TY - JOUR A1 - Ertugrul, Gökhan A1 - Emdadi, Aliakbar A1 - Härtel, Sebastian T1 - Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition JF - 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 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. KW - Iron aluminides (Fe-Al) KW - Laser directed energy deposition (L-DED) KW - Plasma ultrasonic atomization KW - Powder KW - Intermetallic phase Y1 - 2025 U6 - https://doi.org/10.1016/j.addlet.2025.100313 SN - 2772-3690 VL - 14 PB - Elsevier CY - Amsterdam ER - TY - JOUR 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 JF - 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. KW - Hybrid manufacturing KW - Laser-directed energy deposition (L-DED) KW - Hot-forming KW - Inconel 625 (In625) KW - Microstructure manipulation Y1 - 2025 U6 - https://doi.org/10.1016/j.addlet.2025.100267 SN - 2772-3690 VL - 13 PB - Elsevier CY - Amsterdam ER - TY - JOUR A1 - Alimov, Artem A1 - Sviridov, Alexander A1 - Jensch, Felix A1 - Sydow, Benjamin A1 - Härtel, Sebastian T1 - Additive manufacturing of hot-forming dies using laser powder bed fusion and wire arc direct energy deposition technologies T1 - Additive Fertigung von Warmumformwerkzeugen unter Verwendung von Laser Powder Bed Fusion und Wire Arc Direct Energy Deposition Technologien N2 - 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. N2 - Additive Technologien sind derzeit für die Herstellung komplexer, präziser Teile weit verbreitet und weisen ein hohes Potenzial für die Herstellung von Umformwerkzeugen auf. In dieser Arbeit wurden Warmumformwerkzeuge, die für die additive Fertigung optimiert sind, entwickelt und mit den Technologien WA-DED (Wire Arc Direct Energy Deposition) und L-PBF (Laser Powder Bed Fusion) hergestellt. Es wurde ein Konzept für Leichtbau-Warmumformwerkzeuge mit einer 2D-Gitterstruktur entwickelt, das das Gewicht jedes Werkzeugs bei der Produktion mit L-PBF um 56 % von 14,2 kg auf 6,1 kg reduzierte. Als Alternative zu konventionellen Warmarbeitsstählen wurde der martensitische/ausscheidungsgehärtete Stahl 17-4PH verwendet, der geringfügig niedrigere mechanische Eigenschaften und eine wesentlich bessere Verarbeitbarkeit im additiven Fertigungsprozess aufweist. Die Verwendbarkeit der hergestellten Gesenke wurde durch Schmiedeversuche auf einer industriellen Schraubspindelpresse nachgewiesen. KW - Additive manufacturing KW - Hot-forming dies KW - L-PBF KW - WA-DED KW - WAAM KW - Additive Fertigung KW - Warmumformwerkzeuge KW - L-PBF KW - WA-DED KW - WAAM KW - Warmumformen KW - Rapid Prototyping (Fertigung) KW - Selektives Laserschmelzen Y1 - 2023 U6 - https://doi.org/10.3390/met13111842 VL - 13 IS - 11 PB - MDPI CY - Basel ER - TY - JOUR A1 - Grüger, Lennart A1 - Jensch, Felix A1 - Dittrich, Fabian A1 - Härtel, Sebastian T1 - 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 JF - Materials N2 - 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. KW - AZ91 KW - Ti-6Al-4V KW - Additive manufacturing KW - L-PBF KW - Implant technology Y1 - 2024 U6 - https://doi.org/10.3390/ma17184667 SN - 1996-1944 VL - 17 IS - 18 PB - MDPI CY - Basel ER -