Post on 04-Jun-2018
f r a u n h o f e r i n S T i T u T e f o r m a n u fa C T u r i n G a n d a d Va n C e d m aT e r i a L S i fa m
Powder TechnologyRELIABILITY In FORM And FunCTIOn
Our offer includes component design and optimization,
computer simulation of shaping processes as well as technical
implementation in the industrial production and providing the
related training for customer staff.
Our R&D activities on functional materials deal with improving
the properties and processing of materials. Functional mate-
rials can either be directly integrated into components during
the manufacturing process or applied later by printing or
sputtering them onto the components’ surfaces. They provide
additional or completely new characteristics, for example
electronic or sensory functions. Cellular materials have special
properties that are in demand for energy absorption, noise
absorption and heat exchangers. Additional research focuses
on biomaterials made from metals, ceramics or polymers and
their biological interaction with the environment.
Based on these two areas of expertise, we are expanding into
the new application field of electric mobility, with a special
focus on energy storage and electrical power trains. Analyzing,
testing, evaluating and optimizing the complete system is the
main objective of our work.
© Fraunhofer - Institut für Fertigungstechnik und
Angewandte Materialforschung IFAM
Formgebung und Funktionswerkstoffe
T h e f r a u n h o f e r - G e S e L L S C h a f T
Practice-oriented research and development is the principal task
of the Fraunhofer-Gesellschaft. Founded in 1949, the research
organization performs applied research and development for
the benefit of economy and society.
The customers and contractual partners of the Fraunhofer-
Gesellschaft are industrial enterprises, service providers and
public authorities. At present, the Fraunhofer-Gesellschaft
operates 60 research institutes with a total staff of 17 000, the
majority of whom are qualified scientists and engineers.
S h a P i n G a n d f u n C T i o n a L m a T e r i a L S
The Shaping and Functional Materials Division of the Fraunhofer
Institute for Manufacturing and Advanced Materials IFAM,
with its facilities in Bremen and Dresden, develops innovative
materials and adapts and improves existing manufacturing
processes. Our R&D work ranges from material engineering,
shaping and manufacturing technologies to functionalizing
components and systems. We develop individual solutions for
customers in various industrial sectors including automotive
industry, medical technology, aviation and aerospace, mecha-
nical, electrical and environmental engineering, as well as the
electronics industry.
In the area of shaping the focus is on the cost- and resource-
efficient production of increasingly complex-shaped, or mini-
ature precision components. Using innovative manufacturing
processes in both powder and casting technology, we give
additional functionality to components.
we UnderSTAnd MATerIAlS
C o n T e n T S
P o w d e r T e C h n o L o G Y 3
T a i L o r - m a d e C h a r a C T e r i S T i C S 5
f u n C T i o n B Y P o w d e r - T e C h n o L o G i C a L S h a P i n G 6
a d d i n G f u n C T i o n w i T h m e T a L P o w d e r S 8
o u r S e r V i C e S 1 0
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For quite some time, powder technological solutions have proved their worth in
many different industrial applications. Continuous technological advancement and
innovative new products have opened up new market segments.
from powder to component
State-of-the-art products manufactured by powder technology dominate their markets because
of their high efficiency, their reliability and their added value. Throughout the entire production
process, powder technology offers many possibilities to alter the properties of materials as well
as parts’ shapes and functions and thereby influence product quality.
Our core competence is the deep and comprehensive knowledge about the entire production
process from powder to part. We can answer any questions concerning materials, shaping
processes, tolerances and process reliability. Also, we offer manufacturing solutions for specific
component requirements, based on mechanical, physical or a combination of several properties.
For implementing the research and development results on an industrial scale, Fraunhofer IFAM
uses modern industry equipment.
We are looking forward to accepting new challenges to surpass today’s technical constraints by
using powder technology together with our customers, either in direct bilateral and confidential
cooperation or in publicly funded consortial projects.
Powder Technology: deSIgnIng ProPerTIeS, ShAPeS And fUncTIonS
Cover: Flame arrest made from
stainless steel.
Above: Tensile test bars made from
different metals (bronze, stainless
steel, 42CrMo4, 16MnCr5, NiAl,
titanium, WNiFe).
Contact:
Dr. - Ing. Frank Petzoldt
Phone +49 421 2246 -134
frank.petzoldt @ ifam.fraunhofer.de
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The powder technological process route offers many poss ib i l i t ies to specif ica l ly
adjust mater ia l propert ies l ike no other manufactur ing process.
Powder technology provides functional material solutions
There are numerous ways to alter material properties, one of them being density modification.
According to the degree of porosity, materials obtain different properties and can thus be used
for specific functions, ranging from filtering to energy absorption.
Alloys, composite materials, material combinations and structural materials can be produced
with very specific properties simply by mixing metal powders. The possible combination of
properties in the finished parts can often be directly deduced from and realized by certain powder
compositions – however, the thermodynamic constraints have to be taken into account. Thus,
one can adapt part properties like hardness, ductility, Young’s modulus, wear and thermal
expansion to the requirements of the final application.
The key process steps in the powder technological manufacturing route are shaping and sinte-
ring. During the sintering process, the final material quality characteristics are created. Because
of the importance of sintering for the entire production process, we place special emphasis on
this process step. Our customers benefit from our extensive sintering know-how that is based
on twenty years of experience in powder metallurgical manufacturing with a broad range of
materials. Fraunhofer IFAM owns a number of well-equipped furnaces of different sizes, from
lab-scale to industrial scale, that allow the sintering of all common materials under all possible
sintering conditions.
For optimizing process control and reproducibility, we can analyze sintered materials and sinte-
ring atmosphere regarding their composition and purity. Process development and optimization
are supported by the thermodynamic calculation of phase transformations of metals, alloys and
composites.
Powder MeTAllUrgIcAl MATerIAlS wITh TAIlor-MAde chArAcTerISTIcS
4 | 5
Left page: Laser-sintered structure made
of stainless steel.
Fig. 1: Bronze filter element, sintered
from tap density.
Fig. 2: Aluminium foam elements.
Contact Metal foams:
Dipl. - Phys. Joachim Baumeister
Phone +49 421 2246 -211
joachim.baumeister @ ifam.fraunhofer.de
Contact Sintering:
Dr. - Ing. Georg Veltl
Phone +49 421 2246 -211
georg.veltl @ ifam.fraunhofer.de
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fUncTIon by Powder TechnologIcAl ShAPIng
»Whether i t be the sweeping eagle in his f l ight, or the open apple-blossom,
the toiling work-horse, the blithe swan, the branching oak, the winding stream at
its base, the drifting clouds, over all the coursing sun, form ever follows function,
and this i s the law. Where funct ion does not change form does not change«
Louis H. Sul l ivan (1856-1924), architect
Powder pressing
At Fraunhofer IFAM, the following aspects of the powder pressing technology are examined:
powder characterisation, powder processing and process development for the compaction of
metallic powders. We have a so-called Powder Test Center in which we analyze the pressing
behavior of powders from form filling behavior of the powder to the ejection of the powder
compact from the die. For designing and developing new pressed parts, Fraunhofer IFAM employs
a hydraulic 125 t-Dorst press with a warm compaction device.
metal injection molding (mim)
Using industrial-scale equipment, Fraunhofer IFAM analyzes and improves all aspects of the
different steps of the MIM process. In close co-operation with our customers and partners, we
strive to broaden the available range of materials and advance part quality by optimizing
process control and applying process simulation. Lastly, we adapt existing processes to manu-
facture parts with increased functionality.
Fraunhofer IFAM’s MIM equipment is well suited to solve material and technological problems
regarding all common powders and binder systems. In addition to our research on the
suitability of powders for MIM and the sintering of new materials, we also offer test batch
production of newly developed parts. Using our comprehensive and state-of-art equipment, we
can implement the entire injection molding manufacturing process, from powder processing
via feedstock production and homogenization to debinding and sintering. In addition to the
process R&D, we provide a variety of analytical services that can also be ordered separately.
In our Application Center for Metal Injection Molding, we are able to produce pilot series.
Moreover, we offer MIM training courses for our customer’s staff for regular and adapted
processes.
Fig. 1: Warm compacted gear
wheels made from 0.3 C-distaloy-
powder.
Fig. 2: Turbine stator vane (made
of intermetallic NiAl phase and
produced by MIM) after hot gas
corrosion test.
Contact Powder pressing:
Dr. - Ing. Georg Veltl
Phone +49 421 2246 -211
georg.veltl @ ifam.fraunhofer.de
Contact MIM:
Dr. - Ing. Thomas Hartwig
Phone +49 421 2246 -211
thomas.hartwig @ ifam.fraunhofer.de
Contact Application Center MIM:
Dipl. - Ing. Lutz Kramer
Phone +49 421 2246 -211
lutz.kramer @ ifam.fraunhofer.de
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feedstock extrusion
The manufacturing of continuous metal profiles by this particular method of extrusion is based
on the use of a viscous mixture of metal powder and binder. By extrusion, one can produce
both full and hollow profiles with a complex sectional geometry. Immediately after the green
part has been shaped by extrusion, it is calibrated, trimmed if necessary, then debinded and
sintered subsequently.
For feasibility studies on the production of smaller geometries, with simultaneous determination
of ideal feedstock and process parameters Fraunhofer IFAM offers single-screw extruders with a
variety of different test molds as well as specially designed support structures for the extruded
material.
Laser sintering (Laser melting)
By employing the “Direct Metal Laser Sintering (DMLS)” process, complex parts can be created
directly from 3D CAD data without using tools. DMLS allows the generative build-up of com-
ponents with intricate structures – e.g. internal channels – that cannot be produced any other
way, not even by investment casting. The parts, which are manufactured from layers of metal
powder, obtain their specific material and surface properties either directly during the laser
sintering process or by a subsequent conventional heat treatment or finishing. The standard
materials for DMLS range from stainless and tool steel to CoCr-based alloys and light metals
such as titanium and aluminium and their alloys.
Laser sintering is not only used to rapidly produce prototype parts (Rapid Prototyping) and tools
(Rapid Tooling), but also for the production of customized products for the end user (Rapid
Manufacturing). Fraunhofer IFAM’s services for DMLS process development include the entire
process chain from adapting the initial powder material to creating and checking data models,
topology optimization, generative production and the final inspection.
Fig. 3: Extruded comb profile made
from Cu feedstock; sintered part (left)
and green part (right).
Fig. 4: Replica of a human jaw bone
(study for a medical implant), laser
sintered Ti6AI4.
Contact Feedstock extrusion
and Laser sintering:
Dipl. - Ing. Claus Aumund-Kopp
Phone +49 421 2246 -211
claus.aumund-kopp @ ifam.fraunhofer.de
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The ever- increas ing demand for mult ifunct ional parts requires new methods
for the cost-effect ive implementat ion of a higher degree of funct ional i ty .
intelligent structural parts
At Fraunhofer IFAM, we are working with several processes to increase the functionality of
components. Two-component injection molding and sinter joining techniques permit an
addition of function while simultaneously reducing time and effort in part production. Process
variations like assembly injection molding and lost cores, as well as the combination of different
material properties, e.g. dense / porous, or two different materials with a stable interface help
to increase the functionality of powder metallurgical parts. Possible material combinations that
can be achieved by sintering are:
• magnetic and non magnetic stainless steel
• low alloy steel and cutting material
• stainless steel and zirconia
Another technique for functional integration in metallic parts is screen-printing and subse-
quently sintering powder filled pastes onto them. Once again, the whole range of powder
metallurgical materials can be used to coat the parts or apply structures onto their surfaces.
This way, hard and soft magnetic signatures, hard abrasion-resistant coatings on stainless steel
by reaction sintering of titanium pastes, thermocouples, overload sensors and strain gauges
can be easily manufactured. Moreover, layer systems including an electric isolation of the base
material can be produced. If the parts themselves are also produced by powder metallurgy,
both the metal paste and the part can be sintered in only one manufacturing step.
The most common printing techniques for applying the metal pastes are screen printing and
stencil printing. However, if the desired structures are so fine that they cannot be created by
screen printing, we use specially adapted ink-jet and aerosol printing processes with so-called
functional inks based on metallic nanopowders.
AddIng fUncTIon wITh MeTAl PowderS
Fig. 1: Magnetic nonius structure
produced by printing and sintering
of a magnetic paste.
Fig. 2: Tensile test bar produced
by 2C-MIM; Material combination:
magnetic – not magnetic.
Contact:
Dr. - Ing. Georg Veltl
Phone +49 421 2246 -211
georg.veltl @ ifam.fraunhofer.de
1 2
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The powder metallurgical production of functional surfaces or intelligent structural parts is
based on manufacturing methods that combine metal powders with an organic binder.
Thermodynamic calculations can assist with the choice of materials and powders as well as the
adjustment of process parameters. Please contact us with your ideas on product design and
functional integration. Together, we can improve your products and increase their added value.
Characterization and testing
The materialography and analysis laboratory of Fraunhofer IFAM offers many different methods
to characterize materials and parts. Moreover, data that are relevant for the production
process, such as the viscosity of injection molding feedstocks, thermal capacities or melting
and softening points can be measured. By using EDX and spark spectroscopy, the composition
of materials can be analyzed, while X-ray diffraction allows for the analytical determination of
phase compositions. Impurities such as C, O, N, S are detected by hot-gas extraction analysis.
To analyze those characteristics that are crucial for added functionality of the components,
we use mechanical, thermal, electrical and magnetic measuring methods. For instance, the
properties of soft and hard magnetic materials can be determined by hysteresis measurements.
Gaussmeters and fluxmeters are employed to characterize the magnetic field strength of
components.
Fig. 3: Layer of TiN on stainless steel.
Fig. 4: Strain gauge (produced by
screen printing) with thermocouple
for temperature compensation.
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do you require an individual solution?
Please approach us for the implementation of your ideas on product design and functional
integration. Powder technology offers numerous cutting-edge possibilities to help develop your
product and produce it cost-effectively.
We are an interdisciplinary team of experienced specialists working in fundamental research
as well as under industrial production conditions. We develop ideas and concepts for the
manufacturing of your parts and components – everything, of course, strictly confidential.
our offer includes:
• Developing new parts and processes with powder technological solutions
• Developing parts that feature special combinations of properties and functions
• Process simulation and thermodynamic calculations
• Benchmarking powder metallurgical processes
• Technical and economic studies on parts for new products
• Developing production concepts
• Optimizing processes and enhancing process stability
• Pilot series, technology transfer and staff training
oUr ServIceS
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Contact:
Dr. - Ing. Frank Petzoldt
Phone +49 421 2246 -134
frank.petzoldt @ ifam.fraunhofer.de
w w w. i fa m . f r a u n h o f e r . d e
fraunhofer institute for manufacturing and
advanced materials ifam
managing director
Prof. Dr. - Ing. Matthias Busse
Phone +49 421 2246 -100
matthias.busse @ ifam.fraunhofer.de
Biomaterials Technology
Prof. Dr. - Ing. Kurosch Rezwan, Dr. - Ing. Philipp Imgrund
Phone +49 421 2246 -216
philipp.imgrund @ ifam.fraunhofer.de
Processing and characterizing of biomaterials; injection mol-
ding, extrusion and micro-structuring of metals, bioceramics,
polymers and nanocomposites.
electrical Systems
Dr. - Ing. Gerald Rausch
Phone +49 421 2246 -242
gerald.rausch @ ifam.fraunhofer.de
Electric mobility; electric vehicles; E-motor-test stand up to
100 kW; test stand for batteries up to 50 kWh; driving cycle
analysis; determination of cruising range; system evaluation of
electric powertrain.
functional Structures
Dr. rer. nat. Volker Zöllmer
Phone + 49 421 2246 -114
volker.zoellmer @ ifam.fraunhofer.de
Nanocomposites; nanosuspensions; nanoporous layers;
Functional integration; INKtelligent printing®: ink-jet-printing
and aerosol printing; hybrid materials; specialty equipment.
Casting Technology
Dipl. - Ing. Franz-Josef Wöstmann
Phone +49 421 2246 -225
franz-josef.woestmann @ ifam.fraunhofer.de
Zinc, aluminium and magnesium pressure diecasting; cast iron and
cast steel; cast parts with integrated function (CAST TRONICS®);
lost-foam processes; simulation; rapid prototyping.
materialography and analytics
Dr. - Ing. Andrea Berg
Phone +49 421 2246 -146
andrea.berg @ ifam.fraunhofer.de
Failure analysis; examination of metallographic micrographs;
Powder characterization; scanning electron microscopy with
EDX analysis; thermal analysis; dilatometry; trace analysis;
emission spectrometry.
Powder Technology
Dr. - Ing. Frank Petzoldt
Phone +49 421 2246 -134
frank.petzoldt @ ifam.fraunhofer.de
Powder-metallurgical shaping; metal powder injection molding;
process- and material development; rapid manufacturing;
laser sintering; screen printing; production processes for metal
foam components (FOAMINAL®); simulation.
d r e S d e n B r a n C h L a B
Powder metallurgy and Composite materials
Prof. Dr. - Ing. Bernd Kieback
Phone +49 351 2537-300
Winterbergstraße 28 | 01277 Dresden
www.ifam-dd.fraunhofer.de
Cellular metallic materials
Dr. - Ing. Günter Stephani
Phone +49 351 2537-301
guenter.stephani @ ifam-dd.fraunhofer.de
Fiber metallurgy; high-porosity structures; metallic hollow
sphere structures; open cell PM foams; screen-print structures.
Sinter and Composite materials
Dr. - Ing. Thomas Weißgärber
Phone +49 351 2537-305
thomas.weissgaerber @ ifam-dd.fraunhofer.de
High temperature materials; nanocrystalline materials; materials
for tribological exposure; sputter targets; materials for
hydrogen storage.
oUr coMPeTenceShAPIng And fUncTIonAl MATerIAlS
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w w w. i fa m . f r a u n h o f e r . d e
fraunhofer institute for manufacturing
and advanced materials ifam
Shaping and functional materials
Wiener Strasse 12
28359 Bremen | Germany
Phone +49 421 2246 -0
Fax +49 421 2246 -300
info @ ifam.fraunhofer.de
managing director
Prof. Dr. - Ing. Matthias Busse
Powder Technology
Dr. - Ing. Frank Petzoldt
Phone + 49 421 2246 -134
frank.petzoldt @ ifam.fraunhofer.de
© Fraunhofer - Institut für Fertigungstechnik und
Angewandte Materialforschung IFAM
Formgebung und Funktionswerkstoffe