Collaborative Effort to Advance Sinter-Based Additive Manufacturing for High-Performance Alloys

A new collaborative initiative, dubbed ‘Simsalabim’, is being launched to develop a continuous process chain for sinter-based Additive Manufacturing (AM) of nickel-based alloys. This project brings together three leading research institutions: the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Dresden University of Applied Sciences (HTW), and the Fraunhofer Institute for Material and Beam Technology (IWS). The primary goal is to advance sintering technologies for creating high-performance materials, particularly nickel-based superalloys, which are essential for high-temperature applications in sectors like aerospace, energy, and hydrogen.

Enhancing Efficiency and Accelerating Material Development
The Simsalabim project aims to achieve Technology Readiness Level (TRL) 5, signifying readiness for industrial application. A major focus is on boosting resource efficiency by reducing development cycles and accelerating the calibration of new materials. The project aims to shorten development timelines by two to three cycles and speed up material calibration by five times. As part of the initiative, the team is developing not only sintering processes but also new materials that could offer future industrial partners more options for high-performance components. In the long term, the project aims to create a regional network for sinter-based AM, with potential future expansion to include other materials like tool steels and cobalt-based alloys.

Addressing the Industry’s Need for Advanced Additive Manufacturing Processes
Traditional metal AM has been dominated by laser-based processes, which, while mature, cannot always handle challenging materials, complex geometries, or provide the high productivity required for certain applications. This has led to increasing interest in sinter-based Additive Manufacturing, which has significant advantages in terms of material versatility, cost-effectiveness, and high productivity. Sinter-based AM processes involve the use of metal powders that are not fully melted, reducing issues such as thermal gradients, residual stresses, and cracking that can occur during full melting, making it especially suitable for difficult-to-weld materials like nickel-based superalloys.

Nickel-based alloys, known for their high strength, corrosion resistance, and thermal stability, are often used in demanding sectors such as aerospace, energy, and hydrogen. However, these materials present challenges for laser-based processes, especially in terms of preventing cracks and maintaining material integrity. Sinter-based Additive Manufacturing offers a promising solution to overcome these challenges, ensuring the production of high-quality, crack-free components.

Overcoming Challenges and Enhancing Material Properties
While sinter-based AM holds significant promise, it is still seen as less mature compared to laser-based methods, especially in terms of precision and material properties. One key challenge is predicting and compensating for sintering shrinkage in complex structures and achieving desired material properties such as strength, fatigue resistance, and surface finish. The Simsalabim project is focused on developing more accurate simulations to predict sintering behavior and improve material properties, ensuring better control over the final part quality.

The research initiative aims to enhance the material properties of nickel-based superalloys, making them suitable for advanced, high-temperature applications by refining sintering and post-processing techniques.

Industry Collaboration to Drive Innovation
To ensure that the developments align with industry needs, manufacturers and users of high-temperature materials are invited to join an initial network meeting on November 27-28, 2024. This event will allow industry experts to contribute their requirements and applications to the project, ensuring that the solutions being developed are practical and scalable. The Fraunhofer research teams, along with the support from Dresden University of Applied Sciences, will leverage their expertise in additive manufacturing, powder metallurgy, and high-performance material applications to drive the project forward.