Project proposal: HTCS for

MAM
High thermal conductivity steel for Metal Additive
Manufacturing

R&D, 24/10/2023
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ROVALMA MAM (Metal Additive Manufacturing)

Alloys comparison

Alternative to MAM w/o MAM’s advantages

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 ROVALMAs’ MAM vs SLM, DeD, WAAM

CONVENTIONAL DeD & WAAM SLM ROVALMA-MAM

Design Flexibility: Moderate Moderate Good Excellent

Cost [% to conventional] 100 250 1500 140

Maximum Size [m x m x m]: VERY LARGE VERY LARGE 0.4 x 0.4 x 0.4 1x2x4m

1ry Energy Required

[KWh/Kg] 48 // 85.441 40 // 26.767 75 // 23.882 15 // 4.903

Elongation [%] 11 Weld Quality ~4 Up to 14

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 Main desiderable properties for brake discs steel
• Thermal conductivity determines peak T and heating/cooling rate (HIGHEST
DESIDERABLE)

• Tempering T determines the temperature from which perlite start trasforming to

ferrite (HIGHEST DESIDERABLE)

• C % determines how much can precipitates (LOWEST DESIDERABLE)

Thermal conductivity annealing T C% Mechanical properties over

T range

33,5 W/mK at RT 34,1 W/mK at Ac1 = 745°C 0,38 - 0,45 1200 MPa at 900 MPa at
42CrMo4
450°C Ac3 = 790°C RT 450°C

46 W/mK at RT 34 W/mK at Ac1 = 765°C 0,12 - 0,18 1150 MPa at 910 MPa at
15CrMoV4-6
450°C Ac3 = 950°C RT 450°C

45 W/mK at Ac1 = 803°C 1343 MPa at 1010 MPa at

HTCS 60 W/mK at RT 0,28 - 0,32
450°C Ac3 = 1028°C RT 450°C

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Potential advantages of htcs in POLI brake discs
1. Design flexibility thanks to MAM

2. Lower max T peaks that can brings to decreasing the weight of the final product

3. Surface annealing starts at higher temperature respect to 15CDV6 (if occurs). Ferrite formation is difficult, so
cracks formation is reduced and delayed

4. Ferrite formation % is low because C% is low. The best is however 15CDV6

5. Lead time is short (4/6 weeks)

6. Hardness is higher so that wear is lower (ref: 15cdv6)

7. UTS, R02, conductivity, hardness and many other material properties are very stable over T range.

8. Convective coefficent of heat transfer is higher respect to conventional steel

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 MAM steps and leadtime

Preparation + Printing + Post Processing. Current state: approx. 4/6 Weeks

Structure change

Alternative to MAM w/o MAM’s advantages

Max component dimensions: 1000 x 2000 x 4000 mm

Max 7.200 Kg /piece
Max 15.000 Kg/day (limitating step is HT if required)

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Example of application in Wabtec (FEM caluculated)

T max is ca 450°C

Today.... 15CDV6 WMD (1,2 mln_Km

min)

Mandatory sintered pads (€€)

T max is ca 380°C
HTCS WMD ( disc life > 2
Tomorrow... mln_km)
Reduction in weight - 25%

We can skip to Organic (€)

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