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3D structures by spark plasma sintering
The D-MAVT Advanced Manufacturing Lab (am|z) performs internationally leading research in the field of manufacturing engineering. A recent research focus is put on sustainable manufacturing and low-waste production. Near-net shaping of materials which cannot be processed via the melt state, such as high-performance wrought aluminium alloys (e.g., AA7075) could benefit many applications for weight reduction. For a new research project together with sallea (D-MATL) and inspire, we are looking for a motivated student
Motivation
Some additive manufacturing methods like e.g., laser powder bed fusion LPBF, are unsuitable for high-performance wrought aluminium alloys, causing hot cracks and yielding low mechanical properties. Components from these alloys have therefore to be milled, causing large amounts of scrap (up to 95%).
We aim to reduce manufacturing costs and waste by pre-shaping the partly finished components in a sintering process. For this purpose, the ultra-fast spark plasma sintering (SPS) will be employed. This sintering technique usually yields cylindric semifinished parts that need to be further processed.
New 3D process
For the purpose of near-net-shaping the sintered components, a new process is in development at inspire together with am|z and sallea. In this project, you will work with space holder materials such as salt (NaCl) for pre-shaping sintered PM specimens. Salt is an ideal space holder material, or mold material, for materials that are processed below 750°C. It is well-known (e.g., as cores in permanent mold casting of Al) and easily removable. Sallea provides precise salt structures via their SAL process.
With your help, we will build on previous work (e.g., Al/salt co-sintering) to quickly yield exemplary geometries to assess the potential of this new 3D manufacturing process. Full material characterization (density, mechanical properties, microstructure) will show the suitability of the manufacturing process for lightweight components
Motivation Some additive manufacturing methods like e.g., laser powder bed fusion LPBF, are unsuitable for high-performance wrought aluminium alloys, causing hot cracks and yielding low mechanical properties. Components from these alloys have therefore to be milled, causing large amounts of scrap (up to 95%). We aim to reduce manufacturing costs and waste by pre-shaping the partly finished components in a sintering process. For this purpose, the ultra-fast spark plasma sintering (SPS) will be employed. This sintering technique usually yields cylindric semifinished parts that need to be further processed.
New 3D process For the purpose of near-net-shaping the sintered components, a new process is in development at inspire together with am|z and sallea. In this project, you will work with space holder materials such as salt (NaCl) for pre-shaping sintered PM specimens. Salt is an ideal space holder material, or mold material, for materials that are processed below 750°C. It is well-known (e.g., as cores in permanent mold casting of Al) and easily removable. Sallea provides precise salt structures via their SAL process. With your help, we will build on previous work (e.g., Al/salt co-sintering) to quickly yield exemplary geometries to assess the potential of this new 3D manufacturing process. Full material characterization (density, mechanical properties, microstructure) will show the suitability of the manufacturing process for lightweight components
Tasks
• Assisting the salt mold fabrication by stereolithography at sallea (CAD, salt preparation, DLP)
• Specimen production using a spark plasma sintering machine at am|z
• Specimen analysis (dimensions, microstructure, density, roughness, mechanical properties)
• Written report and presentations (interim and final)
You will work with an interdisciplinary team from materials and mechanical engineering departments. You will work on an entirely new 3D manufacturing process, which can be of great interest to the manufacturing industry.
Interest in circular economy, materials science and analysis, and advanced manufacturing is required.
A hands-on and experimental attitude is needed. No specific knowledge with manufacturing systems is necessary.
Start immediately or upon agreement
Tasks • Assisting the salt mold fabrication by stereolithography at sallea (CAD, salt preparation, DLP) • Specimen production using a spark plasma sintering machine at am|z • Specimen analysis (dimensions, microstructure, density, roughness, mechanical properties) • Written report and presentations (interim and final)
You will work with an interdisciplinary team from materials and mechanical engineering departments. You will work on an entirely new 3D manufacturing process, which can be of great interest to the manufacturing industry.
Interest in circular economy, materials science and analysis, and advanced manufacturing is required. A hands-on and experimental attitude is needed. No specific knowledge with manufacturing systems is necessary.