Periodic Reporting for period 3 - SUPREME (Sustainable and flexible powder metallurgy processes optimization by a holistic reduction of raw material resources and energy consumption.)
Periodo di rendicontazione: 2019-03-01 al 2020-12-31
SUPREME aimed at optimising the sustainability of powder metallurgy (PM) processes throughout the value chain. This H2020-SPIRE funded project focused on a combination of fast growing industrial production routes and advanced ferrous and non-ferrous metals. By offering more integrated, flexible and sustainable processes for powder manufacturing and metallic parts fabrication, it enabled the reduction of raw material resource losses while improving energy efficiency and thus carbon dioxide emissions, into sustainable processes and towards a circular economy.
A cross-sectorial integration and optimisation has been designed between several PM processes; gas and water atomisation as well as mechanical alloying for metal powder production, additive manufacturing (AM) and near-net shape technologies for end-parts fabrication. The consortium covered the full value chain from mining to end parts applications. The innovations resulted from the close cooperation between RTD organizations and companies aim a transfer to the market to have significant impact on wealth and jobs creation. SUPREME addressed several key process industries: minerals, ferrous and non-ferrous metals.
Processes optimizations were quantified by a set of Key Performances Indicators (KPI), measured thanks to monitoring systems (IRIS) and validated by an eco-innovation methodology (CEA).
A cross-sectorial integration and optimisation has been designed between several PM processes; gas and water atomisation as well as mechanical alloying for metal powder production, additive manufacturing (AM) and near-net shape technologies for end-parts fabrication. The consortium covered the full value chain from mining to end parts applications. The innovations resulted from the close cooperation between RTD organizations and companies aim a transfer to the market to have significant impact on wealth and jobs creation. SUPREME addressed several key process industries: minerals, ferrous and non-ferrous metals.
Processes optimizations were quantified by a set of Key Performances Indicators (KPI), measured thanks to monitoring systems (IRIS) and validated by an eco-innovation methodology (CEA).
Energy and material flows were quantified for 38 processes (baseline and SUPREME ones). Life cycle assessment (LCA) of these processes allowed to calculate all relevant KPIs and identify the reduction in energy, raw material resources, water, gases and CO2 emissions. A map of the SUPREME PM value chain has been provided (CEA).
10 use-cases representing 20 production routes were studied: a gang saw blade tool for cutting stones (Dellas; Metal Injection Moulding MIM); a motor bracket for aeronautics (WAA; Laser Powder Bed Fusion, L-PBF); 2 medical implants and 2 medical tools (MBA; L-PBF, MIM and Metal Fused Filament Fabrication M-FFF); 2 automotive engine brackets (GKN: L-PBF and RHP: Plasma Metal Deposition, PMD); and mould inserts for injection moulds (IPC; L-PBF). Four demonstrators were monitored in detail: (i) iron ore grinding (Outotec), (ii) gas atomization (ASL), (iii) 3D metal printing (GKN) of automotive bracket (CRF) with 3 different L-PBF machines.
Regarding mineral processing, significant improvements were reached without compromising the production rate or end-product quality: 1.2% reduction of grinding energy consumption (2400 kWh reduction annually for an average plant), 89% reduction of water consumption, 9.9 kt reduction of CO2 emissions per year for 3 concentrator plants. A huge potential for further energy savings around the world is expected.
Regarding powder production, KPIs were quantified for gas atomization (GA), water atomization (WA) and high energy ball milling (HEBM). To produce GA AM + MIM powder by using SUPREME atomizer, the resulting energy & gas consumption, powder yield and production rate could be improved by 33.8 %, 35.7 %, 66.1 % and 90.5 %, respectively. A 62% reduction of energy consumption based on the use of WA powder instead of GA powder was obtained. To produce MIM powder by using optimized HEBM process, the powder yield, production rate and CO2 emissions could be improved by 53%, 71% and 32%, respectively.
SUPREME helped ASL to identify the main energy losses, thus acting directly in the factory to save >15% of energy consumption. This directly affects the production price of the AM and MIM powders. GKN-Hoeganaes has gained knowledge on usage of low-cost WA ferrous alloys powders for several processes. MBN is the first material producer able to offer high quality and added value Fe-based powder to the diamond tool market.
Regarding metal AM, a dozen times re-use of L-PBF powders, without any impact on mechanical properties and with a 95% recovery rate, was shown. KPIs were quantified for L-PBF, PMD and Laser Metal Deposition (LMD) processes. Compared to the baseline, build time of an automotive L-PBF engine bracket was reduced by 51 % and production rate increased by 1050 %. Nitrogen consumption was reduced by 21.6% (GKN). GKN offers now to the market lightweight L-PBF topologically optimized >99% Hard Carbon Steels parts with detailed datasheets. LMD process optimization with HC22 superalloy (TWI) resulted in a 500% improvement of productivity and an 83% reduction in argon consumption. PMD process optimizations with WA 17-4PH steel (RHP) led to a 100% increase in the deposition rate with same mechanical performances. Regarding the aeronautics topologically optimized bracket (WAA), after slightly more than one year of flight, the impact cost in terms of CO2 emissions due to the L-PBF process will be compensated by CO2 savings in flight compared to the initial baseline part. L40 steel moulding tools (IPC) achieved a 31% reduction in material yield losses, a 14% improvement in energy efficiency, a >230% increase in production rate and a >30% reduction in CO2 emissions after 6000 parts injected.
Regarding the MIM process, Fe-based raw material usage was reduced by 35% thanks to use of scrap materials (sprues) and L-PBF powder. A 100% reutilization of sprues and a reduction of the amount of rejected parts was proved (CEA & IDONIAL). Good quality Co-free diamond cutting tools were obtained and the process optimisation led to fully dense parts with properties comparable to the commercial counterparts (Tecnalia). Thanks to MIM, 97% and 82% reduction in energy consumption were obtained for Fe-based medical use-cases and diamond composites, respectively. CO2 emissions were reduced by 97% and by 83%, respectively. Compared to the current sintering process, MIM process of cutting tools (Dellas) achieved a 5% reduction in material yield losses, a 35% improvement in energy efficiency, a 25% increase in production rate and a 33% reduction in CO2 emissions.
Regarding the medical use-cases studied (MBA), the overall results are: a 36% reduction of raw material yield losses; a 72% reduction in energy consumption; a 5444% increase of production rate and a 52% reduction in CO2 emissions compared to baseline processes.
Regarding the HIP process (TWI), the sub-marine part use-case demonstrated a 75% improvement of the buy-to-fly ratio and an important energy saving.
SUPREME was promoted through various materials (website, EPMA newsletter, 6 SUPREME Newsletters, Conferences & Exhibitions…). Three training sessions were given (EPMA Summer School 2019, PM Life AM module 2019, Experts Training workshop 2020). Many technical papers were published: most of them were presented at Euro PM 2019 and 2020, others were accepted by peer-reviewed journals.
10 use-cases representing 20 production routes were studied: a gang saw blade tool for cutting stones (Dellas; Metal Injection Moulding MIM); a motor bracket for aeronautics (WAA; Laser Powder Bed Fusion, L-PBF); 2 medical implants and 2 medical tools (MBA; L-PBF, MIM and Metal Fused Filament Fabrication M-FFF); 2 automotive engine brackets (GKN: L-PBF and RHP: Plasma Metal Deposition, PMD); and mould inserts for injection moulds (IPC; L-PBF). Four demonstrators were monitored in detail: (i) iron ore grinding (Outotec), (ii) gas atomization (ASL), (iii) 3D metal printing (GKN) of automotive bracket (CRF) with 3 different L-PBF machines.
Regarding mineral processing, significant improvements were reached without compromising the production rate or end-product quality: 1.2% reduction of grinding energy consumption (2400 kWh reduction annually for an average plant), 89% reduction of water consumption, 9.9 kt reduction of CO2 emissions per year for 3 concentrator plants. A huge potential for further energy savings around the world is expected.
Regarding powder production, KPIs were quantified for gas atomization (GA), water atomization (WA) and high energy ball milling (HEBM). To produce GA AM + MIM powder by using SUPREME atomizer, the resulting energy & gas consumption, powder yield and production rate could be improved by 33.8 %, 35.7 %, 66.1 % and 90.5 %, respectively. A 62% reduction of energy consumption based on the use of WA powder instead of GA powder was obtained. To produce MIM powder by using optimized HEBM process, the powder yield, production rate and CO2 emissions could be improved by 53%, 71% and 32%, respectively.
SUPREME helped ASL to identify the main energy losses, thus acting directly in the factory to save >15% of energy consumption. This directly affects the production price of the AM and MIM powders. GKN-Hoeganaes has gained knowledge on usage of low-cost WA ferrous alloys powders for several processes. MBN is the first material producer able to offer high quality and added value Fe-based powder to the diamond tool market.
Regarding metal AM, a dozen times re-use of L-PBF powders, without any impact on mechanical properties and with a 95% recovery rate, was shown. KPIs were quantified for L-PBF, PMD and Laser Metal Deposition (LMD) processes. Compared to the baseline, build time of an automotive L-PBF engine bracket was reduced by 51 % and production rate increased by 1050 %. Nitrogen consumption was reduced by 21.6% (GKN). GKN offers now to the market lightweight L-PBF topologically optimized >99% Hard Carbon Steels parts with detailed datasheets. LMD process optimization with HC22 superalloy (TWI) resulted in a 500% improvement of productivity and an 83% reduction in argon consumption. PMD process optimizations with WA 17-4PH steel (RHP) led to a 100% increase in the deposition rate with same mechanical performances. Regarding the aeronautics topologically optimized bracket (WAA), after slightly more than one year of flight, the impact cost in terms of CO2 emissions due to the L-PBF process will be compensated by CO2 savings in flight compared to the initial baseline part. L40 steel moulding tools (IPC) achieved a 31% reduction in material yield losses, a 14% improvement in energy efficiency, a >230% increase in production rate and a >30% reduction in CO2 emissions after 6000 parts injected.
Regarding the MIM process, Fe-based raw material usage was reduced by 35% thanks to use of scrap materials (sprues) and L-PBF powder. A 100% reutilization of sprues and a reduction of the amount of rejected parts was proved (CEA & IDONIAL). Good quality Co-free diamond cutting tools were obtained and the process optimisation led to fully dense parts with properties comparable to the commercial counterparts (Tecnalia). Thanks to MIM, 97% and 82% reduction in energy consumption were obtained for Fe-based medical use-cases and diamond composites, respectively. CO2 emissions were reduced by 97% and by 83%, respectively. Compared to the current sintering process, MIM process of cutting tools (Dellas) achieved a 5% reduction in material yield losses, a 35% improvement in energy efficiency, a 25% increase in production rate and a 33% reduction in CO2 emissions.
Regarding the medical use-cases studied (MBA), the overall results are: a 36% reduction of raw material yield losses; a 72% reduction in energy consumption; a 5444% increase of production rate and a 52% reduction in CO2 emissions compared to baseline processes.
Regarding the HIP process (TWI), the sub-marine part use-case demonstrated a 75% improvement of the buy-to-fly ratio and an important energy saving.
SUPREME was promoted through various materials (website, EPMA newsletter, 6 SUPREME Newsletters, Conferences & Exhibitions…). Three training sessions were given (EPMA Summer School 2019, PM Life AM module 2019, Experts Training workshop 2020). Many technical papers were published: most of them were presented at Euro PM 2019 and 2020, others were accepted by peer-reviewed journals.
SUPREME results may impact several industries (Oil & Gas, machine production, space, energy…). In addition, the monitoring experience could also tackled several other industries (food, chemistry…).
The whole European PM industry (€11.6bn turnover, 233kt of powder produced and 232kt of PM parts produced in 2019) should also be impacted. Progressively, several parts produced today by casting or machining will be produced by AM processes with optimized geometries. For example, the Ferrous Structural Parts Industry using mainly the Press and Sinter process (63% of the 2019 PM parts produced) will likely invest in more AM processes, generating significant revenues in the future (AM parts were <1% of the 2019 total PM parts produced).
The whole European PM industry (€11.6bn turnover, 233kt of powder produced and 232kt of PM parts produced in 2019) should also be impacted. Progressively, several parts produced today by casting or machining will be produced by AM processes with optimized geometries. For example, the Ferrous Structural Parts Industry using mainly the Press and Sinter process (63% of the 2019 PM parts produced) will likely invest in more AM processes, generating significant revenues in the future (AM parts were <1% of the 2019 total PM parts produced).