@article{ErtugrulEmdadiHaertel2025, author = {Ertugrul, G{\"o}khan and Emdadi, Aliakbar and H{\"a}rtel, Sebastian}, title = {Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition}, series = {Additive Manufacturing Letters}, volume = {14}, journal = {Additive Manufacturing Letters}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2772-3690}, doi = {10.1016/j.addlet.2025.100313}, year = {2025}, abstract = {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 hightemperature 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.}, subject = {Iron aluminides (Fe-Al); Laser directed energy deposition (L-DED); Plasma ultrasonic atomization; Powder; Intermetallic phase}, language = {en} } @article{ErtugrulEmdadiJedynaketal.2025, author = {Ertugrul, G{\"o}khan and Emdadi, Aliakbar and Jedynak, Angelika and Weiß, Sabine and H{\"a}rtel, Sebastian}, title = {Hot forming behavior of tungsten carbide reinforced Ni-based superalloy 625 additively manufactured by laser directed energy deposition}, series = {Additive Manufacturing Letters}, volume = {13}, journal = {Additive Manufacturing Letters}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2772-3690}, doi = {10.1016/j.addlet.2025.100267}, year = {2025}, abstract = {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.}, subject = {Hybrid manufacturing; Laser-directed energy deposition (L-DED); Hot-forming; Inconel 625 (In625); Microstructure manipulation}, language = {en} } @article{AlimovSviridovJenschetal.2023, author = {Alimov, Artem and Sviridov, Alexander and Jensch, Felix and Sydow, Benjamin and H{\"a}rtel, Sebastian}, title = {Additive manufacturing of hot-forming dies using laser powder bed fusion and wire arc direct energy deposition technologies}, volume = {13}, number = {11}, publisher = {MDPI}, address = {Basel}, doi = {10.3390/met13111842}, year = {2023}, abstract = {Additive technologies are now widely used for the production of complex precise parts and have high potential for the production of forming dies. In this work, hot-forming dies optimized for additive manufacturing were developed and produced with wire arc direct energy deposition (WA-DED) and laser powder bed fusion (L-PBF) technologies. The concept of lightweight hot-forming dies with a 2D-lattice structure was developed, which reduced the weight of each die by 56\%, from 14.2 kg to 6.1 kg, in production using L-PBF. Maraging/precipitation-hardened steel 17-4PH was used as an alternative to traditional hot-working steels with slightly lower mechanical properties and a much higher processability in the additive manufacturing process. The workability of the manufactured dies was confirmed by forging tests on an industrial screw press.}, subject = {Additive manufacturing; Hot-forming dies; L-PBF; WA-DED; WAAM; Additive Fertigung; Warmumformwerkzeuge; L-PBF; WA-DED; WAAM; Warmumformen; Rapid Prototyping (Fertigung); Selektives Laserschmelzen}, language = {en} } @article{GruegerJenschDittrichetal.2024, author = {Gr{\"u}ger, Lennart and Jensch, Felix and Dittrich, Fabian and H{\"a}rtel, Sebastian}, title = {On the creation of a material bond between L-PBF manufac-2tured AZ91 and Ti-6Al-4V components in the context of medi-3cal applications}, series = {Materials}, volume = {17}, journal = {Materials}, number = {18}, publisher = {MDPI}, address = {Basel}, issn = {1996-1944}, doi = {10.3390/ma17184667}, year = {2024}, abstract = {Within the scope of these investigations, the feasibility of a material bond between Ti-6Al-4V and the magnesium alloy AZ91 is analyzed. Ti-6Al-4V is frequently used for implants due to its biocompatibility, corrosion resistance, and specific strength. However, depending on the surface quality, the attachment behavior of the bone to the implant varies. Magnesium implants promote the regeneration of bone tissue and biodegrade as the bone tissue heals. Combining the properties of both materials in one implant enables a reduced implant volume and increased stability. For this reason, this study aims to demonstrate the feasibility of creating a material bond between the materials Ti-6Al-4V and AZ91. For this purpose, Ti-6Al-4V truncated cones and AZ91 sleeves were produced using the additive manufacturing process of laser powder bed fusion (L-PBF). The as-built sleeves were then pressed onto machined truncated cones. Since zinc serves as a lubricant and has good diffusion properties with the materials used as a result of heat treatment, a comparison was made between zinc-coated and the as-built Ti-6Al-4V samples. This showed that a bond was created after hot isostatic pressing and that the push-out force could be increased by more than 4.5 times. Consequently, a proof of feasibility was demonstrated, and a high potential for applications in medical technology was shown.}, subject = {AZ91; Ti-6Al-4V; Additive manufacturing; L-PBF; Implant technology}, language = {en} }