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Technical Program

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Status: 18 April, 2025
Friday, 6 June, 2025

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08:30
Method to Alleviate Thermal Fatigue in X-ray Anode Focal Tracks
Sommerauer M.1, Siller M.2, Bostrom N.3, Maier-Kiener V.4
1Montanuniversität Leoben, Austria
2Plansee SE, Austria
3Varex Imaging Corp, USA
4Montanuniversität Loeben, Austria
Abstract
Thermal fatigue, manifested as focal track erosion, degrades the radiation output of X-ray sources and leads to diminished imaging performance.
This study explores a mitigation strategy to address the cyclic thermal expansion and contraction responsible for such damage. A novel approach involving targeted thermal shock crack formation was selected.
Two distinct microstructures of a W10Re alloy were examined using pulsed electron beam exposure in a specialized test setup, supported by extended finite element method simulations. After inducing a thermal shock crack network, a temperature-time profile comparable to that in computed tomography environments was applied.
Comparisons between pristine and pre-cracked samples for both materials allowed for insights into the interaction between cracks, microstructure, and fatigue. In columnar microstructures, pre-cracking effectively mitigated damage accumulation. However, in globular microstructures, the efficacy of this approach was limited due to thermal cutoffs caused by deflected cracks.
08:50
Hot corrosion behavior of Mo-based alloys with different deposits
Korell L.1, Beck K.1, Oskay C.1, Heilmaier M.2, Galetz M.1
1DECHEMA Forschungsinstitut, Germany
2Karlsruhe Institute of Technology, Institute for Applied Materials – Materials Science and Engineering, Germany
Abstract
To improve gas turbine efficiencies, turbine inlet temperatures must increase, necessitating new alloy systems that can operate beyond the temperature limits of current Ni-based alloys. Due to their high melting points and creep strength, refractory elements like molybdenum (Mo) are potential new structural material candidates. However, their use is limited by poor oxidation and corrosion resistance. Research on the hot corrosion of Ni-based alloys identifies two mechanisms: melting of Na2SO4 (type I, ~900°C) and the formation of lower melting point eutectics (type II, ~700° C). In Mo-based alloys, Na2MoO4 forms under sulfate deposits, with much lower melting points capable of dissolving surrounding material. This alters the corrosion mechanism to super-acidic Na-Mo-based attack. This study investigates the hot corrosion resistance of several Mo-based alloys with different deposits between 500-900 °C. Post-testing analysis via XRD, SEM, and EPMA aims to reveal the degradation mechanisms to develop mitigation strategies, such as protective coatings for Mo-based systems.
09:10
A Near-Atomic-Scale Study of the Microstructure and Mechanical Properties of Tungsten and Tungsten-based Alloys
Youssefi S.1, Pickering E.1, Edmondson P.1
1University of Manchester, United Kingdom
Abstract
Tungsten is the primary candidate for plasma-facing-materials in a nuclear fusion reactor due to tungsten’s exceptional properties. However, their mechanical properties including ductility and fracture toughness, severely degrade under the extreme conditions experienced. Tungsten alloys represent a potential solution: W-K alloy, demonstrates high thermal shock resistance and fracture toughness, whereas nanoengineered W-Ti-Cr alloy offers improved thermomechanical properties and higher resistance to detrimental surface morphology evolution. This study aims to characterise the mechanical properties of tungsten and tungsten-based alloys focussing on grain boundary behaviour, dislocation motion and pile-up under tensile testing. Testing was conducted in-situ of a scanning electron microscope combined with Electron BackScatter Diffraction to observe deformation. High-Resolution Digital-Image-Correlation allowed for the measurement of full-field surface deformations and strains at the nanoscale providing insight into atomistic behaviour during deformation. The results will be discussed with relevance to understanding the deformation behaviour of tungsten alloys under these conditions, predicting and mitigating potential failures during operations, thus enabling of development of new alloys and predictive models thereby enhancing the reliability of W-based materials for future reactors.
09:30
Microstructure dependent fatigue behavior of tungsten and doped tungsten fine wire
Lichtenegger H.L.1, Alfreider M.1, Lenz M.2, Mark M.2, Kiener D.1
1Montanuniversity Leoben, Austria
2Plansee SE, Austria
Abstract
To meet the ever-growing demand for specialized products, new alloys and a deeper understanding of fundamental material properties and failure mechanisms are required. For long-term dynamic applications, the influence of microstructure on material fatigue properties becomes crucial, especially in fine wires due to the highly anisotropic microstructure. To explore the fatigue behavior of tungsten and potassium-doped tungsten fine wires micro- and nanomechanical tests are utilized, such as nanoindentation and micrometer-scale fatigue experiments. For assessing the influence of the elongated microstructure, cantilevers are milled with a focused ion beam and tested in different loading directions, namely along and perpendicular to drawing direction. To exclude possible grain size influences, wires with similar grain size are compared for the two tungsten alloys, respectively. These experiments are conducted with a displacement-controlled in situ nanoindenter inside a scanning electron microscope at room temperature. The fatigue threshold and fatigue crack growth behavior will be assessed along and against the texture for the two investigated materials.

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08:30 SIM14-B 1
Prediction of mechanical properties of WC-Co cemented carbides from magnetic data: comparison between machine learning and conventional fitting
Brückl H.1, Breth L.1, Fischbacher J.1, Schrefl T.1, Kührer S.2, Pachlhofer J.2, Schwarz M.2, Weirather T.2, Czettl C.2
1University for Continuing Education Krems, Austria
2Ceratizit Austria GmbH, Austria
Abstract
Based on experimental data and extensive experience, magnetic coercivity and saturation magnetization are traditionally used to estimate the microstructure and quality of cemented carbides, especially in the manufacturing industry. Using an artificial neural network (ANN), structural and mechanical properties of WC-Co elements can be predicted from magnetic data alone. The total field distribution, which is extracted from first-order-reversal-curves, serves as input data for the ANN. A collection of WC-Co pellet samples with a variety of powder compositions and processing parameters was produced to cover a wide range of characteristic features for ANN training. It is shown that microstructural parameters such as mean grain size and mechanical properties such as hardness (HV30) and fracture toughness (stress intensity factor KIC) can be derived with high accuracy. The standard deviation of the ANN is compared to the standard deviation of conventional fitting.
08:50 SIM14-B 2
Unlocking the Potential of Data Science: Optimizing Chemical Vapour Deposition and Beyond with Integrated Modeling and Machine Learning
Koronaki E.1, Loachamin Suntaxi G.2, Giovanis D.3, Kathrein M.4, Czettl C.5, Boudouvis A.6, Bordas S.P.A.1
1University of Luxembourg, Luxembourg
2University of Luxembourg and National Technical University of Athens, Luxembourg
3Johns Hopkins University, USA
4Ceratizit S.á r.l., Luxembourg
5Ceratizit GmbH, Austria
6National Technical University of Athens, Greece
Abstract
Data Science (DS) is able to enhance product- and technology-driven developments by improving quality and cost efficiency. Focusing on challenges in Chemical Vapor Deposition (CVD), such as temperature control, gas flux, and chemical reactions, the study demonstrates how DS can optimize complex manufacturing processes. Applied to CVD the methods show significant improvements in forecasting, sensitivity analysis and optimization. These techniques are also extendable to other deposition methods, e.g. PECVD, MOCVD, ALD, and other fields, including sintering and furnace construction. However, challenges remain in integrating DS into technical problem-solving. Technological gaps with main among them the lack of sensors, is a critical obstacle, which needs to be addressed as a problem in its own merrit. The pathway for unlocking the full potential of Data Science in technical domains, is combining traditional, equation-based, modeling, machine learning and natural language processing. This approach opens new prospects, beyond the technical applications, enhancing fields such as neuroscience or business management.
09:10 SIM14-B 3
Characterizing WC powder materials using deep learning computer vision methods
Liu K.1, Zhong Y.2, Zhou S.1, Liu Y.2, Lv Y.1, Wen G.1, Chen X.1, Wang Y.1, Wang S.1
1Zhuzhou Cemented Carbide Cutting Tools Co., Ltd, China
2Xiangtan University, China
Abstract
WC-Co cemented carbides exhibit exceptional properties of hardness, fracture strength, and wear resistance, which lead to their wide applications in industries such as cutting, mining, and drilling tools. The WC powder characteristics such as size distribution, morphology, and surface textures have a direct influence on the final cemented carbides properties. However, the traditional statistical approaches have been unprecedentedly challenged to disclose the full profile of WC granules due to agglomeration. In this work, near-monodisperse WC particles supported on SiO2 were prepared using a colloidal layer-by-layer method. Subsequently, the particle images were acquired and treated by a modified U2-Net method to output probabilistic grayscale images containing granular information. Finally, an improved adaptive H-minima watershed algorithm was developed to effectively separate any adherent WC particles and statistically estimate the particle size distribution. The standard deviations of the particle size obtained by the proposed method are less than 3%, and the segmentation accuracy and efficiency are greatly enhanced compared to other algorithms. The deep-learning methods in this work lay the foundation to interpret structure–properties–processing relationships during cemented carbides manufacture.
09:30 SIM14-B 4
Context & Attention is All You Need: Metallurgy in the Age of the Data Mesh Paradigm - KEYNOTE
Hauser D.1, Reichl G.2, Baumann D.2, Eidenberger-Schober M.2, Hell T.1
1Data Lab Hell GmbH, Austria
2Plansee SE, Austria
Abstract
Powder metallurgy is crucial for modern refractory metal production, where precision, quality, and efficiency are essential. However, a vastly complex value chain complicates monitoring, optimization and innovation. This paper presents case studies that utilize a sociotechnical approach called Data Mesh to empower domain experts with decentralized data management and machine intelligence across the production chain.

Traditional AI-initiatives often fall short of addressing the intricate requirements of powder metallurgy, such as context, variability and the integration of domain knowledge. Within the Data Mesh framework, we propose combining machine learning with human-in-the-loop (HITL) strategies, embedding expert knowledge into model development to overcome these challenges. Our case studies highlight significant improvements in anomaly detection, process optimization, also utilizing predictive capabilities. 

By embedding domain expertise into the process, this hybrid approach enhances contextual understanding, optimizing resources and empowering teams to focus on innovation rather than routine tasks. This represents a paradigm shift for prescriptive analytics, by driving the attention and action towards some of the industry’s most pressing challenges.

On behalf of the Data Mesh Team.

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10:10 MAT11-B 1
On the microstructure and properties of Co-Ru binder alloys - KEYNOTE
Primig S.1, Farabi E.1, Rielli V.1, Czettl C.2, Plachlhofer J.2, Ringer S.3
1UNSW Sydney, Australia
2CERATIZIT Austria GmbH, Austria
3The University of Sydney, Australia
Abstract
Ru is commonly added to improve the properties of the Co-binder in WC-Co hardmetals. While it is widely understood that the composition and microstructure of the Co-binder significantly influence the fatigue and toughness performance of hardmetals, fundamental understanding of the underlying mechanisms remains limited. We systematically investigate the effect of Ru addition on the fundamentals of the fcc (γ) to hcp (α) phase transformation and the crystallography in Co-binder model alloys made via arc melting. It is shown that stabilisation of the γ-phase promotes formation of low-energy (0001) α/γ interphase and α/α symmetrical tilt boundary planes. Nanohardness mappings at room temperature versus 600ºC are employed to understand the influence of γ/γ, α/α, and α/γ interfaces on the deformation response. At both temperatures, we show that the toughness is higher in regions adjacent to α/γ interfaces, resulting in a 20–50% increase in nanohardness compared to the grain interior, α/α and γ/γ boundaries. We propose that controlling the population of α/γ interfaces by Ru addition to Co-binder alloys is essential for improved performance of WC-Co hardmetals.
10:40 MAT11-B 2
Ru-containing multi-component binders for hardmetals
Dorner L.M.1, De Oro Calderon R.1, Schubert W.-D.1, Useldinger R.2
1Technische Universität Wien, Austria
2Ceratizit Luxembourg, Luxembourg
Abstract
The search of novel binders for hardmetals has been a continuous focus of research in the last decades. The so-called multi-component binders have been considered by some authors. However, in the hardmetals field this concept must be treated with care, because the interaction between metallic and hardphases can lead to the formation of detrimental compounds, and to significant variations in the metallic binder composition. As the addition of Ru has proved to increase the solubility elements in metallic binders, this element can help to understand the possible benefits of the multi-component concept in hardmetals.

In this study, Ru was added in varying amounts to FeCoNi and FeCoNiCr-based binders, to reach binders with as many elements as possible in solution. Phase formation and chemical composition of the binders were investigated. The results confirmed how the addition of Ru increases the solubilities, and bring the possibility of having significantly high amounts of W dissolved in the metallic binder. This plays an important role in aspects like grain growth inhibition, hardness and corrosion behavior.
11:00 MAT11-B 3
Effect of Carbon, Nitrogen and Binder Content on the Mechanical Properties of WC-Ti(C,N)-Cr3C2-Co Ultrafine-grained Cemented Carbide.
Tsutsumi T.1, Takada M.2, Terasaka S.3
1Nippon Tokushu Goukin, Co. Ltd., Japan
2Nippon Tokushu Goukin Co.Ltd, Japan
3Tohoku University, Japan
Abstract
WC-Ti(C,N)-Cr3C2-Co ultrafine-grained cemented carbides with varying contents of C, N, and Co binder phases were prepared. Their microstructures and mechanical properties were investigated, focusing on the relationship between the existing form of Ti(C,N) and various conditions. The hardness of the samples increased while their fracture toughness decreased with decreasing C content. The average T.R.S. peaked at 4.8 GPa on the low-C side. The microstructures changed significantly with variations in N2 partial pressure. At a N2 partial pressure of 2.6 kPa, the microstructure became finer, resulting in the highest average T.R.S. Conversely, at N2 partial pressures of 0 and 11.7 kPa, the microstructure became coarser, leading to a decrease in the average T.R.S. The average T.R.S. was maximized at 16.4 vol% Co and decreased with increasing Co content but was higher than those of conventional cemented carbides. The existing form of Ti(C,N) varied depending on the N content. In conclusion, a N2 partial pressure of 2.6 kPa and low C contents were deemed optimal.
11:20 MAT11-B 4
Influence of Grain Size in High Entropy Hard Phase based Hardmetals
Pötschke J.1, Vornberger A.1, von Spalden M.1, Berger L.-M.1
1Fraunhofer IKTS, Fraunhofer Institute for Ceramic Technologies and Systems, Germany
Abstract
During the last years research on substitution of WC in hardmetals and cermets by novel high entropy hard phases (HEH) has been significantly increased. The use of HEH has shown the potential of achieving high hardness, fracture toughness and enhanced thermal as well as electrical properties. However, until now most research was done on different compositions produced by in-situ-formation of carbides or nitrides using Co or Ni binders, resulting in just one HEH grain size. To investigate the influence of HEH grain size two high entropy carbides (Ta,Nb,Ti,V,W)C and (Ta,Nb,Ti,V,W,Mo)C were produced in three different grain sizes each and mixed with Ni. These HEH based hardmetals sintered between 1250 °C and 1450 °C were characterized by was carried out by FE-SEM as well as by magnetic and mechanical measurements. The results show that by changes in composition, HEH preparation methods as well as sintering conditions the mechanical properties can be specifically tailored.
11:40 MAT11-B 5
Effects of Cooling Rate and Binder Fraction on the Microstructure of Cemented Carbides with Steel-based Binder
Mohammadpour Kasehgari S.1, Lisa Toller-Nordström L.1, Borgenstam A.1
1KTH Royal Institute of Technology, Sweden
Abstract
Cemented carbides, composed of tungsten carbide as the hard phase and cobalt as the binder phase, demonstrate an exceptional combination of hardness and toughness, making them suitable for various industrial applications. However, due to sustainability and ethical considerations with cobalt, there is an ever-increasing demand for new alternative binder alloys. The transformation-induced plasticity effect due to a martensitic transformation in advanced high-strength steel proposes a solution for enhancing the overall properties of cemented carbides with steel-based binders. However, the microstructure with a hard tungsten carbide skeleton affects the martensitic transformation in the binder in several ways. This fact, coupled with the limited accepted carbon content, has always been a barrier to designing new iron-based binders with tailored microstructure and needs more attention. In this study, cemented carbides with different iron-based binder fractions ranging from 5 to 20 wt.% were investigated using scanning electron microscopy and electron back-scattered diffraction. The effect of the cooling rate on the microstructure and subsequently on the mechanical properties was studied, comparing the binder structure of as-sintered, quenched, and slow-cooled samples.