Abstract: Aluminium Alloys with a 22 wt.-% Mg2Si content were spray formed. This alloy features
a low density and is therefore a superior material for lightweight applications. The main problem in
the spray forming of this type of alloy was the occurrence of high porosities. First process
optimizations have been performed to decrease porosity under a certain level, so that it can be
closed by an extrusion process.
Abstract: Metal/diamond binary composite coatings on Al substrate without grit blasting were
deposited by cold spray process with in-situ powder preheating. Microstructural characterization of
the as-sprayed coatings with different diamond size, strength and with/without Ti coating on
diamond was carried out by OM and SEM. The assessment of basic properties such as tensile bond
strength and hardness of the coatings, and the deposition efficiency was also carried out.
Particular attention on the composite coatings was on the diamond fracture phenomenon during the
cold spray deposition and the interface bonding between the diamond and the Fe-based metal matrix.
Abstract: NiTiZrSiSn bulk metallic glass powder was produced using inert gas atomization and
then was sprayed onto a SS 41 mild steel substrate using the kinetic spraying process. Considering
the principle of kinetic spraying and the temperature dependent deformation behavior of the bulk
metallic glass, an attempt to change the in-flight particle temperature was tried by modifying the
kinetic spraying apparatus. Through this study, the effects of thermal energy of in-flight particle and
crystallization degree by powder preheating temperature were evaluated. The deformation behavior
of bulk metallic glass is very interesting and it is largely dependent on the temperature and the
strain rate. The crystalline phase formation at impact interface was dependent on the in-flight
particle temperature. In addition, variations in the impact behavior need to be considered at high
strain rate and in-flight particle temperature.
Abstract: Ti45Zr38Ni17 powders were thermally sprayed onto mild steel substrates in air and under
a reduced pressure of argon. Two kinds of powder samples were used in this study. For one type
the elemental powders were gently (manually) mixed in a vial, and for the other type they were
mechanically alloyed by a planetary ball mill. Several kinds of oxides were formed after
thermally-spraying the mechanically-alloyed powders in air. After spraying in a reduced pressure
of argon, on the other hand, the coating layers obtained from the gently mixed powders consisted of
the three elemental metals (Ti, Zr, Ni), but an amorphous phase primarily appeared in the thermallysprayed
mechanically-alloyed powders. This amorphous phase transformed into the icosahedral
quasicrystal phase and a minor Ti2Ni-type crystal phase after annealing in vacuum at 828 K. The
Vickers hardness and the contact angle with pure water for the quasicrystal layers were about 7 GPa
and 92˚ respectively.
Abstract: The fabrication of complex-shaped parts out of Co-Cr-Mo alloy and 316L stainless steel
by three-dimensional printing (3DP) is studied using two grades of each alloy with average particle
size of 20 and 75 )m, respectively. To produce sound specimens, the proper 3DP processing parameters
were determined. The sintering behavior of the powders is characterized by dilatometric
analysis and by batch sintering in argon atmosphere at 1280°C for 2h. The 3DP process has
successfully produced complex-shaped biomedical parts with total porosity of 12-25% and homogenous
pore structure, which is suitable for tissue growth into the pores.
Abstract: Laser additive direct deposition of metals is a new rapid manufacturing technology,
which combines with computer aided design, laser cladding and rapid prototyping. The advanced
technology can build fully-dense metal components directly from CAD files without a mould or
tool. With this technology, a promising rapid manufacturing system called “Laser Metal Deposition
Shaping (LMDS)” is being constructed and developed. Through the LMDS technology, fully-dense
and near-net shaped metallic parts can be directly obtained through melting coaxially fed powder
with a laser. In addition, the microstructure and mechanical properties of the as-formed samples
were tested and analyzed synthetically. The results showed significant processing flexibility with
the LMDS system over conventional processing capabilities was recognized, with potentially lower
production cost, higher quality components, and shorter lead time.
Abstract: Direct Metal Laser Sintering (DMLS) has been utilized for prototype manufacturing of
functional metal components for years now. During this period the surface quality, mechanical
properties, detail resolution and easiness of the process have been improved to the level suitable for
direct production of complex metallic components for various applications.
The paper will present the latest DMLS technology utilizing EOSINT M270 laser sintering machine
and EOSTYLE support generation software for direct and rapid production of complex shaped
metallic components for various purposes. The focus of the presentation will be in rapid
manufacturing of customized biomedical implants and surgical devices of the latest stainless steel,
titanium and cobalt-chromium-molybdenum alloys. In addition to biomedical applications, other
application areas where complex metallic parts with stringent requirements are being needed will be
Abstract: This paper investigates the characteristic of single-layered and multi-layered compacts
made by selective laser sintering using titanium powder. The surface texture and tensile strength
were investigated by using single-layered compacts. There were few defects in surface of specimen
laser sintered in vacuum, and the roughness was smoother than that of the specimen laser sintered in
argon. Maximum tensile strength of single-layered compact laser sintered in vacuum was about
200MPa. The shrinkage and mechanical strength were investigated by using multi-layered compacts.
There was a unique tendency in the shrinkage of multi-layered compacts, which the density was
around 75% and the adhesive bonding was not observed between layers, resulted in 70MPa of
maximum bending strength and 50MPa of maximum tensile strength.
Abstract: Powder library of pseudo four components Li-Ni-Co-Ti compounds were prepared for
exploring the composition region with the single phase of the layer-type structure by using
combinatorial high-throuput preparation system “M-ist Combi” based on electrostatic spray
deposition method. The new layer-type compounds were found wider composition region than the
previous report. This process is promising way to find functional multi-component materials.
Abstract: New powder compaction process, in which a Bingham semi-solid/fluid mold is utilized,
is developed to fabricate micro parts. In the present process, a powder material is filled as slurry in a
solid wax mold, dried and compressed by either of conventional pressing methods, such as isostatic
pressing or die compaction. It is important to use slurry for filling because dry powder is hard to fill
in the micro cavity. It is also essential to control process temperature to treat micro parts. The wax
mold is heated during compaction and becomes semi-solid state, which can acts as a pressurized
medium for isostatic compaction. Since the compacted micro parts are very fragile, the mold's
temperature is controlled to higher than its melting point during unloading, to avoid breakage of the
compacts. To demonstrate effectiveness of this process, some micro compacts of alumina are shown