2012 11-15-high-value-manufacturing-sirris-verlee

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This document summarizes research conducted by le centre collectif de l’industrie technologique belge on controlling the density and porosity of 316L stainless steel parts created using additive manufacturing and sintering. It describes how porous metallic parts can be made through powder metallurgy, and how additive manufacturing allows for more complex geometries and integrated functions compared to traditional pressing and molding injection techniques. The 3D printing and sintering process is explained, along with characterization of properties like density, porosity, permeability, and pore size. Test results on 316L stainless steel powders show how sintering temperature, time, and powder properties impact the final part density, porosity, pore size,

Technology

High Value Manufacturing

Density/porosity control of sintered 316L stainless steel
parts shaped by additive manufacturing

15-11-2012

le centre collectif de l’industrie technologique belge

Table of contents

• Porous metallic parts

• 3D-printing Prometal process

• Sintering cycle

• Characterization

• Property ranges of 316L powders

• Examples

© sirris 2007 | www.sirris.be | info@sirris.be 3

Porous metallic parts

• Shaping by powder metallurgy  lots of parameters
• Porosity range from a few % to 90%
• Application list:
• Filtration
• Distributing/dispersing/damping
• Airing/cooling
• Lightening
• Catalysts supports
• Prosthesis
• But simple geometries (Pressing, MIM)

4

Porous metallic parts

• Additive manufacturing  no limit in shape + integrated
functionalities
• SLM  1 step
 no control of porosity
• 3D-printing  indirect route: shaping + sintering
 possibility to control porous characteristics

R10:
1000x500x280mm RXD:
60x40x15mm

5

3D- Printing Prometal Process

3. Sintering
Complete

Partial
1. Curing 2. Debinding - presintering
(green part) (brown part) (3’. Infiltration)

6

Sintering cycle

• From a powder tap to full dense material
• Passing by porous state
• Opened to 92% density, then closed

• Evolution functions of:
• Initial state
• Packing density
• Particle size distribution
• Particle shape
• Sintering conditions
• Temperature
• Time
• (Atmosphere)

•  Stop at different stage to keep or eliminate porosity following
target application

7

Characterization

• Density – porosity (opened and closed)  Archimedes (3 weightings)

• Permeability k  Darcy (flux Q through thickness L and surface A under DP)

Q.L.µ
k=
A.∆P

• Pore size (bubble point and Hg porosimetry)  Washburn

− 4.γ . cos θ
d=
P

© sirris 2007 | www.sirris.be | info@sirris.be 8

Property ranges for 316L powders
100 40
22µm

• Effect of sintering T° 95 31µm
20-53µm
35

(90min at T°) for 4
45-90µm
90 30

Opened porosity (%)
Relative density (%)
spherical powders 85 25

80 20

75 15

70 10

65 5

60 0
1180 1200 1220 1240 1260 1280 1300 1320 1340 1360 1380 1400 1420 1440
Temperature (°C)

0,9
Porous part Dense part 0,89
0,88 1315°
• Effect of sintering time 0,87 C
Density (-)

0,86 1335°
at 3 T° for 31µm 0,85
C
1345°
powder 0,84
0,83
C

0,82
0,81
0 50 100 150 200 250 300 350
Time at sintering temperature (min.) 9

Property ranges for 316L powders

35 1,00E-12 • Pore size and permeability
22µm
functions of opened
porosity for 4 spherical
31µm
30
20-53µm

powders
Mean pore size (µm)

45-90µm 1,00E-13
25

Permeability (m²)
20

1,00E-14

15 • Link between parameters:
• Powder size sets pore size
10
1,00E-15 • Thermal cycle sets final
density/porosity
5
•  all defines permeability

0 1,00E-16

Main challenge: shrinkage
0 5 10 15 20 25 30 35 40
•
control!
Opened porosity (%)

Pore mean size
Permeability 10

Property ranges for 316L powders

45-90µm powder
Gas atomised particles Water atomised particles

Sintered 90min at 1395°C

65% density – 35% opened porosity 47% density – 53% opened porosity
Mean pore size 35µm Mean pore size 30µm
Permeability 10-12m² Permeability 10-12m²

© sirris 2007 | www.sirris.be | info@sirris.be 11

Examples
Ø 70mm
Pores 30µm
Perméa. 10-12 m²

L 270mm
Ø 50mm Pores 17µm

Pores 30µm Perméa. 5.10-13 m²
L 30mm
Perméa. 10-12 m²

Ø 300mm
L 90mm
Pores 35µm
Pores 35µm
Perméa. 10-12 m²
Perméa. 10-12 m² 12

Thank you for your attention !

Bruno.Verlee@sirris.be

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Corrosion monitoring is important for the offshore renewable energy (ORE) sector due to the technical and economic consequences of corrosion. Current corrosion monitoring methods include corrosion coupons, ER probes, and environmental sensors for oxygen, pH, and temperature. However, these methods have limitations like needing retrieval, providing only historic data, and requiring frequent recalibration. New sensor technologies are needed for improved pitting monitoring, mudline corrosion inspection, and microbially influenced corrosion monitoring. Effective monitoring strategies combine direct corrosion monitoring with environmental data and inspections to reduce uncertainty and support corrosion risk-based inspection planning.

Challenges and solutions for improved durability of materials - Concrete in m...

Sirris

The document discusses challenges and solutions for improving the durability of materials, specifically reinforced concrete in marine environments. It covers monitoring and modeling of reinforced concrete durability, costs of maintenance in complex marine environments, technologies like structural health monitoring (SHM) that can optimize maintenance, and challenges like fatigue, chloride ingress, and spatial variability that require further progress. The document provides examples of applications of SHM to grouted joints in offshore wind turbines and monitoring of stresses and chlorides in concrete structures.

Challenges and solutions for improved durability of materials - Coatings done...

Sirris

This webinar discussed challenges and solutions for improving durability of materials for shell & tube heat exchanger coatings. It provided an overview of Donelli Alexo and Säkaphen coating companies and their facilities. It then reviewed the ISO 12944 standard for selecting coating systems based on identifying the corrosivity category of the operating environment and desired durability timeframe. Specific coating system examples were given for carbon steel in different corrosivity categories. The webinar also discussed fouling issues in heat exchangers and how coatings can help reduce fouling and its negative impacts on performance. Real-world case studies demonstrated significant fouling reduction from coatings. The webinar closed by considering topics for future discussion

Futureproof by sirris- product of the future

Sirris

1) The document discusses how value can be created through smart products using sensors, connectivity, and digital services. 2) It outlines common smart product design areas like business models, mechatronics, and digital services that can enable new competitive advantages. 3) The author argues that companies should apply validated inspiration from proven smart product scenarios, build expertise in proof of concepts, and scale up knowledge through an ecosystem network to successfully create value with smart products.

2018 11-07-verbinden-ongelijksoortige-materialen-hupico multimaterial welding

Sirris

2018 11-07-verbinden-ongelijksoortige-materialen-bil ongelijksoortige materia...

Sirris

2018 11-07-verbinden-ongelijksoortige-materialen-sirris bil-flanders_make_mmj

Sirris

2018 11-07-verbinden-ongelijksoortige-materialen-ku leuven-lijmen

Sirris

Slotevent ‘Verbinden van ongelijksoortige materialen’ - Lcv lasercladding for...

Sirris

Slotevent ‘Verbinden van ongelijksoortige materialen’ - Juno industries mecha...

Sirris

Slotevent ‘Verbinden van ongelijksoortige materialen’ - Castolin verbinden v...

Sirris

Masterclass Mechatronics 4.0 - Indoor and outdoor localisation and positionin...

Sirris

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