TY  - CONF
A1  - Witte, Julien
T1  - The Impact of Ultrasonic-Assisted Milling and Alloying Elements on the Surface Integrity of Additively Manufactured Iron Aluminides
N2  - The increasing focus on energy and resource efficiency has driven the implementation of additive manufacturing (AM) of high-performance materials, particularly in lightweight constructions with optimization of material efficiency. Iron aluminides (FeAl) hold great potential due to their low density, excellent corrosion and wear resistance, high-temperature stability, and vast availability. However, the inherent heterogeneity and anisotropy of FeAl-AM structures pose significant challenges, especially regarding hardness and brittleness. These material characteristics complicate the mostly necessary post-processing via mechanical finish machining, often resulting in elevated cutting forces, accelerated tool wear, and suboptimal surface integrity. Ultrasonic-assisted milling (USAM), a hybrid machining process, offers significant advantages over conventional milling (CM), including the reduction of cutting forces and tool wear. Notably, USAM has been demonstrated to decrease surface defect density and mitigate tensile residual stresses, while potentially inducing beneficial compressive residual stresses within the depth profile of the component’s surface. These effects can significantly enhance crack propagation resistance, improve corrosion behavior, and extend the fatigue life of components in safety-relevant applications. The present study investigates the effects of additional alloying elements such as molybdenum, nickel, titanium and Vanadium in FeAl as well as milling parameters, including cutting speed vc and feed rate fz, on the surface integrity with special regard to residual stress formations.
T2  - 4th International Conference on Advanced Joining Processes
CY  - Coimbra, Portugal
DA  - 16.10.2025
KW  - Additive Manufacturing
KW  - Wear Protection
KW  - Ultrasonic-assisted Milling
KW  - Iron-aluminides
KW  - MPEA
KW  - Surface Integrity
KW  - Residual Stresses
PY  - 2025
AN  - OPUS4-65235
LA  - eng
AD  - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany
ER  -