D2.2 Production and quality assurance of samples for machining and surface characterization

Additive Manufacturing (AM) is a transformative technology that integrates material creation with part manufacturing, enabling intricate geometries and functional components to be produced with minimal waste. However, achieving the required surface integrity and mechanical properties for industrial applications often demands additional post-processing steps, such as machining and heat treatments. The SuPreAM project focuses on optimizing these processes for steel components, targeting two industrial applications: aerospace components and injection moulding parts. The overarching goal is to reduce manufacturing costs by minimizing scrap and reprocessing while enhancing surface quality and performance. This deliverable corresponds to Work Package 2 (WP2), titled Definition of requirements, AM materials, and process-chain implementation. WP2 establishes the engineering foundation necessary for producing industrial parts by defining requirements and selecting manufacturing processes, materials, and post-treatments to meet those requirements. AM presents a unique challenge because the material and part geometry are created simultaneously, unlike conventional manufacturing where material properties are predefined. This fusion of steps in AM necessitates careful consideration of the process parameters to ensure the part achieves the desired properties across its entirety. This deliverable involves the analysis of requirements for the two selected applications, followed by the selection of suitable AM technologies and materials. A comprehensive evaluation was conducted, including material characterization, parameter optimization, assessment of microstructural behaviour, the influence of shape and orientation, heat treatments, and anisotropy of properties. Additionally, the design and production of test samples for advanced characterization and machining trials were completed during this phase. The primary role of this deliverable is to guarantee the optimal selection of materials and processes tailored to the requirements of each application. It focuses on optimizing manufacturing and heat treatment parameters to achieve target properties and defines and manufacture the necessary samples for testing and validation in subsequent work packages. These steps are crucial for generating realistic samples that address the engineering challenges of AM and support the development of predictive simulation models for finishing operations. Without this groundwork, achieving the project’s objectives—such as minimizing scrap, reducing reprocessing loops, and improving surface integrity—would not be feasible. Positioned at the beginning of the technical work plan, this deliverable establishes the foundation for manufacturing samples used in machining tests, advanced characterizations, and simulation fitting throughout the project. The methodological approach relied on a cascade decision-making process, where materials, processes, parameters, and heat treatments were evaluated iteratively to identify optimal candidates based on technical and performance criteria. The main results highlight two tailored solutions for the selected applications. For aerospace components, Laser Wire Directed Energy Deposition (DED) was identified as the optimal technology due to its scalability, cost-effective wire feedstock, and reliability. The material selected was PH17-4 stainless steel, which demonstrated superior toughness and reduced property heterogeneity after a custom heat treatment. This treatment ensured uniform mechanical properties across different geometries, achieving optimal performance compared to conventional counterparts. For injection moulding, Laser Powder Bed Fusion (L-PBF) was the predefined technology, and a MS1 Maraging steel was selected due to the strong wear resistance, good valance of corrosion resistant and elevated toughness at the working conditions. A custom-designed heat treatment minimized dimensional distortion and reduced costs while achieving target properties. Furthermore, a cobalt-free Maraging steel, patented by ArcelorMittal, was evaluated and will be included in final demonstrator tests to benchmark its performance against MS1. For this application, optimizations in part positioning, raw material quality assurance, and process parameters were also implemented to ensure an optimum AM process.