We develop novel structural and functional alloys as well as composites by combining computer simulations with sophisticated experiments. A special emphasize is on the design of alloys for additive manufacturing. Our activities cover mainly, but not exclusively, the following materials classes:

• High-strength Ni, Al and Ti alloys and structural intermetallics (e.g γ-TiAl)

• Oxide dispersion strengthened (ODS) alloys and (nano-) composites

• Precious metal alloys

• Shape memory alloys

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Figure 1: Fe–Mn–Si shape memory alloy fabricated by LPBF [1].

[1]        I. Ferretto, D. Kim, N.M. Della Ventura, M. Shahverdi, W. Lee, C. Leinenbach, Laser powder bed fusion of a Fe–Mn–Si shape memory alloy, Additive Manufacturing 46 (2021) 102071. https://doi.org/10.1016/j.addma.2021.102071.

Controlling the microstructure in metal additive manufacturing (AM) is essential for optimizing the mechanical properties and performance of printed parts. Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) offer inherent advantages in tailoring the microstructure, enabling site-specific or gradient structures. Grain size, orientation, phase distribution, and material composition can be locally manipulated by adjusting processing parameters such as scan speed, laser power, scan strategy, and powder composition. Our research focuses on advanced microstructure control strategies to enhance the properties of metals, improving their performance in complex applications.
 

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Figure 2: Tailoring microstructure of FeMnSi-based shape memory alloys during LPBF [1]

[1]  Ferretto et al., Fabrication of FeMnSi-based shape memory alloy components with graded-microstructures by laser powder bed fusion, Additive Manufacturing 78 (2023) 103835. https://doi.org/10.1016/j.addma.2023.103835.

We develop and produce our own advanced engineered powders dedicated to additive manufacturing for fabricating 3D materials with site specific and improved properties.

Advanced alloy powders are produced using an atomization approach. A thermal plasma process allows for functionalisation of powders, i.e. spheroidization for improved flowability, surface curing and purification, decoration process with nanoparticles. Blending of metal particulate materials with nanoparticles is additionally performed in high energy ball mills.
 

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Figure 3: Atomization facilities for powder production.