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

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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