ResearchActivities

Additive processing of metallic materials

Abstract:
The research focuses on expanding knowledge in additive processing of metallic materials using the Laser Powder Bed Fusion (LPBF) process. It aims to understand the relations between process parameters, microstructure, and mechanical properties of additively processed materials and lattice structures and their effective use for design of components with high added value in aerospace and medical applications.

Main objectives:

  • To process materials for high-temperature applications using laser powder bed fusion (LPBF).

  • To explore LPBF processing of biocompatible and biodegradable materials for medical applications.

  • To describe numerically and experimentally mechanical properties of the lattice structures.

Research content:
Additive processing of metallic materials offers innovative solutions for producing highly complex parts from hard-to-machine metals. A key advantage is the ability to process spatial thin-walled and strut structures that are impossible to achieve using conventional methods. These structures allow for customization of material properties in specific directions or locations due to their high variability and ease of step or gradient shape adjustments, providing opportunities to enhance part performance across a range of applications.

The research focuses on describing the relationships between process parameters, relative density, surface structure, and the mechanical and thermal properties of additively manufactured materials, thin-walled, and strut structures. The aim is to define these relationships to support the industrial scaling of additive manufacturing technologies for advanced components. The research methodology covers the entire production chain—from powder properties and modifications of manufacturing strategies to controlled processing and post-processing, such as heat treatment or surface modification.

Recently, new, industrially unestablished materials have been processed, such as magnesium alloys (WE43, AZ61) and pure metals (copper, iron, titanium). Specific manufacturing parameters and support structures have been fine-tuned for thin-walled aerospace engine components made from temperature-resistant nickel and cobalt alloys (Inconel 718, Inconel 939, CoCr). Aluminium alloys (AlSi10Mg, AlSi7Mg0.6) were also qualified, and aerospace components from these alloys were optimized. The research included computational modelling and adjustment of process parameters for micro-lattice structures made of stainless steel and aluminium alloys.

Significant achievements include identifying plasticity loss in additively manufactured Co-28Cr-6Mo alloy and developing a modified heat treatment to prevent instability at high temperatures. The research also addresses processing of Inconel 939 and pure copper under elevated temperatures, managing LPBF processing of bioresorbable magnesium alloy WE43 and biocompatible titanium alloys. Additionally, the mechanical properties of lattice structures have been thoroughly examined, including optimized manufacturing strategies and validated numerical models.

Through understanding these complex interdependencies, the research aims to optimize additive manufacturing processes, enabling the design and production of components with tailored properties to meet the stringent demands of high-value applications in sectors such as aerospace and medicine.

Publications:
MALÝ, M.; HÖLLER, C.; SKALON, M.; MEIER, B.; KOUTNÝ, D.; PICHLER, R.; SOMMITSCH, C.; PALOUŠEK, D. Effect of Process Parameters and High-Temperature Preheating on Residual Stress and Relative Density of Ti6Al4V Processed by Selective Laser Melting. Materials, 2019, vol. 12, no. 6, p. 1-13. ISSN: 1996-1944.
https://doi.org/10.3390/ma12060930

VRÁNA, R.; JAROŠ, J.; KOUTNÝ, D.; NOSEK, J.; ZIKMUND, T.; KAISER, J.; PALOUŠEK, D. Contour laser strategy and its benefits for lattice structure manufacturing by selective laser melting technology. Journal of Manufacturing Processes, 2022, vol. 74, no. 1, p. 640-657. ISSN: 1526-6125. https://doi.org/10.1016/j.jmapro.2021.12.006

SUCHÝ, J.; KLAKURKOVÁ, L.; MAN, O.; REMEŠOVÁ, M.; HORYNOVÁ, M.; PALOUŠEK, D.; KOUTNÝ, D.; KRIŠTOFOVÁ, P.; VOJTĚCH, D.; ČELKO, L. Corrosion behaviour of WE43 magnesium alloy printed using selective laser melting in simulation body fluid solution. Journal of Manufacturing Processes, 2021, vol. 69, no. 1, p. 556-566. ISSN: 1526-6125. https://doi.org/10.1016/j.jmapro.2021.08.006

Partners and Collaboration:
Czech Academy of Sciences, Institute of Physics of Materials, Žižkova 513/22, 616 00 Brno, Czech Republic.

Central European Institute of Technology, Purkyňova 123, Brno, Czech Republic.

Vienna University of Technology, Institute of Lightweight Design and Structural Biomechanics, Gumpendorfer Straße 7 / Objekt 8, A-1060 Vienna, Austria.

Graz University of Technology, Institute of Materials Science, Joining and Forming, Kopernikusgasse 24/I, 8010 Graz – Austria.

Projects:
MEBioSys – Mechanical engineering of biological and bio-inspired systems, Johannes Amos Comenius programme, CZ.02.01.01/00/22_008/0004634, 2023-2028.

BAANG – Building Actions in Smart Aviation with Environmental Gains, EU-HORIZON EUROPE, HORIZON-WIDERA-2021-ACCESS-03, SEP-210806308, 2022-2025.

Additive Manufacturing of Turbine Engine Components from Heat-Resistant Alloy Inconel 939, Technology Agency of the Czech Republic (TA CR) – ZÉTA applied research support programme, TJ04000314, 2020-2022.

ReMaP – Research of Magnesium Alloys for Additive Manufacturing of Structural and Biomedical parts, Interreg AT-CZ, ATCZ229, 2020-2022.

Structural Biodebradable Implants Processing by Means of Direct Metal Laser Sintering, Ministry of Industry and Trade of the Czech Republic – TRIO, FV20232, 2017-2021

National Competence Centre of Mechatronics and Smart Technologies for Mechanical Engineering, Technology Agency of the Czech Republic (TA CR) – National Centres of Competence 1, TN01000071, 2019-2022.

Architectured Materials Designed for Additive Manufacturing, EU Operational Programme Research, Development and Education, EF16_025/0007304, 2018-2022.

National Competence Centre for Aeronautics and Space, Technology Agency of the Czech Republic (TA CR) – National Centres of Competence 1, TN01000029, 2019-2022

Additive Design for Aerospace Applications Capabilities (ADAAC), contract research, ESA Express Procurement Plus – EXPRO+, AO/1-9018/17/NL/GLC/hh, 2018-2021.

Development of 3D printing for selected materials and topology optimization of components for aerospace industry, Technology Agency of the Czech Republic (TA CR) – EPSILON applied research support programme, TH02010514, 2017-2019.

Contact person:
doc. Ing. Daniel Koutný, Ph.D.