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Case Study

Case Study List

Enhancing the mechanical properties and corrosion resistance…

“Material Research with InssTek” - Title : Enhancing the mechanical properties and corrosion resistance of commercially pure titanium using tungsten carbide composites fabricated via additive manufacturing - Summary : • This study investigates the fabrication of CP Ti-WC MMC using InssTek's Technology and explores the effect of the WC content on the microstructure, mechanical properties, and corrosion resistance. • The addition of WC to CP Ti matrix composites fabricated using the DED, mechanical properties(hardness & tensile strength) and corrosion resistance of CP Ti were enhanced. • The results from this study show that CP Ti-(1–5 %) WC samples produced with DED exhibit superior combinations of strength and ductility compared to those of conventionally processed composites. Reference: ????https://lnkd.in/dvi_dvtW

LFM2 - Automatic Zoom Optics Printing Test

InssTek’s LFM-2 Technology Benefits: - Various beam sizes with automatic lens position adjustment - Save manufacturing time and adjust the fineness. • Case 1 (Pyramid): We printed the pyramid by changing the beam size to SDM 2400, 1600, 1200, and 800. → By changing the beam size, rough or smooth structures can be printed. • Case 2 (Cooling channel): We printed 2 cooling channels of the same shape using the beam size of SDM 800 / SDM 800 + SDM 1600 respectively. - Cooling channel with SDM 800: 20hrs 45min - Cooling channel with SDM 800 + SDM 1600: 14hrs 31min → Deposition time was saved about 30%.

"Hf-Modified Ni-Based Superalloy: Hot Cracking Prevention"

“Microstructural evolution and hot cracking prevention in direct-laser-deposited Ni-based superalloy through Hf addition(2023)” #Material_Research_with_InssTek - link: https://www.sciencedirect.com/science/article/pii/S026412752300713X - Highlights • This study revealed the Hf-driven microstructural changes and mechanism to prevent hot cracking in IN738 by using InssTek’s Technology • The addition of 2.5 wt% of Hf suppressed the hot cracking by modified microstructures in DEDed non-weldable Ni-based superalloy. • The results from this study provide suggestions on how hot cracking could be prevented through microstructural changes, which could be applied to other potential alloying trials for hot cracking prevention. * Written referring to the study For more information  http://insstek.com

Metal DED AM HS Modeling and RSA

Heat Source Modeling and Residual Stress Analysis for Metal Directed Energy Deposition Additive Manufacturing - Highlights • This study evaluating heat source model for single and multi-track deposition by using InssTek's DMT Technology • The concentrated heat source does not require melt pool dimension measurement for thermal model simulation. Thus, it reduces the considerable time for preprocessing. • A good agreement was noticed for the concentrated heat source model melt pool, with an experimentally determined melt pool, using an optical microscope. * Written referring to the study

Functionally Graded Material Rocket Nozzle

“Functionally Graded Material Rocket Nozzle” The field of aerospace is an extreme environment. Each part of the Rocket Nozzle requires different characteristics. Recently InssTek successfully manufactured FGM Rocket Nozzle and proceed post-process. We have used our internal technology for the entire process, from testing for each alloy to obtaining process variables to designing and actual printing. ✔️Material: - Top: Al-Bronze - Bottom: SS316L ✔️Size: - Diameter: 420 mm - Height: 552 mm ✔️Deposition Time - 32 Hours

Aluminium Alloy & Aluminium + Ceramic MMC Wear Test

“Aluminium Alloy & Aluminium + Ceramic MMC Wear Test” The possibility of Aluminum manufacturing using InssTek's DED technology was studied. Pure Aluminum, Aluminum Alloy and Aluminum MMC were tested and their characteristics were compared through Wear Test. ✔️Test: - The ball on Disc Test was performed at 5 kgf / 30 min / 50 rpm with InssTek’s DED technology. ✔️Material: Pure Al Al 4000 series Al 6000 series Al + Al2O3 (MMC) ✔️Result: - The Friction Coefficient value of the aluminum + ceramic MMC was similar to the aluminum alloy. - Wear Quantity showed the best results than pure Al and Al-based alloys.

Processing of Niobium-Alloyed High-Carbon Tool Steel via Add…

“Processing of Niobium-Alloyed High-Carbon Tool Steel via Additive Manufacturing and Modern Powder Metallurgy – Materials(2023)” - Highlights • This research adopted InssTek`s DED process to fabricate Niobium-Alloyed High-Carbon Tool Steel and compared it with modern method (Spark Plasma Sintering) • This work explores the potential of additive manufacturing for processing Nb-alloyed tool steel with a high content of carbon. • The hardness and wear resistance of the additively manufactured material was slightly higher than the Spark Plasma Sintered one. * Written referring to the study

Wear behavior of aluminum-matrix particle (TiH2 and ZrH2)

“Wear behavior of aluminum-matrix particle (TiH2 and ZrH2)-reinforced composite foam additively manufactured using directed energy deposition – Journal of Materials Research and Technology 25(2023)” - Highlights • This research adopted InssTek`s DED process to fabricate aluminum-matrix particle-reinforced composite form by   adding TiH2 and ZrH2 to AlSi10Mg. • Owing to the intermetallic compound formed upon the reaction between AlSi10Mg and foaming agent,   only a part of the aluminum matrix was removed due to wearing. • Wear test results showed that the deposited AlSi10Mg fabricated with ZrH2 had the best wear resistance.

Damage Evolution Simulations

“Damage Evolution Simulations via a Coupled Crystal Plasticity and Cohesive Zone Model for Additively Manufactured Austenitic SS 316L DED Components – Metals 2022” - Highlights • This study represents damage simulation for SS316L using DED additive manufacturing using InssTek's DMT Technology. • Regarding the impact of the number of melt pools on the tensile properties, melt pool size controlling can be prone as a significant way to achieve the required features. • The proposed methodology is expected to yield satisfactory outcomes in dealing with the grain morphology and melt pool size effects on the mechanical behavior, and it is believed that it will provide complementary insights into the material design concept and pave the way for the broader use of DED in the industry. Reference: Metals is an international, peer-reviewed, open access journal published monthly online by MDPI.