“Advances in Metal Additive Manufacturing”

published by Elsevier / Woodhead Publishing

Authors: Sachin Salunkhe, Sergio T. Amancio-Filho and J. Paulo Davim

The new book provides fundamental information and the latest research on metal additive manufacturing technologies, including powderbedfusion, direct edenergy deposition using high-energy beams, and hybrid additive and subtractive methods.

We would like to thank all book chapter authors for their valuable contribution to this project. A special thanks to Rafael Paiotti from our institute, who led the preparation of two excellent chapters (Chs. 1 and 2) with the participation of University of Applied Sciences Upper Austria and JOANNEUM RESEARCH Forschungsgesellschaft mbH.

Save the date:
September 1, 2022, 2 p.m., lecture room E, Kopernikusgasse 24/I

As the Welding Engineering undergraduate programme at The Ohio State University (OSU) is completing 75 years in 2023, it has evolved to become a key player in the education and research on materials joining within the U.S. and across the world. In 2010 OSU joined efforts with the U.S. National Science Foundation (NSF) and other key universities across North America to establish the Manufacturing and Materials Joining Innovation Center (Ma2JIC). This center has brought together researchers from seven different universities in U.S. and Canada and more than 60 industrial and government organisations from around the globe to cooperatively develop state-of-the-art and economically relevant research on materials joining and metal additive manufacturing (AM), totaling more than US$50M. Today Ma2JIC invests $5.5M per year to support approximately 30 different research projects, which involve about120 researchers and students across The Ohio State University, University of Tennessee-Knoxville, Pennsylvania State University, Colorado School of Mines, and the University of Waterloo.

In his Guest Lecture, Antonio J. Ramirez from Ma2JIC will present highlights of the research and technologies developed by OSU and Ma2JIC, ranging from fundamental studies on solidification cracking during welding and Additive Manufacturing, powder- and wire-based metal AM, and conventional welding processes like friction stir welding and resistance spot welding of advanced steels and dissimilar materials.

About Antonio Ramirez

Antonio Ramirez from the Ohio State University (OSU) – which is the top ranked university in welding and joining in the US) – is an expert in Metal Additive Manufacturing and solid-state welding processes and director of the Ma2JIC center.

We are pleased to announce another great award.

Florian Pixner was awarded the "Welding in the World Best Paper" sponsored by the IIW International Institute of Welding at the 75^th IIW Annual Assembly in Tokio 2022 http://www.iiw2022.com/
in the Category A: Welding Processes and Additive Manufacturing in Recognition of his outstanding research paper:

Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

Co-authors: Ricardo Buzolin, Sebastian Schönfelder from pro beam additive GmbH, Gilching, Germany; David Theuermann, Fernando Warchomicka and Norbert Enzinger.

We are happy to announce our award at this year's Energie Globe Award Styria 2022.

The project team at IMAT, Willian Carvalho, Carlos A. Belei Belei and Prof. Sergio T. Amancio Filho Amamcio, BMK Endowed Professorship for Aviation and head of the institute Prof. Christof Sommitsch was awarded for the project: "GreENJOINable - Enabling next-generation green aircraft structures" in the research category and is nominated for the international Energy Globe Award in the AIR category.
Content: Innovative composite materials and efficient ultrasonic joining technology reduce CO2 emissions through lower aircraft weight.

to the award:
http://www.news.steiermark.at/cms/beitrag/12879196/154271055/
http://www.energyglobe.at/ueber-energy-globe

After receiving our new welding machine in April, we were now able to carry out the official introduction and demonstration by Matthias Moschinger followed by a celebration.
Head of the joining group is Norbert Enzinger: "SBI M3DPSL plasma welding unit with multiple filler material input options opens a whole range of new possibilities.

equiment at the joining lab

Guest lecture "Welding and repair solutions for damaged large components in turbomachinery".
Sorin Keller, President of IIW (International Institute of Welding) and  Manager Welding & Brazing Technology, GE Power.

Save the date:

27^th of April 2022, at 13:00 in the lecture room A, Kopernikusgasse 24/I

GE has many years of experience with welded rotors for steam, gas turbines and turbogenerator rotors. From 1929 to the present, more than 7,800 rotors have been manufactured from identical materials or different combinations of materials. The future challenge lies in mastering the welding technology on new materials, as well as in further optimizing and streamlining the welding processes, with the aim of increasing the efficiency of the power plants. The greatest challenge lies in the development and implementation of repair processes that ensure the operation of these machines to a modern environmentally friendly standard, thus making a sustainable contribution to the conservation of resources and the environment. In the context of these developments, failure analysis is an essential tool that is used to bring reliable products to market.

A constant motivation in aeronautical engineering is the research of new materials that enable the weight reduction of flying objects without reducing their strength and thus effectively decrease their fuel consumption. However, since most of today’s commercial airplanes and helicopters are powered by fossil fuels, a reduction of the CO₂ emissions towards zero is not possible. Therefore, another research focus is looking at the development of alternative propulsion systems that can reduce CO₂ emissions even further and thus effectively counteract future climate changes.

In the course of the FFG-funded project IonAs, an all-electric propulsion system powered by ion wind was studied by IMAT in cooperation with the IHS (Institute of High Voltage Engineering and System Performance – TU Graz) and the IAV (Institute of Aviation – FH-Joanneum). Due to the fact that such ionic wind powered systems provide much lower thrust than conventional systems, weight reduction is even more important. This goal can be achieved by combining lightweight materials and additive manufacturing (in this case Laser – Powder Bed Fusion), which enables the production of highly complex parts that cannot be manufactured in any other way.

In this project, the team has successfully manufactured a hybrid demonstrator in the shape of an air foil that consists of two parts: The front part was additively manufactured with the use of AlSi10Mg alloy and shows the possibility of printing small structures of 200µm in thickness. The rear part of the air foil was made out of CFRP (Carbon Fibre-Reinforced Polymer) and was manufactured by the colleagues of IAV. Due to the great outcomings of this project, the follow up FFG-project IonAs² was approved and is already running, including two additional project partners (Institute of Fluid Mechanics and Heat Transfer – TU Graz and Institute of Electrical Measurement and Sensor Systems – TU Graz), with the aim to bring the idea of flying with the power of ions to a new level!

On the occasion of the event "From Science to Innovation" on 9th of November at the Karl-Franzens University the Technische Universität Graz honors its inventors.
The award "Inventor of the TU Graz" was given to Sergio T. Amancio Filho, Christof Sommitsch, Pedro Effertz and Mohammad Reza Ahmadi (from left to right) for their groundbreaking inventions in the field of materials science.

• "Method and equipment to produce metallic wire and polymeric filament using friction energy"  - with focus on materials recycling and repurposing for additive manufacturing
• "Ferritic steel for service temperatures from 650 to 700°C"
• "Development of post heat treatment for terrific creep resistant steels containing 15% Chromium"
• "Additive manufacturing powders for use in additive manufacturing processes resulting in improved stability of steel melt-track"

Mr. Dipl.-Ing. Matthias Moschinger, IWE and university project assitant at the IMAT Institute, has received the “Richard Marek Award 2021” for his article „Elektronenstrahlschweißen dünnwandiger Aluminium Liner“  Congratulations!

The award was handed over by the speaker of the presidium of the ÖGS, Mr. Guido Reuter. The prize was given for innovative solutions in welding technology.

further information

The HPS students managed again, after an exciting overtaking jad before the last stroke, with only a distance from 0.2 nautic miles but with a 30-minute lead over the second-place finisher in the home stretch, after a continuous 3-day race over the distance of 370 nautical miles in the class B46.

Round Palagruza Cannonball in 2016 1^st place and again 1^st place in 2021.

https://roundpalagruza.at/rpc-2021-wertung-bavaria-46/

Our Congratulations  to the High Performance Sailing HPS Students Team of TU Graz:

Felix Meixner from IMAT, Tobias Wöhr, Jakob Fuchsberger, Bernhard Golser, Michael Kolm, Jakob Kreisel, Valentin Leutgeb and Vincent Philipp

http://sailing.tugraz.at/

Guest lecture "Welding and Brazing technology, as key processes in the manufacturing of power generation components" Sorin Keller, IIW president and  Manager Welding & Brazing Technology, GE Power on
virtual:

https://tugraz.webex.com/meet/norbert.enzinger

New book on Numerical Modeling and Simulation of Metal Processing edited by Prof. Christof Sommitsch.

published - open access - on the MDPI Books platform!

V_REX by Peter Steinkogler

Peter Steinkogler, multiple state champion in various boat classes, designed a revolutionary sailboat concept, not only as a record-breaking sailboat, but especially how a sailboat could function most economically and effectively. - This especially for possible implementations for zero-emission cargo sailboats.
IMAT and furhter institutes at TU Graz were partners in the development of the V_REX in the fields of avionics, sensor technology, materials science, fluid mechanics, optimization and modeling.

At IMAT, bachelor theses for the finite element calculation of the hydrofoils as well as the production of the boat models for tests, which is now being put into action and can be actively supported via Kickstarter.

Build the fastest serial sailing vessel this summer AND scaling it up for emission-free offshore transportation for the future!

Projekt Partners and Institutes at TU Graz:

Univ.-Prof. Siegfried Vössner, Institute of Engineering and Business Informatics

Univ.-Prof. Franz Wotawa; Institute of Software Technology

Assoc.Prof. Walter Meile; Institute of Fluid Mechanics and Heat Transfer

Student Projects at IMAT:

• Miha Gulic, 2020: „Designing a hydrofoil of an A-Class catamaran using Altair OptiStruct™ for composite analysis“
• Bernhard Staggl and Julia Pohn, 2016: „Werkstoffwahl und Spannungsberechnung am Hydrofoil eines Hochgeschwindigkeitssegelbootes“
• Hanno Pardatscher, 2018: „Modellbau eines Hochgeschwindigkeitssegelbootes für Windkanalversuche“
• Christoph Resch, 2018: „Durchführung von Windkanaltests am V_REX Modell“

Poster: New concept highspeed sailing boat – model setup and wind tunnel test
H. Pardatscher¹, C. Resch¹, P. Steinkogler², W. Meile³, L. Weingrill¹ and C. Sommitsch¹

1. Graz University of Technology, Institute of Materials Science, Joining and Forming, Kopernikusgasse 24, 8010 Graz, Austria
2. Godspeed sail racing academy, Pfaffingstraße 20, 4802 Ebensee, Austria
3. Graz University of Technology, Institute of Fluid Mechanics and Heat Transfer, Inffeldgasse 25F, 8010 Graz, Austria

Das Programm zur 15. Werkstofftagung steht unter dem Motto "Additve Fertigung von performanten und hybriden Strukturen" und ist online verfügbar. Weitere Informationen zur Anmeldung und zu unserem Sponsoringangebot finden Sie unter

Materials Day

Gastvortrag "Behebung von Schäden an Dampf und Gasturbinen -Rotoren durch Schweissen" von Hr. Dr. Sorin Keller, Manager Welding & Brazing Technology, GE Power am

Montag, online am 08.03.2021 14:15 - 17:15 Uhr

https://tugraz.webex.com/tugraz-de/j.php?MTID=m0e6ad3b8730597aa1ac4bfc642e55351

The development of structural shape-memory alloys dates back the 1940s and 1950s, being the most employed alloy the well-known Nitinol (or NiTi). Due to the shape memory effect, these functional metals have the ability to be deformed and recover their shape when heated. In a nutshell, these functional effects deliver high stresses, therefore enabling Nitinol to be used as an actuator. However, their use in main stream functional-structural applications has been somehow hindered mainly to their complex processing, machining, and high reactivity. Additive manufacturing has the potential to mitigate these drawbacks, as near-net shape parts can be produced with lesser manufacturing steps and higher materials savings. In our recent publication https://doi.org/10.1177%2F1464420720975059 we have shown that NiTi alloys can be successfully additively manufactured with electron beam free forming fabrication (EBF3), also known as wire-based electron beam additive manufacturing (w-EBAM). The project has been led by Rafael Paiotti, project assistant and PhD candidate at BMK Endowed Professorship of Aviation in close collaboration with Florian Pixner from the Joining Technology group  Printed parts were tested in cooperation with Institute for Chemistry and Technology of Materials, under ad-hoc consultancy of Embraer.
Contact: Univ. Prof. Dr.-Ing. Sergio Amancio

The best students are in great demand at all institutions in order to collaborate in research projects as well as in teaching. As a consequence, the ESP – IMAT Elite Student Programme for Materials Science, Joining and Forming was launched in the academic year 2016/17 to enable high-potential students to be in an interesting programme.  We welcome our new Elite Students for the academic year 2020/21.

furhter information ...

the guest lecture is canceled.

Vienna, 9/26/2020

The 1^st Meeting of the Brazilian Scientific Diaspora was held on 9/26/20, in Vienna, with the presence of the Minister of Science, Technology and Innovations, Mr. Marcos Pontes, the Ambassador of Brazil in Vienna, José Antônio Marcondes de Carvalho, and 21 researchers, residing in Austria and Slovakia. The meeting was opened with the words of the Ambassador of Brazil to Austria, which was followed by a speech by Minister Marcos Pontes and interactive debate with members of the diaspora. In his opening speech, Ambassador Marcondes highlighted the importance of observing the phenomenon of emigration of qualified professionals from the perspective of networks formed by researchers, instead of a concept exclusively of “brain drain”. He noted the diversity of present researchers, coming from different regions of Austria, and with different areas of expertise. The Brazilian Ambassador stressed the fact that ‘Brazil is an innovative and creative country’ and mentioned ‘the mobilization of Brazilian scientific diasporas abroad as one of the main tools to increase the scientific and technological cooperation between Austria and Brazil.’

Minister Marcos Pontes – an engineer and retired NASA astronaut - welcomed the organization of the meeting of the Brazilian scientific community in Austria, highlighting the importance of technology in human development and the fundamental role played by science, technology and innovation. Following topics were discussed in this meeting: (a) exchange of Brazilian and Austrian students, by supporting partnerships between research and teaching institutions in both countries; (b) identification of new R&D trends in Austria as a way to contribute to the establishment of new topics in Brazil; (c) Creation of an association for the Brazilian diaspora in Austria to foster the above-mentioned topics.

Marina Melo Gontijo, Willian Sales de Carvalho and Prof. Sergio Amancio (in the picture with Minister Marcos Pontes) had the honor of representing TU Graz and IMAT in this important event. Prof. Amancio had the chance to discuss current and future developments in the field of materials science and manufacturing with Minister Pontes.

Prof. Sommitsch is Speaker at the 11. Ranshofenener Leichtmetalltage

"Leichtmetalle, Werkstoff- und Prozesstechnologien im Kontext von Dekarbonisierung und Digitalisierung"

The widely known and respected newspaper “Der Standard” publishes weekly a portrait of a young talent from science in the column called “Geistesblitz”. Researchers working in Austria are interviewed and invited to tell about their work, motivation and a small personal insight.

Marina Gontijo, one of the PhDs at IMAT, was invited to share about her work in this column, published on the 4^th of March.

the article

The publication of IMAT team brings new insight to the successful printing process of the neodymium-based magnets.The paper describes in an detailed way behaviour of the material molten by laser and its influence on the final magnetic properties of a 3D printed component.

published:

https://www.mdpi.com/1996-1944/13/1/139

One step closer to effective 3D printing of super-strong magnets. The team of IMAT / TU Graz researchers developed an effective 3D printing process of NdFeB magnets. Next goal is to translate the lesson learned to another promising material: FeCrCo.

THE ARTICLE

more arcticles:

https://www.pressetext.com/news/nachhaltige-supermagnete-aus-dem-3d-drucker.html

http://www.elektroniknet.de/markt-technik/industrie-40-iot/3d-druck-macht-seltene-erden-ueberfluessig-173074.html

https://www.studium.at/forscher-stellen-hochleistungsmagnete-3d-drucker-her

The Chamber of Commerce of Styria awarded the WKO Research Promotion Prize to 19 fellows and institutes this year. Mr. Anto Zelic received for his outstanding master’s thesis, which he carried out at our IMAT institute and under the supervision of Mr. Florian Pixner, the research prize of EUR 2,100 that was given by Mr. Josef Herk, President of the Chamber of Commerce of Styria on December 4, 2019 as part of the official grant ceremony. In total there were 5 scholarship holders from TU Graz.

We congratulate quite cordially!

Link zum Video:

The AddLab@tugraz has recently started as cooperation between the two institutes IMAT (Institute of Materials Science, Joining and Forming) and IFT (Institute of Production Engineering) in the area of metal additive production using selective powder printing techniques. Currently two printers are available:

• the SLM solutions 280 HL printer focuses on the printing process, the optimisation of the topology and the printing of comlex parts particularly of stainless steel
• the printer Coherent ORLAS Creator RA is used in the area of materials research in particular of Ti alloys and magnetic materials as well as for the research topics reduction of support structures and the use of optimized powder

It is planned to extend together the AddLab@tugraz regarding technologies and materials

The international student project marathon was a cooperation between Peter the Great St. Petersburg Polytechnic University (SPbPU) and Graz University of Technology. The IMAT was involved in two out of six projects.

The Student Project Marathon

The 14^th Materials Day of the Institute of Materials Science, Joining and Forming of Graz University of Technology took place on November 28, 2019 and focused on innovative solutions in modern joining technology. In the beautiful assembly hall, Rector Prof. Harald Kainz welcomed around 130 participants coming from science and business, among them selected students of the vocational education and training college – HTL Mödling. In his opening speech, he introduced the impressive development of Graz University of Technology and responded to the contribution on this success of Em.Prof. Horst Cerjak, the person celebrating his big birthday. The head of the institute, Prof. Christof Sommitsch, subsequently paid tribute to his predecessor Em.Prof. Dr.mont. Horst Cerjak on his 80^th birthday by pointing out selected contributions from his very fulfilling and and successful professional life. Afterwards Prof. Sommitsch presented an overview of the ongoing and prospective main topics of the institute.

In the first block of the event, two specialist lectures on current research topics were presented. Mr. F. Pixner talked about the wire based additive manufacturing as part of joining technology and Dr. M. Skalon presented the powder bed process, where he focused his lecture on an innovative approach to parameter development of new powders. After the coffee break Prof. G. Wilhelm, who also works for Lorch Schweißtechnik GmbH, introduced his research results of the MSG build-up welding processes of iron-tungsten pseudo-alloys under consideration of the welding process. Mr. E. Wagner focused then on the current situation of the additive manufacturing with electron beam in general and in particular on features at pro-beam GmbH. Ms. A. Putz presented parts of her PhD thesis in the field of flux-cored wire welding of standard duplex steel, notably the very innovative AHT method. After lunch, Mr. Th. Willidal (voestalpine Böhler welding Austria) presented the concept of the flux cored wire in general and in particular the implementation for a nickel-based alloy. Mr. H. Staufer from Fronius International GmbH, demonstrated the possibilities and potential of the laser-MAG tandem hyprid process in terms of the large tolerance to variable gap dimensions. Next, Prof. Amancio presented selected methods for joining dissimilar compounds, paying particular attention to the friction-based processes. The last presentation of Ass.Prof. Domitner focused on the simulation of self-pierce riveting in modern car body construction.

At the end of the seminar guided tours through the labs of the institute were offered. Summing up the Materials Day showed current trends and innovative solutions in modern joining technology from a scientific and industrial point of view and everybody had the chance of interdisciplinary discussions and networking.

further upcoming events

On November 7, 2019 Prof. Sergio Amancio delivered his cutting-edge Inaugural Lecture at TU Graz with the title: Flying fast forward: Innovative hybrid materials and manufacturing technologies for aviation. In his talk he addressed the historical aspects of lightweight materials and structures in modern civil aviation and presented the latest developments on manufacturing of lightweight hybrid structures for future airplanes. The focus of Prof. Amancio’s lecture was set on novel joining and additive manufacturing techniques for metals, composites and metal-composite structures.

pictures of the event

Mr. Josef Plangger, Master student at the IMAT Institute, has received the this year’s “Richard Marek Award” for his article „Process development for additive manufacturing of a crane component“ within the scope of the fair „Schweissen 2019“ in Linz. Congratulations!

The award was handed over by the speaker of the presidium of the ÖGS, Mr. Guido Reuter. The prize was given for innovative solutions in welding technology.

further information

you will find us ...

für weitere Informationen ...

Programmheft

Mateusz Skalon hat ein innovatives Pulver für den 3D-Metalldruck entwickelt und arbeitet nun an dessen Marktreife.

An der TU Graz wurde ein Stahlpulver für die additive Fertigung entwickelt, das die Produktion komplexer Bauteile entscheidend vereinfacht. In einem Spin-Off-Förderprogramm wird nun an der Marktreife gearbeitet.

Kürzere Produktionszeiten, geringere Kosten und weniger Produktionsfehler: Dies sind nur einige Gründe, warum die metallverarbeitende Industrie immer öfter additive Verfahren einsetzt. 

... zum Artikel

Recently the STYRIAM METALS team took part in Fifteen Seconds Festival from 6 - 7 June 2019 in Graz and gave a pitch about the product.

STYRIAM METALS is a start-up team located in Graz (Styria, Austria) at TU Graz working on metallic powders for Additive Manufacturing.

Head of the team is Mr. Mateusz Skalon from IMAT.

The team develops a modification process of steel powders utilised for Selective Laser Melting (SLM). The powder modification allows to eliminate the need of supporting the printed components during the printing process. This extends a freedom of design by enabling a unique feature of horizontal printing without supports. With this unique technology it is planned to enter the rapidly growing market of additive manufacturing.

STYRIAM METALS is an outcome of FFG Spin-Off Fellowship programme: NewGen SLM Powder.

Download: Conference Proceeding Book  - Open Access ...

12^th International Seminar 'Numerical Analysis of Weldability' - furhter information ...

course 303.105 Advanced Processing Technologies

AND THE WINNER IS ...

On March 7 2019, the Dörrenberg Studien AWARD was awarded for the 11^th time to students, who have studied materials engineering topics such as steel, heat treatment, surface engineering or process engineering.

Ms. Jana Joeressen is one of this year’s award winners!
She was honored for her excellent Bachelor thesis „Corrosion tests on duplex steels“, that she carried out at the IMAT institute in 2018 under the supervision of Prof. Norbert Enzinger, Dipl.-Ing. Andrea Putz and Wolfgang Steinbäck from the corrosion laboratory. Congratulations!

In a press conference on Dec. 12, 2018, the Austrian minister Mr. Hofer (BMVIT) has launched the Research, Technology and Innovation (FTI) Strategic Advisory Board for the Austrian aviation sector. Prof. Sergio Amancio – a member of the board - represents TU Graz in the area of materials and manufacturing technologies.

... for further information

Vienna, 13.09.2018. Prof. Sergio Amancio met the Federal Minister of Transport, Information and Technology, Ing. Norbert Hofer at the official BMVIT Endowed Professorship event introducing the new university professors.

... for further information

... more information on wiley.com

The Graz University of Technology, and Austrian industry key-players establish Austria’s first endowed chair for aerospace research