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PEOPLE@HES-SO – Annuaire et Répertoire des compétences

PEOPLE@HES-SO
Annuaire et Répertoire des compétences

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Rodriguez Arbaizar Mikel

Rodriguez Arbaizar Mikel

Adjoint-e scientifique HES A

Compétences principales

Powder Metallurgy

Powder characterization

SLM & Binder Jetting 3D-Printing

Materials characterization

Advanced Materials

Functional materials

Powder Injection Moulding

  • Contact

  • Recherche

  • Publications

  • Conférences

Contrat principal

Adjoint-e scientifique HES A

Bureau: ENP.23.N115

HES-SO Valais-Wallis - Haute Ecole d'Ingénierie
Rue de l'Industrie 23, 1950 Sion, CH
HEI - VS
Domaine
Technique et IT
Filière principale
Systèmes industriels
Aucune donnée à afficher pour cette section

Terminés

S19_Powder Technology & Advanced Materials
AGP

Rôle: Collaborateur/trice

Financement: VS - Institut Systèmes industriels

Description du projet : Projet destiné à l'acquisition de nouveaux projets et à la promotion des activités (publication, représentation,...) dans le domaine concerné.

Equipe de recherche au sein de la HES-SO: Girard Hervé , Bianchi Christophe , Carreno-Morelli Efrain , Lopes Almeida Manuel José , Cardoso Kevin , Marclay Vincent , Sallem Haifa , Rodriguez Arbaizar Mikel , Rey-Mermet Samuel

Durée du projet: 01.01.2019 - 31.12.2019

Montant global du projet: 50'000 CHF

Statut: Terminé

EcoSwissMade - Projet PrintCell Fabrication par impression 3D d'une pile à combustible à oxyde solide
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Bidaux Jacques-Eric, VS - Institut Systèmes industriels

Financement: HES-SO Rectorat

Description du projet : Le but de ce projet est de réaliser intégralement par impression 3D les trois composants principaux d'une pile à combustible à oxyde solide (SOFC pour Solid Oxyde Fuel Cell) que sont la cathode, l'électrolyte et l'anode. L'ensemble de ces trois éléments est appelés PEN (Positive electrode-Electrolyte-Negative electrode). La PEN est le coeur de la pile à combustible où se déroule la réaction chimique qui, en combinant le gaz combustible à l'oxygène de l'air, fournit le courant électrique. Les composants de la PEN ont des fonctions, des morphologies et des compositions différentes mais sont tous généralement produits à partir de poudres par pressage, tape casting, sprayage ou pulvérisation cathodique. Les PEN sont ensuite empilés de manière à augmenter la puissance fournie par la SOFC. Les composants des SOFC actuellement disponibles sur le marché, sont produit séparément et à l'aide de technologies différentes, ce qui nécessite un assemblage final. Ce projet permettra d'améliorer l'efficience de ce procédé de fabrication et sa flexibilité. Des piles de tailles et donc de puissances différentes pourraient être fabriquées à l'aide de la même imprimante. Cela permettrait à un même produit d'être décliné en fonction de l'application visée. Finalement, l'impression 3D permet d'envisager des designs novateurs intégrant des fonctionnalités directement aux électrodes comme par exemple : ' de la porosité contrôlée pour augmenter la densité de puissance ' des canaux pour faire circuler les gaz consommés et produits ' des grilles de renforts pour supporter les contraintes thermiques Le projet vise à réaliser une PEN fonctionnelle par impression 3D, en un seul cycle d'impression et un seul cycle de frittage. La PEN sera testée électrochimiquement et sa puissance sera mesurée.

Equipe de recherche au sein de la HES-SO: Girard Hervé , Gallay Steve , Bircher Fritz , Maître Gilbert , Kessler Philip , Soutrenon Mathieu , Carrie Natalia , Rodriguez Arbaizar Mikel , Rey-Mermet Samuel

Partenaires académiques: VS - Institut Systèmes industriels; FR - EIA - Institut IPRINT; Bidaux Jacques-Eric, VS - Institut Systèmes industriels

Durée du projet: 01.04.2017 - 28.02.2019

Montant global du projet: 200'000 CHF

Statut: Terminé

Novel titanium alloys for cost-effective production of parts by powder metallurgy
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Financement: Höganäs AB

Description du projet : The development work concerns production and investigations of different Ti-based alloying systems, in order to find a Ti-alloy suitable for compaction and sintering, and for MIM. The work will start with a comprehensive literature study to establish the state of art, and to find suitable alloying elements that might improve the possibility to use the alloy in PM applications. Alloys of interest will be produced by Höganäs AB, the Helmholtz-Zentrum Geesthacht (HZG) or be purchased. Processing of parts and evaluation of the alloys in different applications will be performed at the HZG, the HES-SO Valais-Wallis, and at Höganäs.

Equipe de recherche au sein de la HES-SO: Carreno-Morelli Efrain , Rodriguez Arbaizar Mikel

Partenaires académiques: VS - Institut Systèmes industriels; Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Durée du projet: 01.09.2015 - 31.12.2018

Montant global du projet: 26'850 CHF

Statut: Terminé

PIM - Moulage d'aimants permanents par injection de poudres - Contrat The Ark No 516-06
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels

Financement: The Ark Energy; YX Magnetic SA

Description du projet : Ce projet vise à développer la technologie PIM des aimants permanents du type NdFeB (néodyme-fer-bore), dont la demande est en pleine croissance. Les objectifs sont : 1. Développer des systèmes poudre-liant, des procédés de préparation de feedstock, d'injection sous champ magnétique, déliantage et frittage pour produire des aimants NdFeB par technologie PIM. 2. Maitriser les paramètres de fabrication pour l'obtention des bonnes propriétés mécaniques, préservation de la forme, reproductibilité et bonne performance magnétique pour des pièces de géométrie simple.

Equipe de recherche au sein de la HES-SO: Girard Hervé , Carreno-Morelli Efrain , Germanier Alain , Rodriguez Arbaizar Mikel

Partenaires académiques: VS - Institut Systèmes industriels

Durée du projet: 20.06.2016 - 31.01.2018

Montant global du projet: 60'000 CHF

Statut: Terminé

Processing of low thermal expansion alloy parts by a novel three dimensional printing technique (3DP-lnvar)
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Financement: Swiss Space Center EPFL

Description du projet : The goal of this project is to assess the feasibility of producing Invar (Fe-36Ni), low thermal expansion parts by the novel 'Solvent on Granule Three Dimensional Printing Technique', which has been recently developed at HES-SO Valais. The field of application is the manufacturing of light weight and thermallly stable structural elements for high precision mechanisms and scientific instruments to be flown in space, in particular optics instruments. Low coefficient of thermal expansion below 1 ppm/°C, reduced porosity and high sintered density, reduced contamination, good shape preservation and dimensional stability are among the target properties.

Equipe de recherche au sein de la HES-SO: Carreno-Morelli Efrain , Rodriguez Arbaizar Mikel

Partenaires académiques: VS - Institut Systèmes industriels; Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Durée du projet: 01.06.2017 - 30.11.2017

Montant global du projet: 14'700 CHF

Statut: Terminé

Moulage par injection de poudres métalliques à l'aide de liants biosourcés
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Financement: HES-SO Rectorat

Description du projet : Le but de ce projet est de développer un nouveau procédé pour produire des pièces par moulage par injection de poudres métalliques, à l'aide de liants polymères biosourcés. Les domaines d'application sont l'horlogerie et l'industrie biomédicale. L'originalité du projet réside dans l'utilisation de liants écologiques pour le transport des poudres lors du moulage et pour conférer de la résistance aux corps verts. Ces liants sont retirés par la suite et ne sont donc pas présents dans les pièces frittées, qui sont faites de matériaux conventionnels. Donc, le projet ne concerne pas le développement de nouveaux matériaux mais un nouveau procédé de fabrication. Un avantage du moulage et du micromoulage des pièces net-shape est la quantité réduite de matière qui est nécessaire. Le caractère biodégradable des polymères naturels permet en plus de réduire l'impact sur l'environnement. Haute résistance à la corrosion et absence de ferromagnétisme sont d'une importance majeure dans les domaines d'application visés, Des poudres d'alliages de titane et d'acier inoxydable sans nickel seront utilisées. Les liants seront sélectionnés parmi des polymères générés par fermentation bactérienne, des gélatines d'origine végétale ou animale, de la cellulose, de l'amidon et d'autres polymères naturels. Leur capacité à conférer de la résistance aux corps verts et remplacer des liants conventionnels dérivés du pétrole sera établie. Des pièces de test seront produites et caractérisées. Des procédés récemment développés à la HES-SO Valais seront notamment utilisés: d'une part le moulage par injection d'alliages de titane à partir d'hydrures métalliques, d'autre part la biosynthèse de polyhydroxyalcanoates (PHAs) par fermentation bactérienne. La HEIA-FR contribuera dans la caractérisation, la sélection et la réutilisation des liants, plastifiants, surfactants et solvants. Le contrôle dimensionnel des pièces, l'analyse des défauts par tomographie, le bilan énergétique et l'évaluation des impacts environnementaux du procédé seront réalisés à l'HEPIA. En collaboration avec la Société Soprod SA, on produira pièce complexe des dimensions réduites pour mouvement de montre en quartz, qui permettra d'évaluer le potentiel et les limites des nouveaux feedstocks.

Equipe de recherche au sein de la HES-SO: Girard Hervé , Dabros Michal , Micaux Fabrice , Zinn Manfred , Carreno-Morelli Efrain , Grand Pascal , Sthioul Hervé , Richard Jacques , Chappuis Thierry , Hanik Nils , Rodriguez Arbaizar Mikel

Partenaires académiques: VS - Institut Systèmes industriels; VS - Institut Technologies du vivant; hepia inSTI; FR - EIA - Institut ChemTech; Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Durée du projet: 01.10.2015 - 30.11.2017

Montant global du projet: 237'500 CHF

Statut: Terminé

Composants ferromagnétiques fabriqués par pressage uniaxial de poudres SMC (soft magnetic composites)
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Financement: HES-SO Rectorat

Description du projet : Le but de ce projet est la fabrication des composants ferromagnétiques doux à partir des poudres métalliques enrobées d'une couche isolante. La mise en forme se fait par pressage uniaxial suivi d'un traitement thermique à basse température (sans frittage). Le noyau conducteur des grains reste isolé et la résistivité électrique augmente, ce qui permet de réduire les pertes par courants de Foucault. Le procédé est de grand intérêt du point de vue énergétique, car le rendement peut être augmenté dans un grand nombre d'applications, en particulier dans les moteurs électriques.

Equipe de recherche au sein de la HES-SO: Ottonin Cyril , Carreno-Morelli Efrain , Germanier Alain , Rodriguez Arbaizar Mikel , Herzog Raoul , Mabillard Eric

Partenaires académiques: IAI; VS - Institut Systèmes industriels; Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Durée du projet: 01.04.2013 - 15.09.2014

Montant global du projet: 60'000 CHF

Statut: Terminé

Moulage par injection de pièces poreuses à partir de feedstocks contenant des additifs formateurs de pores
AGP

Rôle: Collaborateur/trice

Requérant(e)s: VS - Institut Systèmes industriels, Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Financement: HES-SO Rectorat

Description du projet : Le but de ce projet est le développement des matériaux poreux pour implants par moulage par injection des poudres (PIM). Biocompatibilité, bon accrochage et module d'élasticité comparable à l'os sont requis pour les implants permanents, pour des raisons de fonctionnalité et sécurité, ainsi que pour limiter les opérations de remplacement. Des implants en titane ou zircone poreux produits par technologie PIM peuvent satisfaire ces exigences, pourvu que le taux de porosité et la taille des pores soient appropriés pour une croissance rapide des tissus dans l'implant. À cet effet, des nouveaux feedstocks contenant des additifs formateurs de pores seront développés, pour une porosité ouverte entre 30% et 60% avec des pores de taille comprise entre 50um et 500um.

Equipe de recherche au sein de la HES-SO: Girard Hervé , Carreno-Morelli Efrain , Rodriguez Arbaizar Mikel

Partenaires académiques: VS - Institut Systèmes industriels; Carreno-Morelli Efrain, VS - Institut Systèmes industriels

Durée du projet: 01.03.2012 - 28.02.2013

Montant global du projet: 30'000 CHF

Statut: Terminé

Novel feedstock for metal injection molding
AGP

Rôle: Collaborateur/trice

Requérant(e)s: HES-SO Valais-Wallis

Financement: GKN Sinter Metals

Description du projet : Agar-based feedstock for MIM of big parts

Equipe de recherche au sein de la HES-SO: Carreno-Morelli Efrain , Rodriguez Arbaizar Mikel , Mabillard Eric

Partenaires académiques: HES-SO Valais-Wallis

Durée du projet: 01.08.2006 - 05.03.2009

Montant global du projet: 155'000 CHF

Statut: Terminé

2022

Fused filament fabrication of stainless steel structures - from binder development to sintered properties
Article scientifique ArODES

Marius A. Wagner, Amir Hadian, Tutu Sebastien, Frank Clemens, Thomas Schweizer, Mikel Rodriguez Arbaizar, Efrain Carreno-Morelli, Ralph Spolenak

Additive Manufacturing,  2022, vol. 49, article no. 102472

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Résumé:

Additive manufacturing of metals by 3D printing of polymeric filaments containing high loading of metal powder, subsequent debinding, and sintering offers a potent alternative to the widespread beam-based processes. The polymeric binder is the decisive component for a successful fabrication process. This study presents the development of a multi-component binder system for filament-based 3D printing of 316 L stainless steel in various optimization steps. The binder contains a polyethylene (PE) backbone, which ensures the structural integrity during solvent debinding. A soluble binder component consisting of a thermoplastic elastomer (TPE) and a second PE is used, to reduce the polymer content via solvent extraction prior to thermal debinding. The TPE grants flexibility to the filaments, while the PE allows reduction of the viscosity and increase in stiffness and strength. This enables precise tuning of the rheological and mechanical properties of the filaments. The capabilities of the binder system developed, are demonstrated by the fabrication of 3D plate-lattices. The structures are printed, subjected to a two-step solvent – thermal debinding procedure, and finally sintered. In the compression tests the structures are able to undergo large plastic deformations without fracture, highlighting their potential for energy absorption applications. The main contribution of this work is the development and disclosure of a binder system with two types of soluble polymers. This allows the precise control of the mechanical and rheological properties, as well as the backbone fraction of the binder. Based on the characterization performed, the binder system can be easily modified to adapt for other solid loading materials and fractions, as parameters like stiffness, viscosity, or backbone content can be adjusted precisely.

2021

https://www.researchgate.net/profile/Mikel-Rodriguez-Arbaizar
Article scientifique
link to researchgate with all the publications

Rodriguez Arbaizar Mikel

https://www.researchgate.net/profile/Mikel-Rodriguez-Arbaizar, 2021

Résumé:

https://www.researchgate.net/profile/Mikel-Rodriguez-Arbaizar

2020

Three-dimensional printing of hard materials
Article scientifique ArODES

Efrain Carreno-Morelli, Patricia Alveen, Steven Moseley, Mikel Rodriguez Arbaizar, Kevin Cardoso

International Journal of Refractory Metals and Hard Materials,  2020, vol. 87, article no. 105110

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Résumé:

Tungsten cemented carbide parts have been produced by the “Solvent on Granule” 3D-Printing technique. It consists in growing layer-by-layer a green part by spreading a powder-polymer granule bed, followed by selective solvent jetting, and layer consolidation after solvent evaporation. The granules are prepared by wet blending, drying, milling and sieving to appropriate size range. The printed green parts are consolidated by thermal debinding and liquid phase sintering. Fully dense WC-Co test parts and a drill bit have been produced from presintered powder and elementary Co powder. The microstructures are equivalent to those of press and sintered parts. Good shape retention and tolerances are achieved.

2017

MIM of nickel-free nitrogen strengthened austenitic stainless steel from bipolymer based feedstock
Article scientifique ArODES

Efrain Carreno-Morelli, Manfred Zinn, Mikel Rodriguez Arbaizar, Hervé Girard, Monica Bassas-Galia, Thierry Chappuis, Jacques Richard

Powder Injection Moulding International,  2017, vol. 11, no. 4

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Résumé:

Nickel-free stainless steels are of high interest for medical and dental applications, as well as consumer goods where contact with the skin is a consideration. In this paper Prof Efraín Carreño-Morelli and colleagues from the University of Applied Sciences and Arts Western Switzerland evaluate the MIM processing of the high-nitrogen content austenitic stainless steel P558. This is processed using a novel environmentally friendly binder that incorporates a polymer produced by bacterial fermentation.

Sintering optimisation of Fe–Si soft magnetic materials processed by metal injection moulding
Article scientifique ArODES

A. Páez-Pavòn, A. Jiménez-Morales, Mikel Rodriguez Arbaizar, Efrain Carreno-Morelli, J. M. Torralba

Powder Metallurgy,  2017, vol. 60, no. 2, pp. 112-119

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Résumé:

Soft magnetic materials are used in a wide variety of electromagnetic devices such as motors, relays and sensors. Over the years, the devices are becoming smaller. Therefore, it is essential to produce small parts without compromising the final properties. Metal injection moulding (MIM) is a cost-effective technique to produce small and complex soft magnetic parts with optimal mechanical and magnetic performance. These properties can be improved by maximising the sintered density and by the reduction of impurities content. These factors are strongly related to the sintering parameters. The goal of this study is to determine the influence of the sintering parameters on the final properties of iron–silicon soft magnetic alloys processed by metal injection moulding. In this work, two alloys were sintered under different conditions. The effect of the sintering conditions on both mechanical and magnetic properties was evaluated.

2016

Metal injection moulding of superelastic TiNi parts
Article scientifique ArODES

Jacques-Eric Bidaux, Alexandra Amherd Hidalgo, Hervé Girard, Mikel Rodriguez Arbaizar, Lionel Reynard, Jacques Chevallier, François Aeby, Jean Charles Giachetto, Efrain Carreno-Morelli

Key Engineering Materials,  2016, vol. 704, pp. 173-182

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Résumé:

TiNi shape-memory properties are successfully used today for the fabrication of various technical devices. The limited machinability and high cost of TiNi encourage the use of near-net shape production techniques such as metal injection moulding. In this work TiNi alloys tensile test specimens are produced by metal injection moulding from pre-alloyed powders. A binder based on a mixture of polyethylene, paraffin wax and stearic acid is used. Parts with a density of about 96.6% of theoretical density are obtained. Scanning electron microscopy coupled with EDX measurements reveals a microstructure consisting of a TiNi matrix with small Ti4Ni2Ox and TiC inclusions. DSC and X-ray diffraction observations indicate the presence of additional Ni4Ti3 precipitates. The parts exhibit full superelasticity at room temperature even for strains of up to 4%, without the need for additional thermal post-treatments. Ultimate tensile strengths up to 980 MPa are obtained.

2014

Low elastic modulus Ti–17Nb processed by powder injection moulding and post-sintering heat treatments
Article scientifique ArODES

Jacques E. Bidaux, Richard Pasquier, Mikel Rodriguez Arbaizar, Hervé Girard, Efrain Carreno-Morelli

Powder Metallurgy,  2014, vol. 57, no. 5, pp. 320-323

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Résumé:

Ti–Nb alloys are attractive as biomaterials because of their excellent combination of low elastic modulus, high strength, corrosion resistance and enhanced biocompatibility. The effect of a post-sintering quenching treatment on the microstructure and mechanical properties of powder injection moulded Ti–17Nb has been investigated. Tensile test specimens were produced using a feedstock based on blended elemental powders, some of which were solution-treated in the β phase field and water quenched. Both as-sintered and quenched alloys had densities 95·5% of theoretical. The as-sintered material showed an α−β structure, whereas after quenching a fully martensitic α″ structure was obtained. The modulus of elasticity of the water-quenched alloy (∼45 GPa) was about 40% lower than that of the as-sintered alloy (∼76 GPa).

Production of titanium grade 4 components by powder injection moulding of titanium hydride
Article scientifique ArODES

Efrain Carreno-Morelli, Jacques-Eric Bidaux, Mikel Rodriguez Arbaizar, Hervé Girard

Powder Metallurgy,  2014, vol. 57, no. 2, pp. 89-92

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Résumé:

Recent developments are presented on powder injection moulding of titanium from metal hydride powders and binders composed of polyethylene, paraffin wax and stearic acid. The feasibility of using this route to process fit for purpose, complex parts is assessed. Titanium hydride offers a low cost solution compared with pure titanium powders. Feedstocks for powder injection moulding were prepared in a sigma mixer. Tensile test specimens and demonstration parts were injection moulded. Solvent debinding in heptane was followed by thermal debinding and dehydrogenation under argon. Titanium parts were sintered at 1200°C under argon. Sintered parts exhibit a linear shrinkage of about 20%, good shape preservation and reproducibility. The yield strength (519 MPa), ultimate tensile strength (666 MPa), elongation to fracture (15%) and interstitial content measured by quantitative analysis meet the requirements for titanium grade 4.

Porous titanium processed by powder injection moulding of titanium hydride and space holders
Article scientifique ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Jacques-Eric Bidaux

Powder Metallurgy,  2014, vol. 57, no. 2, pp. 93-96

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Résumé:

Biocompatibility, bone-like mechanical properties, and good bone-to-implant anchorage are current requirements for permanent implants. Porous titanium can satisfy these requirements provided that sufficient porosity, large enough pores and interconnections allowing bone ingrowth can reliably be obtained with controlled processes. In the present work, porous parts are processed from titanium hydride based feedstocks containing space holders. Two formulations have been developed: a feedstock with a polyethyleneglycol based binder and NaCl space holders, and a feedstock with a paraffin based binder and PMMA space holders. Depending on the sintering conditions, porosity levels between 30 and 60% and open porosity between 10 and 40% are obtained, with pore sizes in the range 50–500 μm. The microstructure, porosity and mechanical properties of porous titanium sintered at various temperatures have been characterised by scanning electron microscopy and compression tests.

2013

Metal injection moulding of low modulus Ti–Nb alloys for biomedical applications
Article scientifique ArODES

Jacques-Eric Bidaux, C. Closuit, Mikel Rodriguez Arbaizar, Daniel Zufferey, Efrain Carreno-Morelli

Powder Metallurgy,  2013, vol. 56, no. 4, pp. 263-266

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Résumé:

Titanium alloys containing β stabilising elements such as Nb, Zr and Ta are particularly promising as implant materials because of their excellent combination of low modulus, high strength, corrosion resistance and biocompatibility. A low elastic modulus is important for implants to avoid stress shielding and associated bone resorption. The difficulty of producing complex shapes of these alloys by conventional methods makes metal injection moulding (MIM) attractive. Ti–17Nb alloy parts with densities 94% of theoretical have been produced by MIM of a feedstock based on blended elemental powders. Scanning electron microscopy reveals a typical α−β Widmanstätten microstructure with a precipitated α phase layer along the grain boundaries. The parts exhibit an ultimate tensile strength of 768 MPa and a plastic elongation of over 5%. The modulus of elasticity, about 84 GPa, is more than 20% lower than that of cp Ti and Ti–6Al–4V.

Porous titanium by powder injection moulding of titanium hydride and PMMA space holders
Article scientifique ArODES

Efrain Carreno-Morelli, Alexandra Amherd Hidalgo, Mikel Rodriguez Arbaizar, Daniel Zufferey, Alejandro Várez, Jacques-Eric Bidaux

European cells and materials,  2013, vol. 26, suppl. no. 4, p. 16

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Résumé:

Porous titanium is used as implant material because of its high specific strength, bone-like stiffness, biocompatibility and good bone cell ingrowth provided that the open pores have sizes between 100 μm and 500μm. Powder metallurgy has been successfully used to produce titanium foams by using the space holder method. Recently, Ti grade 4 has been obtained by powder injection moulding (PIM) of titanium hydride, which is cheaper and less reactive than pure titanium. The feasibility of a novel route combining TiH2 and space holders to produce porous titanium is explored in this work.

Opportunities and limits of in vitro cytotoxicity test methods exemplified by powder metallurgy titanium alloys
Article scientifique ArODES

Mascha Pusnik, Arie Bruinink, Mikel Rodriguez Arbaizar, Efrain Carreno-Morelli, Manfred Zinn

European cells and materials,  2013, vol. 26, suppl. no. 4, p. 44

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Résumé:

Testing for in vitro cytotoxicity aims at obtaining data for a test material from simplified in vitro systems that can be used to make a prognosis for a key step within the processes occurring after implantation in the human body. Depending on the application of the test specimens, one can choose from a number of different assays to assess its bioacceptance in terms of absence of cytotoxicity. While guidelines (e.g. ISO, ASTM) describe a number of mandatory test procedures for official approval, additional tests have to be performed to properly evaluate the in vitro effects of test specimen on cells. In this work we evaluate for the bioacceptance of different Ti alloys by two different assays; the agar overlay test and the extraction test, both described by the ISO 10993-5 guidelines. Opportunities and limits of cytotoxicity testing based on these and other methods are discussed.

2012

Processing of a low modulus Ti-Nb biomaterial by metal injection moulding (MIM)
Article professionnel ArODES

Jacques-Eric Bidaux, C. Closuit, Mikel Rodriguez Arbaizar, D. Zufferey, Efrain Carreno-Morelli

Powder Injection Moulding International,  2012, vol. 6, no. 4, pp. 70-73

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Résumé:

Ti alloys containing β stabilising elements such as Nb, Zr and Ta are particularly promising as implant materials because of their excellent combination of low modulus, high strength, corrosion resistance and biocompatibility. A low elastic modulus is important for implants to avoid stress shielding and associated bone resorption. The difficulty of producing complex shapes of these alloys by conventional methods makes Metal Injection Moulding attractive. In this work, Ti-17Nb alloy parts with densities of 94% of theoretical density have been produced by metal injection moulding of a feedstock based on blended elemental powders. Scanning electron microscopy reveals a typical α-β Widmanstätten microstructure with a precipitated α phase layer along the grain boundaries. The parts exhibit an ultimate tensile strength of 768 MPa and a plastic elongation of over 5%. The modulus of elasticity, about 84 GPa, is more than 20% lower than that of CP Ti and Ti-6Al-4V.

2011

Net-shape titanium grade 4 parts processed from titanium hydride powders
Article scientifique ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Hervé Girard, H. Hamdan, Jacques-Eric Bidaux

European cells and materials,  2011, vol. 22, suppl. 4, p. 33

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Metal injection moulding of Ti-Nb alloys for implant application
Article scientifique ArODES

Jacques-Eric Bidaux, C. Closuit, Mikel Rodriguez Arbaizar, Efrain Carreno-Morelli

European cells and materials,  2011, vol. 22, suppl. 4, p. 32

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2010

Titanium parts by powder injection moulding of TiH2-based feedstocks
Article scientifique ArODES

Efrain Carreno-Morelli, William Krstev, B. Romeira, Mikel Rodriguez Arbaizar, Hervé Girard, Jacques-Eric Bidaux, S. Zachmann

Powder injection moulding international,  2010, vol. 4, no. 3, pp. 60-63

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Résumé:

Titanium parts have been processed from feedstocks composed of titanium hydride powders, low density polyethylene, paraffin wax and stearic acid. A two-step debinding process has been used, which consists of solvent debinding in heptane at 50°C followed by thermal debinding at 500°C. Sintering was performed at 1200°C. Both thermal debinding and sintering were performed under a protective atmosphere in a MIM furnace equipped with molybdenum heating elements and a debinding retort. Special care in powder handling, feedstock preparation, debinding and sintering atmospheres, allowed to limit the residual oxygen, nitrogen and carbon contents, which were determined by quantitative analysis. The mechanical properties of net‑shape sintered parts were measured by tensile tests. A tensile strength of 580 MPa and an elongation of 1.8% were obtained. Experimental watch bracelet segments were injection moulded, showing good shape preservation and reproducibility.

Investigation of planetary milling for nano-silicon carbide reinforced aluminium metal matrix composites
Article scientifique ArODES

Lauri Kollo, Marc Leparoux, Christopher R. Bradbury, Christian Jäggi, Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar

Journal of Alloys and Compounds,  2010, vol. 489, no. 2, pp. 394-400

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Résumé:

High-energy planetary milling was used for mixing aluminium powders with 1 vol.% of silicon carbide (SiC) nanoparticles. A number of milling parameters were modified for constituting the relationship between the energy input from the balls and the hardness of the bulk nanocomposite materials. It was shown that mixing characteristics and reaction kinetics with stearic acid as process control agent can be estimated by normalised input energy from the milling bodies. For this, the additional parameter characterising the vial filling was determined experimentally. Depending on the ball size, a local minimum in filling parameter was found, laying at 25 or 42% filling of the vial volume for the balls with diameter of 10 and 20 mm, respectively. These regions should be avoided to achieve the highest milling efficiency.After a hot compaction, fourfold difference of hardness for different milling conditions was detected. Therewith the hardness of the Al–1 vol.% nanoSiC composite could be increased from 47 HV0.5 of pure aluminium to 163 HV0.5 when milling at the highest input energy levels.

2023

Solvent-on-granules 3D-printing and material extrusion of soft magnetic Fe-6.5Si alloy
Conférence ArODES

Efrain Carreno-Morelli, Ludovic Meylan, Mikel Rodriguez Arbaizar, Xavier Carthoblaz-Délèze, Benoît Sahli, Rajasundar Chandran, Gioele Balestra

Proceedings of European Powder Metallurgy Congress, EuroPM2023, 1-4 October 2023 , Lisbon, Portugal

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Résumé:

Soft ferromagnetic parts have been produced by two sinter-based additive manufacturing techniques: Solvent on Granules 3D Printing (SG-3DP) and Material Extrusion (MEX). Fe2.7Si and Fe6.5Si powders were mixed with multicomponent binders, then shaped to granules. Different formulations suitable for SG-3DP and MEX respectively were processed. Square section toroids for magnetic measurements, test cubes and a rotor/stator prototype were printed. The green parts were debound under nitrogen and sintered under hydrogen atmosphere, in a single thermal cycle, using a retort furnace. The sintered parts were characterized by measurements of B‐H hysteresis cycles. The impurity contents of carbon and oxygen were measured by melt extraction. The performance of parts processed by both SG-3DP and MEX methods, was compared with literature values obtained from conventional powder metallurgy processes.

Cermet cutting tool inserts :
Conférence ArODES
improved by laser grinding and HIPIMS coating

Efrain Carreno-Morelli, Ludovic Meylan, Mikel Rodriguez Arbaizar, Raymond Constantin, Michel Stucki, Georg Wälder

Proceedings of European Powder Metallurgy Congress EuroPM2023, 1-4 October 2023, Lisbon, Portugal

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Résumé:

Ti(C,N)-MoNi cermets cutting tool inserts have been produced by cold compaction and sintering of commercial ready to press granules. The inserts have been characterized by hardness, density measurements and SEM observations. The cutting edges of sintered inserts were sharpened by laser grinding before coating with a PVD nitride layer by High power impulse magnetron sputtering. Instrumented scratch tests were conducted to evaluate the coating adhesion on both reference cemented carbide and experimental cermet inserts.

2019

Three-dimensional printing of hard materials
Conférence ArODES

Efrain Carreno-Morelli, Patricia Alveen, Steven G. Moseley, Mikel Rodriguez Arbaizar, Kevin Cardoso

Proceedings of ICSHM11 International Conference on the Science of Hard Materials, 25-29 March 2019, Khao Lak, Thailand

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2018

Additive manufacturing of Invar parts by solvent jetting on granule beds
Conférence ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Hervé Girard

Proceedings of Euro PM2018 congress & exhibition, 14-18 October 2018, Bilbao, Spain

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Résumé:

Invar Fe36Ni parts are produced by the “solvent on granule” 3D-Printing technique. Both elementary and prealloyed powders are used. A special purpose tabletopmachine, designed and built in a previous development, is used to print green parts, which are subsequently debinded and sintered in a muffle furnace. Prismatic specimens for thermal expansion tests and metallographicobservation are produced. In addition, benchmark parts are printed to test dimensional accuracy and shape preservation. The results show the feasibility of producing low thermal expansion coefficient material, which matches the target value of 1ppm/°Creported for the wrought alloy.

2016

Processing of titanium parts with optimal tensile properties by press and sintering of low cost titanium hydride
Conférence ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Skakti Corthay, Hervé Girard, Alexandra Amherd Hidalgo, Jacques-Eric Bidaux

Proceedings of Powder Metallurgy World Congress, World PM2016 - AM - Powder bed based technologies, 9-13 October 2016, Hamburg, Germany

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Résumé:

This paper presents recent developments on press and sintering of titanium from metal hydride powder. Titanium hydride offers a low cost solution compared with pure titanium powder. Different lubricants have been used for uniaxial compaction in an electric press. Dog bone specimens for tensile tests have been pressed, dehydrided and sintered. Sintering was performed in a muffle furnace at temperatures between 1100°C to 1400°C under argon. Sintered parts exhibit a linear shrinkage of about 13%. The yield strength (575 MPa), ultimate tensile strength (704 MPa), elongation to fracture (20%) and interstitial content measured by melt extraction meet the requirements for titanium grade 4.

Additive manufacturing by solvent jetting on granule beds
Conférence ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Glenn Flückiger, Christian Cachelin, Fritz Bircher, Johannes Renner, Jacques Richard

Proceedings of Powder Metallurgy World Congress, World PM2016 - AM - Powder bed based technologies, 9-13 October 2016, Hamburg, Germany

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Résumé:

A "Solvent on Granule" 3D-Printing technique has been developed, which consists in the spreading of a powder-polymer granule bed, followed by the selective jetting of a solvent (which softens the polymer contained in the granules), and layer consolidation after solvent evaporation. The granules are prepared by wet blending, drying, milling and sieving. The granule layer thickness can be set between 50 μm and 200 μm, and the volume of the solvent droplets is about 10 pL. A summary of preliminary results obtained with 17-4PH stainless steel parts in a former prototype device is presented. A new concept of table-top machine is developed in this work and its essential components and functions are described.

Powder injection moulding of low modulus Ti-13Nb-13Zr for implant application
Conférence ArODES

Jacques-Eric Bidaux, F. Comby, Mikel Rodriguez Arbaizar, Hervé Girard, Efrain Carreno-Morelli

Proceedings of Powder Metallurgy World Congress, World PM2016 - AM - Powder bed based technologies, 9-13 October 2016, Hamburg, Germany

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Résumé:

Ti-13Nb-13Zr is a low modulus near-β titanium alloy developed for surgical implants. In this work, the possibility of producing Ti-13Nb-13Zr parts by metal injection moulding is evaluated. Tensile test specimens are injection moulded using a feedstock based on elemental powders, then debinded and sintered. In an attempt to further decrease the elastic modulus, additional quenching and ageing post-treatments are applied. The as-sintered material shows a density of 96.5%, an elastic modulus of 85 MPa and a yield strength of 842 MPa. Subsequent water quenching from the β phase allows decreasing the elastic modulus to 58 GPa while retaining a good strength, 684 MPa. Further aging for 4 h at 500°C leads to the highest strength, 951 MPa, but the elastic modulus, 79 GPa, is practically unchanged compared to the as-sintered material. The microstructures before and after thermal treatment are analysed by using scanning electron microscopy and X-ray diffraction.

MIM of nitrogen-strenghtened austenitic stainless steel using biopolymer-based binder
Conférence ArODES

Efrain Carreno-Morelli, Manfred Zinn, Mikel Rodriguez Arbaizar, Monica Bassas, Hervé Girard, Thierry Chappuis, Jacques Richard

Proceedings of Powder Metallurgy World Congress, World PM2016 - AM - Powder bed based technologies, 9-13 October 2016, Hamburg, Germany

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Résumé:

High-nitrogen content austenitic stainless steel parts have been processed by injection moulding of a novel feedstock composed of gas atomized P558 stainless steel powder and biopolymer-based binder. The binder formulation consists of polyhydroxyalkanoate backbone polymer produced by bacterial fermentation, filler wax and surfactant. The solids loading was 60 vol.%. Tensile test specimens were injection moulded, debinded and sintered at 1270°C under nitrogen. The microstructure was characterized by metallographic observation, X-ray diffraction and X-ray computer tomography. Yield stress of 600 MPa, ultimate tensile strength of 900 MPa were achieved, meeting the reference values of the wrought alloy.

Processing Of Titanium Parts With Optimal Tensile Properties By Press And Sintering Of Low Cost Titanium Hydride
Conférence

Girard Hervé, Carreno-Morelli Efrain, Rodriguez Arbaizar Mikel, Corthay Shakti, Amherd Hidalgo Alexandra, Bidaux Jacques-Eric

Powder Metallurgy World Congress WorldPM2016, 09.10.2016 - 13.10.2016, Hambourg, Germany

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2015

Nickel-free P558 austenitic steel parts processed from metal powder :
Conférence ArODES
PHA biopolymer feedstocks

Efrain Carreno-Morelli, Manfred Zinn, Mikel Rodriguez Arbaizar, Monica Bassas

Proceedings of EURO PM2015 - Advanced Materials and Applications 2, 4-7 September 2015, Reims, France

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Résumé:

In this work, the feasibility of a novel processing route for high-nitrogen content austenitic steels is explored. Feedstock for powder injection moulding was prepared with gas atomized P558 stainless steel powder and binder containing a natural polymer as backbone polymer. Binders consisting of 45 wt% P(3HB-co-3HV) processed by bacterial fermentation, 45 wt% paraffin wax and 10 wt% stearic acid were employed. The solids loading was 60 vol.%. Tensile test specimens were injection moulded and subsequently subjected to solvent debinding in heptane, thermal debinding at 500°C and sintering at 1270°C under nitrogen. The microstructure was characterized by metallographic observation and X-ray diffraction. Yield stress values of 600 MPa, ultimate tensile strength of 900 MPa and elongation of 25% were achieved.

Dense and porous materials processed from low cost titanium hydride powder
Conférence

Girard Hervé, Carreno-Morelli Efrain, Rodriguez Arbaizar Mikel, Corthay Shakti, Amherd Hidalgo Alexandra, Bidaux Jacques-Eric

FIMPART'15, 12.06.2015 - 15.06.2015, Hyderabad, India

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Metal injection moulding of superelastic NiTi parts
Conférence

Girard Hervé, Carreno-Morelli Efrain, Rodriguez Arbaizar Mikel, Reynard Lionel, Chevallier Jacques, Amherd Hidalgo Alexandra, Giachetto Jean-Charles

PM Titanium 2015, 30.05.2015 - 03.09.2015, Lüneburg, Germany

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2014

Low elastic modulus Ti-17Nb processed by powder injection moulding and post-sintering heat treatments
Conférence

Girard Hervé, Bidaux Jacques-Eric, Carreno-Morelli Efrain, Rodriguez Arbaizar Mikel, Pasquier Romain

Euro PM2014, 21.07.2014 - 24.09.2014, Salzburg, Austria

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2012

Fe2.7Si, Fe50Ni and Fe50Co soft ferromagnetic materials by powder injection moulding
Conférence ArODES

Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar, Hervé Girard, Hazimeh Hussein, Raoul Herzog

Proceedings of Powder Metallurgy World Congress PM2012, 14-18 october 2012, Yokohama, Japan

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Résumé:

Powder injection moulding is an enabling technology for the production of soft ferromagnetic components, which bring solutions and open the way for new applications. In this work, square toroid parts have been injection moulded for three typical soft magnetic alloy compositions. Fe2.7Si, Fe50Ni and Fe50Co feedstocks were produced by mixing elemental powders and a multicomponent binder. The green parts were first solvent debinded in a heptane bath. Then, thermal debinding under nitrogen atmosphere and sintering under hydrogen atmosphere were performed in a single step in a retort furnace. The sintered parts were characterized by measurements of B‐H hysteresis cycles and optical metallography. The results were compared with literature values obtained from powder metallurgy processes.

Fe2.7Si, Fe50Ni and Fe50Co Soft Ferromagnetic Materials by Powder Injection Moulding
Conférence

Girard Hervé, Carreno-Morelli Efrain, Rodriguez Arbaizar Mikel, Herzog Raoul, Hamdam Hussein

Powder Metallurgy World Congress PM2012, 14.10.2012 - 18.10.2012, Yokohama, Japan

2011

Tape casting of porous titanium thin sheets from titanium hydride
Conférence ArODES

Jacques-Eric Bidaux, J. Garcia-Gomez, H. Hamdan, D. Zufferey, Mikel Rodriguez Arbaizar, Hervé Girard, Efrain Carreno-Morelli

Proc. of European Powder Metallurgy Conference Euro PM2011, 9-12 October 2011, Barcelona, Spain

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Résumé:

Titanium thin sheets have been fabricated by tape casting using slurries based on titanium hydride powder. Titanium hydride is attractive because of its reduced cost with respect to pure titanium. Sheets of various thicknesses were tape cast, debinded, dehydrided and sintered. Porous sheets with even surfaces were obtained. Scanning electron microscopy observations of the polished crosssections showed fine and uniformly distributed pores. Tensile strengths of up to 320 MPa have been obtained for sheets with densities close to 75% of theoretical density.

2010

Hardness of hot consolidated Al-SiC nanocomposites from planetary milled powders
Conférence ArODES

Lauri Kollo, Marc Leparoux, Christopher R. Bradbury, Lembit Kommel, Efrain Carreno-Morelli, Mikel Rodriguez Arbaizar

Proceedings of the World Powder Metallurgy Congress and Exhibition, World PM 2010, 10-14 October 2010, Florence, Italy

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Résumé:

Metal matrix nanocomposites have been processed by hot compaction of aluminium-nanosilicon carbide composite powders, which were produced by high energy planetary milling. The nano-SiC particles were produced by milling of micron-size starting powders. As a reference micron-sized reinforcements were chosen. The densification was carried out namely by hot pressing (in a steel- or graphite die) and by equal channel angular pressing (ECAP). Hardness measurements of the compacted composite samples were performed to compare to the different processing technique. The results showed that in order to obtain increased hardness of the composites, nano-sized reinforcements are required. The hardness of the nanocomposites was further increased by ECAP compaction, by which high plastic deformations are applied to the matrix.

2009

Powder injection moulding of titanium from TiH2 powders
Conférence ArODES

Efrain Carreno-Morelli, W. Krstev, B. Romeira, Mikel Rodriguez Arbaizar, Jacques-Eric Bidaux, S. Zachmann

Proceedings of Euro PM2009 - Powder Injection Moulding - Materials I, 12-14 October 2009, Copenhagen, Denmark

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Résumé:

Titanium parts have been processed from feedstocks composed of titanium hydride powders, low density polyethylene, paraffin wax and stearic acid. A two-step debinding process has been used, which consists of solvent debinding in heptane at 50°C followed by thermal debinding at 500°C. Sintering was performed at 1200°C. Both thermal debinding and sintering were performed under protective atmosphere in a MIM furnace equipped with molybdenum heating elements and a debinding retort. Special care in powder handling, feedstock preparation, debinding and sintering atmospheres, allowed to limit the residual oxygen, nitrogen and carbon contents, which were determined by quantitative analysis. The mechanical properties of net-shape sintered parts were measured by tensile tests. A tensile strength of 580 MPa and an elongation of 1.8% were obtained. Experimental watch bracelet segments were injection moulded, showing good shape preservation and reproducibility.

Powder injection moulding of titanium from TiH2 powders
Conférence

Rodriguez Arbaizar Mikel

European Powder Metallurgy Conference Euro PM2009, Copenhagen, Denmark du 12.10.2009 au 14.10.2009, 12.10.2009 - 14.07.2009, , Copenhagen, Denmark du 12.10.2009 au 14.10.2009

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