstract
The Additive Manufacturing technology Powder Bed Fusion - Laser Beam (PBF-LB) enables the production of complex-shaped components that surpass the limitations of conventional manufacturing methods. PBF-LB is ideally suited for producing functionally optimized parts for cutting-edge high-tech applications, especially when using high-performance materials such as tungsten (W).
However, a drawback of PBF-LB-manufactured W components is that they currently cannot compete with conventional powder metallurgical parts due to their coarse-grained, columnar microstructure, which is prone to cracking. To suppress the formation of such an unfavorable microstructure, it is necessary to tailor the material to the unique solidification conditions of the PBF-LB process.
In this work, different alloying concepts are investigated to, first, induce grain refinement, thereby suppressing the formation of a coarse-grained microstructure, and, second, to purify the grain boundaries from impurities and thus prevent crack formation. Both theoretical foundations and experimental results are presented.
15:30 PRO04-B 2
Additively Manufactured C-alloyed Molybdenum – an Alternative to Conventionally Manufactured TZM?
Distl B.1, Knittl J.1, Malleier A.1, Singer P.1, Braun J.2, Kaserer L.2, Mayr-Schmölzer B.1, Leichtfried G.2
1Plansee SE, Austria
2University of Innsbruck, Austria
Abstract
By processing carbon-alloyed molybdenum (Mo) by Powder Bed Fusion -Laser Beam (PBF-LB), a unique fine-grained microstructure is achieved. Inside the molybdenum-grains, small nanometer-sized molybdenum-cells embedded in a Mo2C-matrix can be found. Due to this microstructure, the material shows promising mechanical and physical properties on a lab scale, similar to conventionally manufactured TZM, a commonly used molybdenum-alloy. To be considered an alternative to TZM, the small-scale lab process needs to be transferred to a manufacturing environment - a challenging task as customized printers are required, and certain process parameters (e.g. build plate temperature) need to be adapted. This work shows mechanical and physical properties of C-alloyed Molybdenum compared to conventionally manufactured TZM. The promising material properties combined with the design freedom of the PBF-LB process can be a key enabler for high-tech refractory metal products of tomorrow.
15:50 PRO04-B 3
Development of Niobium and Tantalum/Tungsten base alloy powders for the additive manufacturing of high-temperature aerospace parts
Weinmann M.1, Stenzel M.1, Fayyazi B.1, Sim N.2, Rapoport A.2, Ishino Y.2
1TANIOBIS GmbH, Germany
2Alloyed Ltd., United Kingdom
Abstract
In recent years, the demand for high-temperature materials for use in aerospace has increased significantly. The thermal limit of state-of-the-art Nickel (Ni) base alloys is around 1050 °C. Refractory metal alloys significantly outperform these materials in terms of high-temperature mechanical properties, i.e., strength and creep behavior. Using additive manufacturing (AM), complex and geometry-optimized components can be manufactured from refractory metal alloys that are not processable otherwise.
In this context, the production of spherical Niobium (Nb) base alloy and Tantalum/Tungsten (Ta/W) base alloy powders using the electrode induction-melting gas atomization (EIGA) process is reported. The powders are investigated in depth, indicating significant differences in their microstructures, i.e., diverging chemical homogeneity of Nb-base (dendrite-type) and Ta/W (fully homogeneous) alloys. Moreover, the additive manufacturing using laser beam powder bed fusion (LB-PBF) is reported, including the development of AM process parameters and investigations of the microstructures of AM parts by means of XRD, SEM and EBSD. Finally, the temperature-dependent mechanical properties of selected AM parts are compared from room temperature to approx. 1600 °C.
16:10 PRO04-B 4
Low-pressure Powder Injection Molding of Tungsten Heavy Alloy and Hardmetals
Bose A.1
1AMfgLabs LLC, USA
Abstract
Processing complex shaped structures of refractory metal alloys and hardmaterials is quite difficult.  Powder injection molding (PIM) provides a route for fabricating small relatively high volumes of complex shaped parts. Quite often the powders of these materials are fine and irregular in shape which results in low volume fraction of solid loadings for most PIM feedstocks (often less than 50 vol.%) resulting in large shrinkages during sintering.  Also, the number of part requirement is often small resulting in making the PIM process unsuitable from an economic standpoint.  A low-pressure PIM process was developed to address these challenges of conventional PIM process. This paper will discuss the processing of tungsten heavy alloy and hardmetals using the low-pressure PIM process.

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15:00 SE13-B 1
PVD and CVD TiAlN hard coatings: history and recent advancements - KEYNOTE
Schalk N.1, Tkadletz M.2, Pohler M.3, Czettl C.3
1Christian Doppler Laboratory for Advanced Coated Cutting Tools at the Department of Materials Science, Montanuniversität Leoben, Austria
2Christian Doppler Laboratory for Sustainable Hard Coatings at the Department of Materials Science, Montanuniversität Leoben, Austria
3CERATIZIT Austria GmbH, Austria
Abstract
Introduced in 1986, Ti1-xAlxN is still one of the most widely used coating materials for cutting tools. Until the late 2000s, Ti1-xAlxN coatings have been exclusively synthesized by physical vapor deposition processes (PVD). More recently, suitable chemical vapor deposition (CVD) processes for the deposition of Ti1-xAlxN have been developed. Using these processes, the deposition of purely face-centered cubic (fcc) Ti1-xAlxN coatings with Al metal fractions of up to x~0.8, compared to x~0.67 for PVD coatings, is possible. The CVD coatings show excellent oxidation properties and remarkable performance in cutting tests. CVD Ti1-xAlxN coatings exhibit a particular characteristic, they commonly form a self-organized nanolamellar structure of alternating Al- and Ti-rich Ti1-xAlxN lamellae with a periodicity of several nm. While the origin of the nanolamellar structure is controversially discussed, efforts of the PVD community to also further increase the Al metal fraction in fcc PVD Ti1-xAlxN coatings are also based on nanolayered structures. This contribution briefly reviews the history of both, PVD and CVD Ti1-xAlxN coatings and gives an overview about the current-state of research.
15:30 SE13-B 2
Towards sustainable PVD and CVD TiAlN hard coatings: Demands, challenges and future prospects
Tkadletz M.1, Schalk N.2, Pohler M.3, Czettl C.3
1Christian Doppler Laboratory for Sustainable Hard Coatings at the Department of Materials Science, Montanuniversität Leoben, Franz Josef-Straße 18, 8700 Leoben, Austria
2Christian Doppler Laboratory for Advanced Coated Cutting Tools at the Department of Materials Science, Montanuniversität Leoben, Franz Josef-Straße 18, 8700 Leoben, Austria
3CERATIZIT Austria GmbH, Metallwerk-Plansee-Straße 71, 6600 Reutte, Austria
Abstract
In modern metal cutting applications, quaternary TiAlN-based coatings are frequently employed to enhance performance, where elements such as Ta, V or Hf are introduced to increase hardness and wear resistance. However, the use of these coatings presents significant sustainability challenges. Many of the elements involved are critical raw materials, with some even classified as conflict materials. Furthermore, the production and purification of the high-purity raw materials required for these coatings demand considerable energy. In addition, the deposition processes, such as physical (PVD) and chemical vapor deposition (CVD), are energy-intensive, and research often relies on trial-and-error methods. As a result, there is an increasing need to develop more sustainable and economical coating solutions. This presentation will explore research approaches aimed at improving the sustainability of TiAlN-based hard coatings by optimizing deposition processes, reducing reliance on critical and conflict materials, minimizing energy consumption, and streamlining development methods to reduce research efforts. The future of TiAlN coatings lies in balancing performance with environmental responsibility, offering promising avenues for both, improved functionality and sustainability in hard coating technology.
15:50 SE13-B 3
A study of CVD-AlTiN prepared by using NH3-substituted new nitrogen source
Nakamura H.1, Okude M.1
1Mitsubishi Materials Corporation, Japan
Abstract
CVD-AlTiN coatings with high Al content have attracted attention because their cutting performance in particular application is superior to conventional CVD products. However, the production yield of CVD-AlTiN is poor because of the fast gas-phase reaction between metal chlorides and NH3.
In this work, several kinds of amines were used as nitrogen source instead of NH3. It was expected to suppress the gas-phase reaction by gradual formation of NH3 during thermal decomposition of the amines. Among the tested amines, tert-Butylamine (TBA) enabled to form cubic-AlTiN coatings with high Al content when it was used as nitrogen source.
Furthermore, the reaction mechanisms of CVD-AlTiN with NH3 (NH3-AlTiN) and CVD-AlTiN with TBA (TBA-AlTiN) were investigated. The relationship between the coating properties and the residence time of the gaseous species was clarified. TBA-AlTiN showed milder dependence of the growth rate on residence time and formed cubic phase over a wider range of residence time than NH3-AlTiN. It was suggested that applying TBA as nitrogen source would be a promising method to improve the productivity yield.