Metal Laser Melting. Efficient, toolless manufacture even of

Transcription

1 Metal Laser Melting Efficient, toolless manufacture even of unusual component geometries

2 Project management Consulting on an optimum production process for your components, whether it is metal laser melting, milling from a solid block, sand casting or precision casting Feasibility test for the respective process Design Component optimisation for metal laser melting (weight optimisation, functional integration) Configuration of contour close coolings for the mold construction Development of plastic, sand cast or die cast components Prototype tools, special engineering, fixture construction, equipment Metal laser melting Production of functional prototypes Production of tool inserts with contour close coolings Herstellung von Designmustern

3 Metal Laser Melting Metal powder development Development of metal powders for metal laser melting Testing of metal powders Milling technology 3-axis/ 5-axis processing Processing of titanium, inconel, steel, aluminium Milling from a solid block Tool inserts for injection moulding, die-casting, core moulding tools Processing of cast components Construction of design patterns Assembly Assembly of modules

4 We use the innovative technology of metal laser melting to produce components for a variety of industries. The melting process generates components layer by layer using 3D CAD data. The layering process enables both prototypes and small to medium-sized series to be produced. We layer thickness of between and 0.1 mm, we can produce the components according to the general tolerances to DIN ISO 2768 m within very short cycle time workdays, depending on the component s size and complexity of the finishing Data Machine Data input preparation setting Production Finishing The metal laser melting value-added chain 1. Design Component optimisation for metal laser melting, e.g. weight optimisation, function integration Auslegung von konturnahen Kühlungen für den Formenbau FEM-Berechnungen 2. Data preparation Preparing the design data and converting it into parametrised component data Optimum virtual placement of the component in the construction chamber Defining the support structures (position and size) Adapting the structure of the component (lattice/hollow structure /grid) Separating or joining individual elements in case the components are larger than the available construction space

5 Metal Laser Melting 3. Production Manufacture of functional, initial samples, pilot series components or small series Production on tool inserts with contour-close coolings EOS M280 with construction chamber 250 x 250 x 300 mm Concept Laser M3 with construction chamber 290 x 340 x 280 mm 3D Systems ProΧ320Β with construction chamber 280 x 280 x 420 mm Following alloys are available: AlSi10Mg, , , , , Inconel 625, Inconel 718 und Ti64 4. Follow-up Unpacking the components from the machine Vacuuming up and preparing the unprocessed powder Separating the component from the construction panel Removing the support structures from the component Hand finishing of the surfaces 5. Finishing Heat treatment, depending on the material and requirements All mechanical reworking is possible, e.g. milling, turning, eroding Grinding, polishing, coatings Quality control (visual inspection, measurement, hardness tests) The advantages of metal laser melting: From CAD data directly to the functioning metallic part Material savings compared to processing from a solid block No tools required for the manufacturing (forming tools, master patterns etc.) Rapid production from sized 1 batch A wide variety is possible within a very short time Very high design flexibility Contour-close tempering possible for tools Hybrid design

6 Metal Powder Development Parameter Processing status A (as constructed) B (surface-treated) C (solution-annealed) Tensile strength Rm 629±4 MPa 656±2 MPa 585±3 MPa Yield strength Rp 0,2 509±3 MPa 542±2 MPa 353±2 MPa Elongation at break A 30±2% 30±3% 44±3% Notched bar impact work Kv 2 80±1 J - 114±3 J Vickers hardness 214±10 HV - 172±7 HV

7 General 3D Laser BW has been a service provider since 2011 and has experience in consulting, designing, manufacturing and finishing of metal laser melting components. These experiences have led us to focus intensively on the development and testing of metal powders. Hereby, we pay close attention to ensuring that the standards required for producing and inspecting the alloys are adhered to. All customer material developments are subject to the strictest non-disclosure agreements and are developed and manufactured exclusively for the client s purposes. Requirements Specification sheets based on the customer s requirements Workability (e.g. laser power, preheating, particle size) Examining the melting suitability Quality Carrying out of RFA analysis (X-ray fluorescence) Determining the wet chemical characteristics of individual relevant alloy elements Creating SEM images (scanning electron microscope) Measuring the particle size and particle distribution Determining the flow time and bulk density Determining the C, S, N, O und H contenct

8 Metal Powder Development Result Chemical Analysis Making prototypes based on geometric specifications Producing samples for metallographic examinations (relative density) Determining the mechanical strength values in line with the specification sheet: tensile test, notch impact strength, bending strength, shear strength and torsional strength Available metal powders AlSi10Mg (3.2382), (316L), (17-4PH), (420), (Ni Maraging 300), Inconel 625, Inconel 718, CoCr, (309) If required, we also provide you with the material data sheets for the aforementioned alloys. All metal powders are packed in standardised plastic containers and protected against oxidation for delivery. Shipment volumes start at 5 kg. With each shipment you receive a factory certificate, the complete chemical analysis and the measured strength and density values of the batch.

9 3D Laser BW range Automotive Motor racing Aeronautics and spacecraft technology Mold construction Special engineering Medical engineering 3D Laser BW GmbH & Co. KG Wielandstraße Kirchheim unter Teck Tel Fax Please feel free to contact us. We are happy to be of assistance & are looking forward to hearing from you.