TY - GEN A1 - Ertugrul, Gökhan A1 - Hälsig, Andre A1 - Hensel, Jonas A1 - Buhl, Johannes A1 - Härtel, Sebastian T1 - Efficient Multi-Material and High Deposition Coating including Additive Manufacturing by Tandem Plasma Transferred Arc Welding for Functionally Graded Structures T2 - Metals KW - additive manufacturing powder KW - 3D Plasma Metal Deposition (3DPMD) KW - austenitic stainless steel KW - super-duplex stainless steel KW - multi-material KW - functionally graded KW - high deposition rate KW - arc KW - powder Y1 - 2022 U6 - https://doi.org/10.3390/met12081336 SN - 2075-4701 VL - 12 IS - 8 SP - 1 EP - 17 ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Alimov, Artem A1 - Sviridov, Alexander A1 - Härtel, Sebastian T1 - Machine learning application for optimization of laser directed energy deposition process for aerospace component rapid prototyping in additive manufacturing T2 - Materials Research Proceedings N2 - Abstract. The paper proposes a methodology for determining the optimal L-DED parameters based on the minimum number planned of L-DED trials. A dataset compiled from planned L-DED experiments was used to train a machine learning model. The algorithm demonstrated a robust ability to predict the output metrics with notable accuracy and proposed a theoretical framework that modeled the complex relationships between the input variables and the resulting critical welding properties for AM. The application of the developed model and its comparison with conventional methods thus offers a methodical approach to determining the optimum process parameters in advance. This is a step towards the development and production of additively manufactured components for future digital twin application in the aerospace industry. Y1 - 2024 U6 - https://doi.org/10.21741/9781644903131-31 SN - 2474-395X VL - 41 SP - 271 EP - 282 PB - Taylor&Francis ER - TY - GEN A1 - Jedynak, Angelika A1 - Ertugrul, Gökhan A1 - Neumann, Andreas A1 - Pippig, Robert A1 - Härtel, Sebastian T1 - Semi-finished powder of aluminum matrix composite for a direct energy deposition additive manufacturing T2 - Material Forming: The 26th International ESAFORM Conference on Material Forming, Kraków, Poland, April 19-21, 2023 KW - Aluminum-Matrix Composites (AMCs), Direct-Vacuum-Casting (DVC), Direct Energy Deposition (DED), Additive Manufacturing (AM) Y1 - 2023 U6 - https://doi.org/10.21741/9781644902479-22 VL - 28 SP - 199 EP - 206 ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Emdadi, Aliakbar A1 - Jedynak, Angelika A1 - Weiß, Sabine A1 - Härtel, Sebastian T1 - Hot forming behavior of tungsten carbide reinforced Ni-based superalloy 625 additively manufactured by laser directed energy deposition T2 - Additive manufacturing letters N2 - The demands of high-performance industries such as aerospace, automotive, tool manufacturing, oil, and gas industries are driving the innovation in high-performance materials and their production methods. This study explores the impact of hybrid manufacturing, specifically the effect of the addition of tungsten carbide (WC/W2C) via Laser-Directed Energy Deposition (L-DED), on the hot workability, hardness, and microstructure of nickel-based superalloy Inconel 625 (IN625). IN625 is known for its high temperature and high corrosion resistance, and tungsten carbide for its high wear resistance and grain refinement effect. The integration of WC/W2C particles into the IN625 matrix, in addition to the use of the hybrid approach of additive manufacturing followed by a hot–forming process, significantly influences the microstructure and mechanical behavior of the material. Thus, while incorporation of the WC/W2C can strengthen the material and extend the mechanical limitations, its full impact, including any potential usages, should be thoroughly evaluated for the intended application of the materials. To understand the effect of WC/W2C, additive manufacturing of IN625 both with and without WC/W2C and isothermal hot compression was carried out. The objective is to analyze the differences in microstructure and properties between L-DED manufactured IN625, and WC-reinforced IN625, and their hot-forming behavior, focusing on the effects of WC addition and post-deformation on microstructure and mechanical properties. This work represents the first investigation into the effect of WC/W2C hard particles on the hot-forming process of additively manufactured Ni-based metal matrix composites. Y1 - 2025 U6 - https://doi.org/10.1016/j.addlet.2025.100267 SN - 2772-3690 VL - 13 SP - 1 EP - 12 PB - Elsevier CY - Amsterdam ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Emdadi, Aliakbar A1 - Härtel, Sebastian ED - MacDonald, Eric W. T1 - Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition T2 - Additive manufacturing letters N2 - With a combination of desirable properties such as low density, high specific yield strength, low material cost, and excellent oxidation and corrosion resistance, iron aluminide (Fe-Al) has shown considerable potential to be an alternative to high-alloy chromium steels, and in some cases even nickel-based superalloys, in high-temperature applications. Due to these features, it is especially suitable for the aerospace and automotive industries. Recent advancements indicate an increasing interest in Fe-Al within the additive manufacturing industry, particularly in directed energy deposition (DED) processes. Despite this progress, processing of Fe-Al materials using the laser directed energy deposition (L-DED) has not been sufficiently investigated. In this study, Fe-Al powder material was produced from a commercial Al rod encased in a commercial low alloy-steel tube by a plasma-based ultrasonic atomization eliminating the need to cast an alloy ingot in advance. Subsequently, the produced powder was used in a l-DED process to fabricate an additively manufactured sample. The sample was investigated in terms of mechanical property, microstructure, chemical composition, and phase structure by scanning electron microscope (SEM) / energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), electron backscatter diffraction (EBSD) and microhardness analyses. KW - Iron Aluminides (Fe-Al); Additive Manufacturing; Laser-Directed Energy Deposition (L-DED); Process Chain Plasma Ultrasonic Atomization; Powder; Intermetallic Phase Y1 - 2025 U6 - https://doi.org/10.1016/j.addlet.2025.100313 SN - 2772-3690 VL - 14 SP - 1 EP - 9 PB - Elsevier BV CY - Amsterdam ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Emdadi, Aliakbar A1 - Härtel, Sebastian T1 - Advancements in iron aluminide alloy processing : a comparative study with DED alternatives T2 - Materials research proceedings N2 - This article investigates the processing and characterization of iron aluminide lightweight alloy by plasma ultrasonic atomization and laser powder based directed energy deposition (DED-LB/p) and its comparison with other additive manufacturing alternatives. DED-LB/p provides precisely controllable process parameters, a wide range of feed materials supplied in powder form, a relatively high deposition rate and low heat input. These features favor the DED – LB/p process for novel materials such as iron aluminide. Thanks to a combination of desirable properties such as low density, high specific strength, low material cost, excellent oxidation resistance, and corrosion resistance, Fe-Al has established considerable potential to replace high-alloy chromium steels and, in some cases, even superalloys in high-temperature applications. In this study, Fe-Al alloy was first atomized into powder form from a commercial rod with core of aluminum and sleeve of a commercial low alloy-steel by plasma ultrasonic atomization. The resulting powder was then used for additive manufacturing with DED-LB/p in order to reduce cost and analyze the process chain. The results show that the use of powder produced by plasma ultrasonic atomization from commercial raw materials in the DED-LB/p process provides an effective combination for additive manufacturing of Fe-Al alloy and has some advantages over the alternative WAAM method. Y1 - 2025 U6 - https://doi.org/10.21741/9781644903599-28 SN - 2474-395X VL - 54 SP - 254 EP - 263 PB - Materials Research Forum LLC CY - Millersville, PA ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Hälsig, Andre A1 - Rimpl, Robert A1 - Hensel, Jonas A1 - Härtel, Sebastian T1 - Artificial neural network based calibration of Goldak heat source parameters in tandem plasma transferred arc process using finite element analysis T2 - The international journal of advanced manufacturing technology N2 - The paper proposes a novel approach for determining multiple heat source parameters to achieve the necessary accuracy in the numerical prediction for a parallel tandem plasma transferred arc process. An artificial neural network (ANN) approach as a supervised learning–based artificial intelligence (AI) was used to model the complex relationship between heat distribution and tandem/dual heat source parameters based on finite element analysis (FEA). This study presents the first ANN-assisted numerical simulation for multiple heat source optimization of the tandem plasma transferred arc process. The model demonstrated high accuracy in predicting and calibrating the tandem heat source parameters, based on systematic simulation trials of the tandem plasma transferred arc welding. The results of the tandem heat source determined by ANN-assisted FEA were verified using experimental data on melt pool size and substrate distortion. This verification considered metrics such as penetration width, penetration depth, melt pool length, melt pool half-width, and the absolute distortion (measured as the difference between minimum and maximum displacement), with relative errors of 7.0%, 7.6%, 0.4%, 1.9%, and 9.7%, respectively. Y1 - 2025 U6 - https://doi.org/10.1007/s00170-025-15843-x SN - 0268-3768 VL - 139 SP - 2349 EP - 2363 PB - Springer Nature CY - London ER - TY - GEN A1 - Emdadi, Aliakbar A1 - Yang, Yitong A1 - Szyndler, Joanna A1 - Jensch, Felix A1 - Ertugrul, Gökhan A1 - Tovar, Michael A1 - Härtel, Sebastian A1 - Weiß, Sabine T1 - Highly printable Fe₃Al intermetallic alloy T2 - Metals : open access journal N2 - Intermetallic Fe₃Al-based alloys reinforced with Laves-phase precipitates are emerging as potential replacements for conventional high-alloy steels and possibly polycrystalline Ni-based superalloys in structural applications up to 700 °C. Their impressive mechanical properties, however, are offset by limited fabricability and poor machinability due to their severe brittleness. High tool wear during finish-machining, which is still required for components such as turbine blades, remains a key barrier to their broader adoption. In contrast to conventional manufacturing routes, additive manufacturing offers a viable solution by enabling near-net-shape manufacturing of difficult-to-machine iron aluminides. In the present study, laser powder bed fusion was used to produce an Fe-25Al-1.5Ta intermetallic containing strengthening Laves-phase precipitates, and the porosity, microstructure and phase composition were characterized as a function of the process parameters. The results showed that preheating the build plate to 650 °C effectively suppressed delamination and macrocrack formation, even though noticeable cracking still occurred at the high scan speed of 1000 mm/s. X-ray tomography revealed that samples fabricated with a lower scan speed (500 mm/s) and a higher layer thickness (0.1 mm) contained larger, irregularly shaped pores, whereas specimens printed at the same volumetric energy density (40 J/mm3) but with different parameter sets exhibited smaller fractions of predominantly spherical pores. All samples contained mostly elongated grains that were either oriented close to <001> relative to the build direction or largely texture-free. X-ray diffraction confirmed the presence of Fe₃Al and C14-type (Fe, Al)₂Ta Laves phase in all samples. Hardness values fell within a narrow range (378–398 HV10), with only a slight reduction in the specimen exhibiting higher porosity. KW - Fe₃Al intermetallic KW - Iron aluminide KW - Additive manufacturing KW - Laser powder bed fusion (LPBF) KW - Porosity KW - Microstructure Y1 - 2026 U6 - https://doi.org/10.3390/met16010005 VL - 16 IS - 5 SP - 1 EP - 15 PB - MDPI CY - Basel ER -