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Recycling nickel aluminium bronze grinding chips to feedstock for directed energy deposition via impact whirl milling: Investigation on processability, microstructure and mechanical properties

  • During the production of ship propellers, considerable quantities of grinding chips from nickel aluminium bronze are produced. This paper examines the mechanical comminution of such chips via impact whirl milling and the utilization of two chip-powder batches as feedstock for a laser-based directed energy deposition process. The materials are characterized via digital image analysis, standardized flowability tests, scanning electron microscopy and energy dispersive X-ray spectroscopy and are compared to conventional, gas atomized powder. The specimens deposited via directed energy deposition are analyzed for density, hardness and microstructure and tensile properties for vertical and horizontal build up directions are compared. At elevated mill rotation speeds, the comminution with impact whirl milling produced rounded particles, favorable flow properties and particle size distribution, making them suitable to deposit additive specimens. The microstructure exhibited characteristicDuring the production of ship propellers, considerable quantities of grinding chips from nickel aluminium bronze are produced. This paper examines the mechanical comminution of such chips via impact whirl milling and the utilization of two chip-powder batches as feedstock for a laser-based directed energy deposition process. The materials are characterized via digital image analysis, standardized flowability tests, scanning electron microscopy and energy dispersive X-ray spectroscopy and are compared to conventional, gas atomized powder. The specimens deposited via directed energy deposition are analyzed for density, hardness and microstructure and tensile properties for vertical and horizontal build up directions are compared. At elevated mill rotation speeds, the comminution with impact whirl milling produced rounded particles, favorable flow properties and particle size distribution, making them suitable to deposit additive specimens. The microstructure exhibited characteristic martensitic phases due to the high cooling rates of the additive manufacturing process. The presence of ceramic inclusions was observed in both the powder and on the tensile fracture surfaces, partly impairing the mechanical properties. However, specimens in the vertical build-up direction (Z) showed competitive tensile results, with 775 MPa in tensile strength, 455 MPa in yield strength and 12.6 % elongation at break. The findings of this study indicate that recycling of machining chips to additive manufacturing feedstock can be a viable option for reducing material costs and environmental impact.zeige mehrzeige weniger

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Autor*innen:Vinzenz Müller, Janek Maria Fasselt, Christian Klötzer-Freese, Tobias Kruse, Rafael Kleba-Ehrhardt, Max Biegler, Michael RethmeierORCiD
Dokumenttyp:Zeitschriftenartikel
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):Additive Manufacturing
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren
Veröffentlichende Institution:Bundesanstalt für Materialforschung und -prüfung (BAM)
Verlag:Elsevier BV
Jahrgang/Band:105
Aufsatznummer:104804
Erste Seite:1
Letzte Seite:9
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Directed energy deposition; Grinding chips; Material characterization; Nickel aluminium bronze; Recycling
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
DOI:10.1016/j.addma.2025.104804
URN:urn:nbn:de:kobv:b43-633442
ISSN:2214-8604
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY-NC-ND - Namensnennung - Nicht kommerziell - Keine Bearbeitungen 4.0 International
Datum der Freischaltung:12.06.2025
Referierte Publikation:Ja
Datum der Eintragung als referierte Publikation:12.06.2025
Schriftenreihen ohne Nummerierung:Wissenschaftliche Artikel der BAM
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