Prospects and Potentials of Metal Additive …...Titanium Ti6Al4V – Aerospace, Motorsports and Biomedical Industry Cobalthrome -C CoCrMo – High-Temperature Engineering, Biomedical

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Chair of Metal Forming Department Product Engineering

we are forming the FUTURE...

Prospects and Potentials of Metal Additive Manufacturing

Bruno BUCHMAYR

Montanuniversitaet Leoben

[email protected]

http://www.metalforming.at/

mailto:[email protected]

2 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015

Outline

• Motivation und trends in production engineering • AM overview and SLM – method and characteristics • Main influencing parameters • Available materials and powder quality • Pros and Cons – Prospects and Potentials of SLM • The Austrian “addmanu”-Project (FFG-leader) • Potentials for economic business developments • Outlook


Motivation und trends in production engineering

reduction of product development time, increasing variant diversity, individualised products and small batches, component parts with multiple functionality, component parts with complex geometry, rapid development of prototypes by tool-free manufacturing, rapid tool availability and topologically optimised component parts for lightweight

construction

Modern production is characterized by


Classification of laser manufacturing based on different mechanisms of laser–material interaction

Source: Gu et.al. Int. Mats Reviews 57, 2012

+ EBM


Comparison of some AM processes

Laser melting Laser sintering

Source: Gu et.al. Int. Mats Reviews 57, 2012


EOSINT M280 System at the Chair of Metal Forming

MUL/LUT


Concept of the SLM process (powder bed)

basic body or support structure

overflow shaft

building platform

dosing unit/ metal powder

coater layer thickness 20-50 µm

fibre laser reflector

metal powder metal part

application of a layer of powder

local laser melting lowering of the building platform


EOSINT M280 Technical Data

Technical Data Building volume incl. building platform 250 x 250 x 325 mm (l/b/h) Heating of the building platform up to 200°C Laser-type: Yb-Fibre laser (λ) 400 W (1064 nm) Precision optics F-theta-lens, high-speed scanner Scan speed during build process up to 7,0 m/s Variable focus diameter 100 - 500 μm Layer thickness 20 – 50 µm Diameter of the powder particles 10 – 45 µm Smallest wall thickness 0,3 mm Power supply 32 A Power consumption max. 8,5 kW / typically 3,2 kW Shielding gases integrated nitrogen generator or argon from gas cylinders

Supp

ort

stru

ctur

e 0,

2mm


Seven steps from CAD to manufactured parts

1 3D-Design 2 Conversion to .stl-files 3 Generation of support structures + slicing (Magics, RP-Tools) 4 Positioning and predefinition of

the process parameters (PSW) 5 SLM Building process 6 Removal of surplus metal powder 7 Finishing steps (shot peening,

heat treatment)

data preparation and slicing

positioning and predefinition of the process parameters

start the building process

building platform with metal parts


Important Processing parameters

Processing parameters

• laser power

• scan speed

• strut width

• hatch distance

• exposure strategy

• temperature of the

building platform

• etc.

density, mech. properties, anisotropy, internal stresses, distortion, ...


SLM process - surface

Surface roughness: as built 20 – 50 µm


Metallographic microsections

Nickel-based alloy IN718 Maraging steel MS1 – 1.2709


Determination of suitable process parameters

Lase

r po

wer

[W

]

Scan speed [mm/s]


Chain of AM based added-value

Source: RolandBerger


Available materials – metal powder production

Aluminium AlSi10Mg – Motorsports and Aerospace Applications

Titanium Ti6Al4V – Aerospace, Motorsports and Biomedical Industry

Cobalt-Chrome CoCrMo – High-Temperature Engineering, Biomedical and Dental Applications

Stainless Steels 1.4542, 1.4540, 1.4404 – Mechanical Engineering, Medical Technology and Aerospace

Nickel Base Alloys HX, IN625, IN718 – Aerospace, Motorsports and Industry

Maraging Steel MS1 (1.2709) – Tooling and Mechanical Engineering

+ new developments !!!

Vacuum Inert Gas Atomizisation

Ar


Homogeneity of AM products

(100x )

Maraging steel MS1

Vol ~ 3mm³

= multi-pass weldment without porosity


Metal Powder Characterization

EOS GP1

HELOS MS1


Materials related problems

e.g. martensitic Cr-steel having 0,54%C

micro-cracking

Laser weldability ???


Laser weldability of similar materials

Source: LASAG AG, Thun, CH


Advantages and disadvantages of the SLM process

Pros • Freedom of design

• Enhanced complexity of the metal parts

without additional costs

• Direct, tool-free manufacturing

• Lightweight construction potential (topology and shape optimisation, FEA)

• Combination of parts (from 3 1 part)

• Reduction of manufacturing steps

• Increased functionality

• Conformal cooling systems of tools and mould inserts

Cons • Low production speed

• High manufacturing costs (limited

building rate and high metal powder costs)

• Extensively effort for the findings of appropriate designs and suitable process parameters

• Problems regarding anisotropy, surface quality and tolerances

• Economically expedient only for small batch production and individual parts

• Limited part dimensions

• Residual stresses and distortion

For details see: B.Buchmayr, G.Panzl: A SWOT-Analysis …, BHM 160, 2015,15-20


industry SME R&D institutes

Branches: (1) Materials/Surface coating: Böhler Edelstahl, RHI, Tiger Lacke, Happy Plating (2) Production/Construction/Engineering: Hage Sondermaschinenbau, PKT Bürtlmair, Lithoz, Haratech (3) Electronics: LAM Research (4) Automotive: Magna Steyr Engineering, Mahle Austria Filtersystem (5) Aerospace: Airbus DS, RHP Technology (6) Power engineering: GE Jenbacher (7) R&D and Education: Joanneum Research, FOTEC, Montanuniversität Leoben, Profactor, TU Wien

FFG-leader project - Partners

Start: May 2015, 3Y, 7-8 Mio € Leading institution: MU Leoben


Addmanu – SLM at MUL/LUT

WP1: AM-Tools for polymers - development of new powders - design for intensive cooling - metallic powders for advanced polymers WP2: Light weight design and automotive applications of SLM - Topology and form optimization - cellular structures - multi-material joining - rapid prototyping of first crash cars WP3: Fine structures for aerospace - geometrical limits for channels - heat sink designs - miniature valve systems

Three PhD-students working on

Inspire, CH

NiCrMo-steel, P=250W

Channel diameter of 0,2 mm

MUL/LUT

MUL/LUT


First prototypes at MUL/LUT

gez. Walzl

Internal cooled drill bits Cooled turbine blade


Production of tool for tooth rings

Rapid prototyping and tooling

punch

tube

die

tool final product

Thread grooving concept

Checking using FE-simulation


Worldwide market for AddManu

see annual Wohlers report


Ready for series production ?

Source: Roland Berger


Application field TOOLING

Conformal cooling channels in tools and mould inserts

source: www.lbc-engineering.de, www.hofmann-innovation.com


Tools for Injection Moulding

dish washer part Cooling very close to the surface


Commercial AM-products for aerospace

GKN-Aerospace GE-aviation

Conventionally designed and produced cast steel nacelle hinge bracket for an Airbus A320 (top) and optimised titanium version of the nacelle hinge bracket made by additive manufacturing technology from EOS

Holder Airbus 380 (source: EOS/EADS) PH-Steel

light weight design


Aerospace applications

Bracket Airbus 380 (source: EOS/EADS) PH-Steel

Flange made of Hastalloy X (Tmax=1200°C)

Source: EOS, Munich


Segment of guiding vane and injection nozzle

Source: EOS Munich


AddManu for Aerospace parts

AM-User: GE Aviation, AIRBUS DS, MTU, GKN, Boeing, GE Avio Aero, …

Light weight design Injection head for Ariane V jet engine

Testing at NASA, Cleveland

Complex Geometries using high performance materials

GE

GKN

GE

Airbus 320


AM space components for satellites

source: OHB System AG

1kg weight saving means 15.000.- €


AM Applications in Automotive Manufacturing


Tools for press hardening of steels (PHS)

Great cycle time dependency on cooling rate advanced tool cooling concepts!


Tools for press hardening of steels (cont.)

Source: Fraunhofer IWU


AM for automotive industry

Audi-Werkzeugbau Ingolstadt, inner door, Concept Laser


SLM - Further Potentials

- Medical use,

- Jewellery design,

- Military applications,

- Light weight design in mechan. Eng.,

- Mobile Production,

- Surface technologies,

- Microsystem-technology,

- Sensors,

- Wear protection,

- Copy protection,

- Electronics etc. development of new material systems with better or adjusted properties-profile

To find additional AM applications, we need much more creativity.


AM Outlook

Quelle: Roland Berger, 2015


Outlook – AM Metal Powder Demand

Source: SmartTech Markets Publishing LLC; Additive Manufacturing Opportunities in the Metal Powder Industry: A 10-Year Market Forecast; Nov.2014


stay in touch - mamc2016

Abstract Submission till Jan. 15, 2016


Thank you for your attention

MS 1 powder

and Merry Christmas !

Maraging Steel powder (SEM and microsection)

Documents

Prospects and Potentials of Metal Additive …...Titanium Ti6Al4V – Aerospace, Motorsports and Biomedical Industry Cobalthrome -C CoCrMo – High-Temperature Engineering, Biomedical