1. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved
2. C O N F I D E N T I A L OMTEC 2017 June 13-15, 2017
Presented by: Ray DeFrain, Regional Metallurgist - Midwest U.S.
/Canada Claudia Mumau, External Collaborations Manager
Considerations for Metal Powders used in Additive
Manufacturing
3. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 3 Introductions Claudia Mumau External Collaborations
Manager email: [email protected] phone: 610.208.4003 Ray DeFrain
Regional Metallurgist for Midwest U.S. & CANADA email:
[email protected] phone: 484.793.5130
4. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Introductions Carpenter Technology: Overview Our Core
Values and History Medical Market Focus & Current Snapshot
Introduction to Additive Manufacturing Interest & growth trends
in Medical market Identify opportunities and advantages of AM
Identify challenges with AM Powder: 5 Whys? Common Powder
Production Methods Carpenters selected methodology Important
attributes of Powder Carpenters Production Method & Process
Flow Path Powder Properties: Meeting Expectation through Innovation
Carpenters Commitment to Powder Carpenters Testing Capabilities
& Powder Inspection capability The importance of defining
design criteria Partnering with a design house &
manufacturer-in-one! Case studies Examples of Printed Parts in use
today Questions 4 Agenda
5. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 5 Advanced Specialty Alloys
6. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved INSTRUMENTS AND TRAUMA IMPLANTS CarTech 316, CarTech
440A/C CarTech Custom 455 Stainless CarTech Custom 465 Stainless Ti
6AI-4V ELI, CP 4 (Dental Implant) Various other ASTM F899 Alloys *
MP35N is a registered trademark of SPS Technologies, Inc. FRACTURE
FIXATION CarTech BioDur 316LS Alloy Ti 6Al-4V ELI CarTech BioDur
108 Alloy HIP AND KNEE REPLACEMENTS CarTech BioDur CCM Alloy
CarTech BioDur CCM Plus Alloy VASCULAR DEVICES (stents) CarTech
MP35N Alloy CarTech L-605 Alloy ARTIFICIAL DISCS & SPINAL
FIXATION CarTech Micro-Melt BioDur CCM Alloy CarTech Micro-Melt
BioDur CCM Plus Alloy CarTech Micro-Melt BioDur GADS Alloy SURGICAL
NEEDLES AND STAPLES CarTech Custom 475 Stainless CarTech 420
Stainless Ti 6AI-4V ELI Medical Alloy Snapshot
7. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Introductions Carpenter Technology: Overview Our Core
Values and History Medical Market Focus & Current Snapshot
Introduction to Additive Manufacturing Interest & growth trends
in Medical market Identify opportunities and advantages of AM
Identify challenges with AM Powder: 5 Whys? Common Powder
Production Methods Carpenters selected methodology Important
attributes of Powder Carpenters Production Method & Process
Flow Path Powder Properties: Meeting Expectation through Innovation
Carpenters Commitment to Powder Carpenters Testing Capabilities
& Powder Inspection capability The importance of defining
design criteria Partnering with a design house & manufacturer
in-one! Case studies Examples of Printed Parts in use today
Questions 7 Agenda
8. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 8 Interest and growth in AM for Medical Market According
to Market Research Reports, Medical demand for additive
manufacturing powder is projected to grow by 23% annually through
2025. 2,681 2,252 1,864 1,518 1,222 950 708 296 213156113 0 1,000
2,000 3,000 201620142012 Additive manufacturing market size ($M)
+23% 20202018 Source: Wohlers Associates (baseline data), SmarTech
Publishing (forecast growth rate) EIGA atomizer: ALD
ForecastHistorical Powder atomization Vacuum furnace upgrades
Titanium alloys Screening & handling ultrasonic cascading
screens, inert handling Product management Technical sales R&D
resources AM application engineers Addition of new AM powder
capabilities Dedicating addition of resources to AM Carpenters
Response to this Need
9. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 9 Interest and growth in AM for Medical Market Key AM
Takeaways: Interest and Growth Titanium, Titanium Alloys, and
Cobalt-Chrome powders will be the largest beneficiaries of
increasing medical Additive Manufacturing demand. Ti, Ti-alloys,
and Co-alloys combine superior mechanical properties with excellent
biocompatibility. Each have shown success in Additive manufacturing
practices, with production-level precedence established in new
designs. Additive Manufacturing has unique advantages over
conventionally machined parts, exhibited in the following
slides.
10. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 10 Opportunities and Advantages of AM AM Changes the
Economies of Scale AM has the potential to reduce the capital
required to reach minimum efficient scale for production, thus
lowering the barriers to entry to manufacturing for a given
location. Reference: Atzeni, Eleonora, Luca Iuliano, and
Allessandro Salmi. 2011. On the Competitiveness of Additive
Manufacturing for the Production of Metal Parts. 9th International
Conference on Advanced Manufacturing Systems and Technology.
11. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 11 Opportunities and Advantages of AM Manufacturing
flexibility reducing the costs associated with production
changeovers and customization. Numerous, and often differing, parts
can be printed concurrently Single machine and tooling for internal
and external features Single input material, rather than numerous
variants of inventory
12. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 12 Opportunities and Advantages of AM Customization Hybrid
conventional machining + AM build up Internal design features
(Physical Modulus Manipulation) Patient specific design
13. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 13 Opportunities and Advantages of AM 510(k) clearance The
FDA has approved multiple devices using additive manufacturing.
Most of them via the 510(k) or emergency use pathways. The FDA has
developed draft guidance approximately 1 year ago for AM. Showing
signs of their expectation of further implementation of this
technology.
14. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 14 Opportunities and Advantages of AM Complex shapes
Ability to create novel shapes Forms that could promote faster
healing Lattice / Hollow structures (only possible through AM) can
enable: custom stiffness custom strength reduced weight
15. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 15 Current Challenges with AM Current Challenges with the
Technology: Low throughput, compared to traditional subtractive
manufacturing New equipment design can advance, but still will be
small volumes. AM recipes dont necessarily produce consistent
results across different machines Equipment manufacturers have
tackled AM through different designs. Metallurgical properties not
fully honed Carpenter Technology can be an integral partner for
this, developing customer AM- specific powder blends, as we have
for numerous customers already. Lack of universal industry
standards Wrought requirements and the expectations of AM parts vs.
wrought parts have not aligned to the point of wide-spread standard
development. Committees to support this growth have been
established. Post-processing operations still required Many
processes still require HIP to drive 100% consolidation.
16. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Introductions Carpenter Technology: Overview Our Core
Values and History Medical Market Focus & Current Snapshot
Introduction to Additive Manufacturing Interest & growth trends
in Medical market Identify opportunities and advantages of AM
Identify challenges with AM Powder: 5 Whys? Common Powder
Production Methods Carpenters selected methodology Important
attributes of Powder Carpenters Production Method & Process
Flow Path Powder Properties: Meeting Expectation through Innovation
Carpenters Commitment to Powder Carpenters Testing Capabilities
& Powder Inspection capability The importance of defining
design criteria Partnering with a design house & manufacturer
in-one! Case studies Examples of Printed Parts in use today
Questions 16 Agenda
17. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 17 Common Powder Production Methods: Gas vs Water
Atomization Material High Alloy Morphology Spherical Density ~100%
Oxygen level ~100ppm Toughness High Cost High No Need to Press
& Sinter Gas Atomized Powder Water Atomized Powder Material Low
Alloy Morphology Irregular Density ~90-95% Oxygen level ~2000ppm
Toughness Low Cost Low Must Press & Sinter
18. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Metal Powder Basic Requirements Chemistry Particle Size
Distribution (PSD) DMLS 10-44 micron EBM 44-106 micron FLM 44-150
micron Morphology and Flow Cleanliness PSD -44u
19. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Powder Characterization Characteristic Test Method(s) ASTM
Std. Benefits Limitations PSD Sieve analysis B214 Large sample
size, No algorithms Size range (low discrimination) Difficult for
fine powder Light scattering B822 Fast, high resolution Relative to
sieve analysis, Powder shape and light scattering assumptions
Digital image processing Comparable to sieve analysis Much of
current industry/customer base relies on light scattering methods
Flow Hall flow B213 Simple Some non-flowing (per B213) powder works
well in AM Carney flow B964 Amenable to more powder Not as commonly
used Angle of Repose B243 (def.) Simple Little correlation
available between test values and real world AM results Rheological
Testing (Freeman, Mercury, etc.) Test many properties Expensive,
Little correlation available between test values and real world AM
results Density Tap Density B527 Simple AM machines lack
tapping/driving force for optimum packing in this manner Apparent
Density B212 / B417 Simple Not analogous to spreading regime in AM
Standard test methods lack ability to discriminate between good and
bad AM powder Further correlation between new test methods
necessary to aid in evaluation of virgin and used material
20. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 20 Powder Production Methods: Detail on Gas Atomization
Environments Air, Inert Gas, or Vacuum Melt Melting type Plasma
Induction Vacuum (Soluble Gas) Atomization Melt Nozzle Straight
bore, conical, etc. Free Fall Close coupled Chamber / Collection
Vessel Configuration Atomization Ar vs. N2 vs. He Example:
Carpenters VIM - Gas Atomization
21. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Melt/ Atomize Screen Classify Blend and/or Pack Process
Flow Chart 1. Melt in Furnace 2. Control flow in tundish 3. Pour
out of Atomization nozzle 4. Obliterate via Gas system 5. Cool in
Atomization tower 6. Sealed in via mechanism 7. Collect in
container Insure uniformity Inert gas handling Avoid moisture Work
to strict packaging requirements Air classified to segregate
particle size into proper distributions for end applications
22. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Introductions Carpenter Technology: Overview Our Core
Values and History Medical Market Focus & Current Snapshot
Introduction to Additive Manufacturing Interest & growth trends
in Medical market Identify opportunities and advantages of AM
Identify challenges with AM Powder: 5 Whys? Common Powder
Production Methods Carpenters selected methodology Important
attributes of Powder Carpenters Production Method & Process
Flow Path Powder Properties: Meeting Expectation through Innovation
Carpenters Commitment to Powder Carpenters Testing Capabilities
& Powder Inspection capability The importance of defining
design criteria Partnering with a design house & manufacturer
in-one! Case studies Examples of Printed Parts in use today
Questions 22 Agenda
23. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 23 Production Locations CENTRAL & SOUTH AMERICA EUROPE
NORTH AMERICA Powder manufacturing Regional sales office Torshalla,
Sweden Air / PHT N2 Bridgeville, PA 2 VIM 1 Air Ar / N2 Woonsocket,
RI Inert Melt Ar / N2 Global HQ: Reading, PA 300 lb vacuum (R&D
furnace) Bruceton Mills, WV Titanium ASIA / APAC Athens, AL VIM Ar
/ N2
24. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 24 Powders & Applications Nickel alloys High
temperature superalloys Duplex and super duplex Austenitic
stainless Magnetic alloys Nitrogen strengthened SS Precipitation
hardened SS Tool steels Maraging steels HSLA steels Cobalt alloys
Copper alloys Titanium alloys (coming soon) High purity,
gas-atomized powder products Serving performance end applications
across our markets Metal injection molding (MIM) Additive
manufacturing (AM) HIP Near Net Shapes HIP Mill Forms Thermal spray
Cladding / metal deposition
25. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Titanium Powder Production Newly refurbished 55,000 square
foot state-of-the-art Titanium & Titanium Alloy facility Powder
Production: Gas Atomizer and Plasma Arc Melter ISO 9001 & AS
9100 certified
26. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Titanium Powder Production All Titanium System eliminates
iron contamination Refractory-Free eliminates refractory
contamination Pure, Spherical, Homogeneous powder
27. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Research and Development
28. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Research and Development R&D Mirror of AM major
process Needs Vacuum Induction Melting (VIM) Fe-base, Ni-base,
Co-base Ingot sizes = 15kg & 180kg VIM Powder Atomization Unit
300lb capacity AM equipment testing on-site and through
partnerships Heat treating Enabler for Product Development and
Process Optimization
29. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Materials Characterization Examples: X-ray Diffraction
Metallography Orientation Imaging Electron Microprobe SEM Image
Analysis565248444036322824201612840 Area (m) 0 150 300 450 600 750
Count 0 20 40 60 80 100 Cumulative(%)
30. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Customer Collaborations Classifier for R&D programs
New power supply for R&D atomizer Yield Improvements Enhanced
controls Water modelling of atomization process Nozzle design
collaboration with Mikro Systems, Inc. Industry
Participation/Standards Creation Mercury Scientific Revolution
analyzer Freeman FT 4 Rheometer Microtrac for PSD Image Analyzer
for Particle Shape Technique for measuring hollow spheres AM
Strategy Team Addition of Resources Development of AM Technology
Center Emerging Measurement Techniques
31. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved 31 Became preferred supplier Highest quality CCM powder
Custom powder PSD and chemistry Optimized for machine performance
Provided supply chain solutions Cooperative re-use / recycling
program Improved CCM alloy for AM production of aerospace component
Tailored 17Cr-4Ni PH powder for Medical AM Instrumentation
Proprietary Engine Component (discussion limited) Identified
mechanical property issue with commercially available powder
Leveraged Carpenter technical expertise to develop alternatives
Improved mechanical properties for AM components (ASTM A564) Became
preferred supplier AM Development Case Studies
32. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Examples of AM Parts In Use Today
33. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved Questions? Thank you for your attention! Are there any
questions?
34. C O N F I D E N T I A L 2017 CRS Holdings, Inc. All rights
reserved