Projects / Programmes
Nanoparticle-reinforced new metal matrix composites manufactured by selective laser melting for tooling industry
| Code |
Science |
Field |
Subfield |
| 2.04.02 |
Engineering sciences and technologies |
Materials science and technology |
Metallic materials |
| Code |
Science |
Field |
| 2.05 |
Engineering and Technology |
Materials engineering |
Metal Matrix Nano Composites, Selective Laser Melting, Nanoparticle Reinforcement, Low-Temperature Plasma Nitriding, Additive Manufacturing, Cellular Structure, Dislocation Cells, Oxide Nanoparticles, TiC, TiB2, Rare-Earth Oxides, Stainless Steel 316L, Maraging Steel M300, Tool Steel H13
Researchers (20)
Organisations (3)
Abstract
In the proposed project we aim to develop novel, steel-based, metal matrix nanoparticle composites (MMNCs) with mechanical, corrosion and wear properties that exceed the current state-of-the-art materials for tool applications available on the market. Such an improvement lies in combining two or more constituting materials with significantly different properties. In order to create such a novel product we will use a synergy of innovative processing and post-processing treatment approaches. While widely used conventional metallurgy procedures allow for some improvement of the MMNC properties, additive manufacturing (AM) opens new perspectives in the MMNCs’ fabrication. Here, the freedom of powder mixing (i.e., feedstock), shape choices, and saving of material, are of great advantage. The reduced number of processing steps leads to decreased energy usage for the processing, which directly influences the amount of greenhouse-gas emissions. Economically, the lead time for bringing a new product to the market is also greatly shortened. To achieve the ambitious aim of the proposed project, we will use a carefully designed step-by-step procedure, where along with the conventional solutions an innovative processing and post-processing treatment techniques will be applied. Firstly, four different mixing procedures for commercially available steel powders of stainless steel 316L, maraging steel M300 and tool steel H13 with reinforcing nanoparticles will be assessed. Secondly, the mixtures will serve as a feedstock for the selective laser melting (SLM) manufacturing of parts. Here, we will vary the SLM processing parameters, such as laser energy input, heating stage and gas atmosphere. One of the innovative solutions in this step is an input of the oxygen into the melt via presence of the oxidizing atmosphere to reinforce the material with nano-oxide particles. Another new approach is to apply atomic nitrogen as an atmosphere in the chamber in order to partially nitride the SLM-processed part. In the third step, the post-processing of SLM MMNC parts will be tailored, i.e., SLM-optimized heat treatment and low-temperature plasma nitriding. The latter procedure is of high applicative importance for manufacturing of tool parts, which is not yet well established for SLM steels. Therefore, the resulting successful MMNC mixtures and SLM procedures will be transferred to the industrial equipment of the industrial co-funding partner of the proposed project, MARSI, which is a leading Slovenian company in the area of additive manufacturing of SLM tooling parts. On the broader scale, the expected project outcome will strengthen the competitiveness and growth of the Slovenian high-tech companies in the fields of automotive, mechanical engineering, tooling and other sectors allowing them to meet the needs of European and global markets. Despite the applicative nature of the proposed project, its intensive interdisciplinary collaboration will bring together researchers from the fields of metallurgy, physics, chemistry and mechanical engineering. The expected output of original basic science results will pave the way for the new research areas in the field of SLM processing.
