Powder and Materials Design for Flexible High-quality Additive Manufacturing

Important results from the project

The project has addressed additive manufacturing of complex metallic parts and connected actors from powder fabrication to component owners in developed value chains. Additiv manufacturing means near 100% materials use and the reuse of powder has also been of interest. In combination with the project goal of rapid materials development for additive manufacturing, direct correlation to resource efficiency is illustrated. The project has hence contributed to broadened and novel powder solutions including improved AM-materials.

Expected long term effects

The project has been focused on the manufacture by means of laser powder bed fusion (L-PBF). The project has here addressed difficult-to-build materials like nickel-base alloys as well as more easy-to-build materials like stainless steel (3316L). In support to materials development methodology has been developed to assess L-PBF-associated hot cracking of nickel-base alloys. The successful L-PBF of dense 316L with good properties has also been shown. Powder characterisation has been reviewed and a technique for in-situ alloying in L-PBF from powder mix has been demonstrated.

Approach and implementation

The project has gathered core knowledge in additive manufacturing and powder technology. The R&D actors have created significant experimental capacity for laser powder bed fusion. Powder manufacturer and component owner have provided the value chain and contributed with powder and problems. For nickel-base alloy methodology to eliminate hot cracking sensitivity has been in focus. For 316L demonstrating material performance has been the goal. Optimum L-PBF parameters have been realised and spectrum of powder characterisation methods and testing have been involved.