RESIST

Conify’s Involvement:

The innovative approach involves the utilization of AM, diverging from conventional methods such as casting, forging, and machining. By opting for novel duplex stainless steel feedstock for LPBF, the project not only aims to enhance performance and durability but also addresses sustainability concerns associated with higher energy consumption and material waste inherent in traditional manufacturing methods (casting and forging). This project introduces a forward-thinking paradigm shift, emphasizing the project’s commitment to efficiency, environmental consciousness, and cutting-edge manufacturing techniques.
It aims at establishing a methodology for introducing a new DSS alloy grade in the MTA sector qualified for AM.

Conify’s Approach

The triparty partnership of 3DC, AMAZEMET and CONIFY will focus on the development of novel Duplex Stainless Steel powder feedstock for LPBF. The high-quality feedstock material will be produced through ultrasonic atomisation utilising the available wire feedstock (AMAZEMET). Critical processing parameters such as laser power, scanning speed, hatching spacing, layer thickness will be identified to attain highest densification (CONIFY). The impact of scanning strategies and tuning of heat input on the resulting microstructure and mechanical properties will be studied experimentally (CONIFY, 3DC) and numerically (3DC) to establish a reliable process dataset and ensure the properties of the DSS. Two demonstrator cases will be designed and developed using advanced CAD/CAM and finite element analysis (3DC) to showcase the outcome of the project. Potential applications include automotive parts subjected to increased temperatures or corrosive conditions and extreme shearing/bending forces (catalytic converters, wheel hubs, suspension parts etc.) as well as hydrogen/LNG storage pressure vessels, hydrogen-resistant impeller materials for hydrogen compression stations and energy product pipeline transportation components (gas tubes, fittings, flanges, fasteners, springs, etc.). Selected demonstrator cases will be manufactured via LPBF and inspected for their dimensional accuracy; an ASME B16.5 flange for pipeline and road transportation sector and a multi-purpose metal catalytic converter scaffold for generic MTA sector.

RESIST REsilience through Sustainable processes and production for the European automotive InduStry