www.nanotune3d.

eu Development of EIGA bars for producing powder

particles of Ti6Al4V nanomodified by gas atomization
(NANOTUN3D European Project)
H. Zoz1, D. Yigit1, A. F. Roiz2, J. M. Martín2, W. G. Vargas3
1Zoz
GmbH, D-57482 Wenden, Germany
2Centro de Estudios e Investigaciones Técnicas (CEIT-IK4), ES-20018 Donostia-San Sebastian, Spain
3TLS Technik GmbH & Co Spezialpulver KG, D-06749 Bitterfeld-Wolfen, Germany

Development of nano-based Materials for Metal Additive Manufacturing and Characterisation of their Operative Life Cycle
The European project NANOTUN3D aims to improve the mechanical performance of Ti-6Al-4V alloys with an effective dispersion of core-shell SiC nanoparticles and to
PM routes process the improved alloy by additive manufacturing. One of the objectives is to manufacture a spherical nanocomposite powder (SiC nanoparticles reinforced Ti64 matrix)
by EIGA (Electrode Induction melting Gas Atomization) process.
to get
TMNCs The raw material of the EIGA process is a bar of the nanocomposite material. Non-spherical nanocomposite powders of SiC reinforced Ti64 are manufactured at Zoz GmbH
using a roll-mill RM1, and especially the Simoloyer® CM01 equipment, a design for High Kinetic Processing (HKP). The nanocomposite powder was shaped into bars
ingot / bar following two methodologies. Samples were hot pressed into an EIGA bar of 55 mm diameter at 500°C for 5 min and 1000 MPa at Zoz GmbH. Bars of 40 mm in diameter
and 400 mm in length were consolidated by Hot Isostatic Pressing (HIP) at 700ºC for 60 min and 120 MPa at CEIT.
Whereas the roll-milled samples only yield broken SiC agglomerates uniformly distributed over the surface of Ti64 particles, the HKP samples show a good dispersion of
the nanoparticles within the Ti64 matrix. SiC did not react with the Ti alloy. A longer milling time for HKP improves the homogeneity, but also leads to higher Fe
contamination from milling media.
It can be concluded that HKP leads to well-dispersed SiC nanoparticles in the Ti64 alloy. The obtained nanocomposite powder could be shaped into EIGA bars by both hot
EBM press and HIP.
POWDER
BATCH
PROCESS PARAMETERS: POST PROCESSES FEASIBILITY Matrix:
• Heat treatments: STUDY
EBM AND SLM
 Stress Relief
 Ti-6Al-4V (+100 µm)
 HIP Nanomaterials:
 Annealing  SiC
EIGA PROCESS two
powder
• Thermomechanical  SiC coated with TiO2 (TiO2@SiC)
treatments:
batches  Shoot peening
 Y2O3
GAS ATOMISED PROCESS
 Laser peening
DIE design GSV simulation
• Machining

SLM
POWDER
BATCH final part
design

Safety and Risks related to Nanoparticles Handling

Composite –Ti6Al4V Powders for Additive Manufacturing with Respect to Industrial Scales

NARA HYBRIDISER
EIGA PROCESS

Technical Data
Bar diameter 30-90 mm
Bar length 200-700 mm
Production capacity 150 t/a
PLASMA SPHERIODIZATION
Physical properties of Ti6Al4V powders Gas Argon
EBM (45-100 µm) SLM (25-45 µm) Gas pressure 20-35 bar
Flowability 30 s/50g 35 s/50g High flowability for EBM / SLM inevitably  Batch size 5 kg – 1 t
Apparent density 2,3 g/cm³ 2,2 g/cm³ spherical particles necessary Mean particle size d50 55-70 µm

Powder atomization via EIGA at TLS Technik

Pre-Processing: Distribution of Nanoparticles by Mixing / Milling

High Kinetic Processing (HKP)

 Mechanical Alloying (MA) 24 Ti + Al11Nb → Ti24Al11Nb

@ ZOZ
 High Energy Milling (HEM) Efficient blending and distribution
rapid flake formation @ CEIT
rapid particle size reduction
Powder ready to use for
 Reactive Milling (RM) Ag3Sn + 2 Ag2O → 7 Ag + SnO2 Simoloyer® CM100
(100 litres volume)
pre-consolidation
scalable process from 1 to 900 litres process volume

@ ZOZ

highly
dispersed
nanoparticles Polished section of pre-
processed powder
SEM @ CEIT
Pre- consolidation by Hot Isostatic Pressing (HIP) or Hot Extrusion (HE)

canister sealed canister HIP press Final EIGA bars

HIP and machining at CEIT HE of bars at ZOZ

 6 bars (2 per composition, ≈400 mm in length x 40 mm in diameter), HIP cycle: 700ºC/ 1h/ 120 MPa  7 bars (≈100-120 mm in length x 55 mm in diameter)
 No need of welding to prepare full size bars  30 min pre-heating, 400 g powder load, 500°C press temp., 380 bar pressure

Suitable EIGA Electrode – Welding of hot extruded bars

minØ/maxØ Target : increase the length for an effective EIGA process
40/80 mm
standardØ: 55mm  length: approx. 400 mm
 diameter: 45 - 55 mm
 weight: 2.5 - 3 kg
preparation of single electrode elements by lathe
min/max 300/700 mm

utilizing alternating current (AC) instead of direct current (DC) because

of stable oxide layers electrode welding
parameters for welding:
 AC current: 140A
 inter gas: 10-12 litres Argon 5.0
 electrode: 2mm Grade 5 (Ti-6-4)
improving by dot/point welds instead of full lines in regard to
Ti64+SiC np powder atomized at TLS 60°
contaminants

Consortium