<p>Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe<sub>2</sub>O<sub>3</sub>, Cr<sub>2</sub>O<sub>3</sub>, NiO, and MoO<sub>3</sub> as feedstock for additive manufacturing, combined with sintering under H<sub>2</sub> to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO<sub>3</sub> and Cr<sub>2</sub>O<sub>3</sub>, is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.</p>

错误:搜索内容不能为空,请输入英文关键词
错误:关键词超出字数限制,请精简
高级检索

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

  • Mingzhang Yang,
  • Rangasayee Kannan,
  • Mohsen K. Keshavarz,
  • Mihaela Vlasea

摘要

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe2O3, Cr2O3, NiO, and MoO3 as feedstock for additive manufacturing, combined with sintering under H2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO3 and Cr2O3, is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.