The Impact of Ultrasonic-Assisted Milling and Alloying Elements on the Surface Integrity of Additively Manufactured Iron Aluminides

  • 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 defectThe 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.zeige mehrzeige weniger

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Autor*innen:Julien Witte
Koautor*innen:Sepehrdad Dorrani, Kai Treutler, Dirk Schröpfer, Thomas Kannengießer, Volker Wesling
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.2 Versuchsanlagen und Prüftechnik
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Additive Manufacturing; Iron-aluminides; MPEA; Residual Stresses; Surface Integrity; Ultrasonic-assisted Milling; Wear Protection
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
Veranstaltung:BMDK der OvGU Magdeburg
Veranstaltungsort:Magdeburg, Germany
Beginndatum der Veranstaltung:10.12.2025
Enddatum der Veranstaltung:10.12.2025
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:19.12.2025
Referierte Publikation:Nein
Eingeladener Vortrag (wissenschaftliche Konferenzen):Nein
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