“Simsalabim” project: progress in sinter-based 3D printing for nickel superalloys

As part of the “Simsalabim” project, the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Dresden, the Dresden University of Applied Sciences (HTW) and the Fraunhofer Institute for Material and Beam Technology (IWS) are developing an end-to-end process chain for the sinter-based 3D printing of nickel superalloys. The project aims to integrate all steps from component design and simulation of the sintering process through to validation on real components. Requirements and feedback from the industry are closely integrated.

Sintering-based additive processes are becoming increasingly important as they solve challenges associated with laser-based processes. While laser processes are technologically mature, they reach their limits with difficult-to-weld materials and complex geometries. Sintering processes avoid complete melting of the metal powder, which reduces thermal stresses and cracking. This makes them particularly attractive for processing high-strength, temperature-resistant nickel alloys, which are used in energy technology, transportation and the hydrogen industry.

Despite their advantages, sintering-based processes lag behind in terms of material properties and accuracy. To improve this, the project is working on digital simulations that predict sintering shrinkage and precisely adjust material properties. The aim is to achieve technology readiness level 5 (TRL 5) through an optimized process chain and to accelerate the development of new materials many times over.

In the long term, the project is intended to serve as the basis for a regional network that promotes the industrial use of this technology. Interested companies are invited to an initial meeting on November 27 and 28, 2024 to contribute specific requirements and applications. The results could also be extended to other materials such as tool steels and cobalt alloys in the future.

With the participating research institutions, a strong network of partners is available to further develop sinter-based 3D printing into a competitive solution for industry.