Antusch, S.

Piotter, V.

KITopen

KIT-IAM1 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATIONKarlsruhe Institute of Technology (KIT)Institute for Applied MaterialsMaterial Process TechnologySteffen Antusch, Volker PiotterChallenges to Developing W-Based Materials for Fusion Applications University of California Santa Barbara February 13 – 15, 2012KIT-IAM2 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012• Motivation• What is Powder Injection Molding (PIM)?• The PIM process for tungsten developed at KIT• Material development for PIM• 2-Component tungsten PIM• Summary & OutlookOutlineKIT-IAM3 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Future fusion power reactor DEMOMotivationOne promising divertor design – developed at KITP. Norajitra et al., KIT. KIT-IAM4 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012 1 Finger-module – 3 main parts 2 – 3 several materials 2 brazed joints assembling, adjustment… DEMO: nearly 300.000 mockups lifetime nearly 2 years Reasonable manufacturing method?MotivationKIT-IAM5 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Advantages Cost-effective mass production Producing of 3D-parts Metal forming of tungsten based materials complicatedChallenges Adequate powders /  powder mixtures preparation / feedstock development Heat-treatment process High density Low porosityWhat is Powder Injection Molding (PIM)?PIM – Powder Injection Molding: manufacturing technology MIM – Metal Injection Molding CIM – Ceramic Injection MoldingKIT-IAM6 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012What is Powder Injection Molding (PIM)?KIT-IAM7 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KITKIT-IAM8 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KIT1. PowderSEM Microstructure tungsten powder W1 SEM Microstructure tungsten powder W2KIT-IAM9 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KIT2. Feedstock development - kneadingKIT-IAM10 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KIT3. Injection Molding of green partsKIT-IAM11 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KIT4. Heat-treatment process (1)KIT-IAM12 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Density >95% - closed porosity!!!Vickers-hardness 420 HV0.1The PIM process for tungsten developed at KIT4. Heat-treatment process (2)S. Antusch et al., J. Nucl. Mater. 417 (2011) 533-535. only pre-sintering pre-sintering + HIPDensity >98%Vickers-hardness 457 HV0.1SEM Microstructure pre-sintering W SEM Microstructure pre-sintering +HIP WKIT-IAM13 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KITKIT-IAM14 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012The PIM process for tungsten developed at KIT5. Tungsten PIM samplesGreen parts (dark) and finished parts (bright)KIT-IAM15 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012SEM image of the fracture surface: no porosity or cracksHeat-treatment process: - pre-sintering (1800 °C, 2 h, H2) + - HIP (2100 °C, 3 h, Ar, 250 MPa)Properties of the finished material:Vickers-hardness: 457 HV0.1Density: 98.6 – 99 % TDThe PIM process for tungsten developed at KIT5. The divertor W PIM part „tile“S. Antusch et al., Fusion Engineering and Design, 86 (2011) 1575-1578. KIT-IAM16 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012 Fabrication of the W PIM tile successful Joining via brazing of W PIM tile and W-alloy thimble (produced by mechanical machining)The PIM process for tungsten developed at KIT…joining… Mass production process? Courtesy of L. Spatafora (Bachelor Thesis 2010) KIT-IAM17 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012 Material produced by mechanical alloying (2 h, n-Hexane, ZrO2 balls + bowl)W-2La2O3W-2Y2O3Mill and equipment grinding bowlgrinding ballsMaterial development for PIMPIM parts (small discs) producedHeat-treatment:- pre-sintering (1800 °C, 2 h, H2) +- HIP (2100 °C, 3 h, Ar, 250 MPa)KIT-IAM18 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012W-2La2O3SEM Microstructure (fracture surface) SEM Microstructure (metallographic section)A selection of La2O3-particles is marked by arrows...Material development for PIMKIT-IAM19 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012W-2Y2O3SEM Microstructure (fracture surface) SEM Microstructure (metallographic section)A selection of Y2O3-particles is marked by arrows...Material development for PIMKIT-IAM20 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.20122-Component tungsten PIMS. Antusch et al., Fusion Science and Technology (2012) submitted. Pretests via insert 2-Component PIM:  W + W-2La2O3 / W + W-2Y2O3 PIM samples produced + characterized Heat-treatment:- pre-sintering (1800 °C, 2 h, H2) +- HIP (2100 °C, 3 h, Ar, 250 MPa)Material produced by mechanical alloyingKIT-IAM21 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Pretests via insert 2-Component PIM:W + W-2La2O3 Joining seam: without cracks or gaps  Material connecting successful black: La2O3red: WSEM Microstructure (fracture surface) AES Map (metallographic section)2-Component tungsten PIMKIT-IAM22 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Pretests via insert 2-Component PIM:W + W-2Y2O3 Joining seam: without cracks or gaps  Material connecting successful black: Y2O3red: WSEM Microstructure (fracture surface) AES Map (metallographic section)2-Component tungsten PIMKIT-IAM23 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012 Design and Engineering of a fully automatic2-Component PIM toolKnowledge transfer - from pretests to real 2-Component Powder Injection Molding process: material combination, heat-treatment process, shrinkage… Tile and thimble in one unit with / without joining layer Joining of 2 different materials without brazing in 1 process step2-Component tungsten PIMKIT-IAM24 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Bicolor plastic test samples to demonstrate the functionality of the new tool2-Component tungsten PIM…first samples…KIT-IAM25 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012 1-finger mockup produced via 2-Component W PIM feasibility study / demonstration of joining via 2-Component W PIM Implementing of the new 2-Component PIM tool  Producing of 2-Component PIM parts: W tile + W-2La2O3 timble W tile + W-2Y2O3 thimble Adaption of the Heat-treatment process Characterization (density, hardness, quality of the joining zone…)Goals for 20122-Component tungsten PIM…next steps….KIT-IAM26 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Summary• Material & process development for W PIM at KIT• Development of a suitable W feedstock: W1 + W2 (50:50) 50 vol.%• Optimization of the heat-treatment process: pre-sintering + HIP• Producing of W PIM parts Properties of the finished divertor part W tile: Density: 98.6 – 99 % T.D. Vickers-hardness: 457 HV0.1 Microstructure without porosity or cracks• Development of new W PIM materials:W-2La2O3W-2Y2O3• Pretests via insert 2-Component W PIM Investigation of the joining zone quality: Joining seam: without cracks or gaps Material connecting successful• Design & Engineering of a new fully automatic 2-Component W PIM toolKIT-IAM27 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Outlook• Establish 2-Component tungsten Powder Injection Molding at KIT• Development of new materials for multicomponent W PIM• Material characterization: Charpy and tensile tests High Heat Flux Tests (IPP Garching / FZ JülichPowder Injection Molding: Mass production & joining process Time & cost effective near-net-shape forming process Shape complexity and high final densityKIT-IAM28 Steffen Antusch – TUNGSTEN POWDER INJECTION MOLDING, TUNGSTEN ARMOR, MOCKUP FABRICATION11.06.2012Thank you very much!

Tungsten powder injection molding, tungsten armor, mockup fabrication

https://publikationen.bibliothek.kit.edu/230087012/3816073

Tungsten powder injection molding, tungsten armor, mockup fabrication

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