Content. Keynote presentation: Akad. Rat Dr.-Ing. Ingomar Kelbassa Dr.-Ing. Andrés Gasser

Transcription

1 1 Keynote presentation: Laser additive manufacturing possibilities and advantages for the factory of the future Akad. Rat Dr.-Ing. Ingomar Kelbassa Dr.-Ing. Andrés Gasser Industrial Laser Applications Symposium (ILAS) 2009 The Abington Hall Conference Centre, TWI July 7 8, 2009 Content Process basics - Laser Metal Deposition (LMD) - Selective Laser Melting (SLM) State-of-the-art State-of-research-and-development Case studies industrially implemented applications Seite 2

2 2 Content Process basics - Laser Metal Deposition (LMD) - Selective Laser Melting (SLM) State-of-the-art State-of-research-and-development Case studies industrially implemented applications Seite 3 LMD with powder feeding 1 step process Seite 4

3 4 Characteristics of LMD and SLM Selective Laser Melting (SLM) characteristics LMD SLM Laser Metal Deposition materials part dimensions part complexity dimensional accuracy build-up rate build-up on roughness R z layer thickness large materials diversity limited by the handling system limited 0.1 mm 3D-surface on existing parts limited and lower experience in comparison to LMD limited by the process chamber (ø : 250 mm, height : 160 mm) nearly unlimited 0.1 mm cm 3 /h 2-10 cm 3 /h flat surface flat preforms µm µm mm mm Seite 7 LMD expertise Handling / powder feeding components Laser sources Process management Materials 100 µm Process modeling Process monitoring Seite 8

4 5 Principles of powder feeding off axis powder feeding optics coaxial powder feeding continuous powder feeding discrete powder feeding Seite 9 Concepts for powder feeding nozzles off-axis 10 mm continous coaxial discrete Seite 10

5 6 LMD head for cladding inner contours IBO Module I: Head IBO Module II: Optic IBO Module III: Fibre connector support Optic and protection glass IBO Module IV: Support for guide tube Fibre connector (Light fibre) Outer diameter: 22 mm Length: 102 mm Guide Tube 2 internal cooling cycles, powder supply, shielding gas supply Seite 11 Zoom optic for variable track width Solid state and diode lasers CNC controlled Laser power up to 3 kw Variable tracks widths approx. 0,6 mm 4 mm Constant tool centre point 3D-cladding possible Up to 90 degrees inclination possible 50 mm In cooperation with Reis Lasertec Seite 12

6 7 Content Process basics - Laser Metal Deposition (LMD) - Selective Laser Melting (SLM) State-of-the-art State-of-research-and-development Case studies industrially implemented applications Seite 13 NGV 2 (+ Liner 1) LMD for Cladding of mesh structures, In 625 on Mar-M 002 (+ CMSX-4) NGV 2 with cladded mesh structures (ILT / LLT) and TBC applied by APS (FZ Jülich) Feasibility study incl. determination of suitable process layout and process parameters finished 4 years ago Now: Manufacture of OEM parts Liner 1 with cladded mesh structures Seite 14

7 8 Reconditioning of damping wire grooves by LMD / Ti-6246 Front drum Laser cladded groove Main challenges: Accessibility Processing without affecting opposite wall Before / after cladding Seite 15 Tip & Leading Edge BLISK repair by LMD / Ti-17 / Ti-6Al-4V By laser cladding reconditioned BLISK-blade tip 10 mm By laser cladding reconditioned BLISK-blade tip By laser cladding reconditioned BLISK-blade leading edge 10 mm By laser cladding repaired BLISKblade leading edge Seite 16

8 9 Laser cladding of glass moulds Materials: Glass mould: grey cast iron Layer: Ni-Base alloy Processing: fiber coupled diode laser P L = 2 kw 3D - cladding with discrete 3 - beam nozzle Processing time for typical glass mould: 5-10 minutes Seite 17 Individual parts and small lot series by SLM Application: Application: manufacturing manufacturingof of internal internalhollow hollowstructures Advantage: Advantage: no no geometric geometriclimitations like likeconventional Vision: Vision: ultralight ultralightstructures structuresinin combination combinationwith withlight weight weightmaterials materialslike like Ti-6Al-4V Ti-6Al-4V (aerospace (aerospaceappl.) appl.) TiAl6V4 Inconel 718 AlSi10Mg Seite 18

9 10 Mould inserts with Conformal Cooling Application: Application: Design Design of of conformal conformal cooling coolingchannels channels Advantage: Advantage: Time Time reduction reductionduring during injection injectionmoulding Quality Qualityenhancement enhancementthrough through reduction reductionof of warpage warpage Vision: Vision: Manufacturing Manufacturingof of inserts insertsfor for critical critical points pointsin in tools tools in cooperation with BRAUN GmbH Seite 19 Mould inserts with Conformal Cooling Application: Manufacturing of of inserts insertson on top topof of preforms preforms made madeof of tool toolsteel Results: Results: Continous Continoushigh hardness hardness of of HRC HRC Small Small heat heataffected affectedzone No No cracking crackingin in SLM SLM part partand and interface interface SLM part of insert preform Hardness 53 HRC in cooperation 49 HRC with BRAUN GmbH 56 HRC Seite 20

10 11 Mould inserts with Conformal Cooling Thermographic Thermographicimage image after after 2sec. 2sec. Cooling Cooling Results: Results: Significantly Significantly higher higher cooling cooling rate rate of of SLM SLM part part in in comparison comparison to to copper copper alloy alloy Improvement Improvement of of plastic plastic part part quality quality through through homogeneous homogeneous temperaturperaturedistribution in in tem- the the mould mould Ampco 940 SLM part Seite 21 Interim conclusion LMD qualified for: - Manufacture of smaller structure sizes by µ-lmd (such as mesh structures) - Local salvage / repair (such as damping wire grooves, BLISK repair etc.) - Wear and corrosion resistance - Materials such as Ti, Ni, Fe, Co base alloys LMD NOT qualified for / deficits: - Manufacture of larger entire parts such as casings, BLISKs etc. - Materials such as Intermetallics, MMCs, CMCs, graded layers etc. - No integration in entire process chains Significant increase of deposition rate Qualification of new materials & smaller structure sizes Integration in CAx-framework Seite 22

11 12 Interim conclusion SLM qualified for: - Manufacture of smaller parts with internal hollow structures - Materials such as Ti, Ni, Fe, Co, Al base alloys SLM NOT qualified for / deficits: - Manufacture of larger entire parts such as casings, BLISKs etc. - Materials such as ceramics, graded layers etc. Significant increase of deposition rate New systems engineering processing chamber Qualification of new materials such as ceramics & smaller structure sizes Seite 23 Content Process basics - Laser Metal Deposition (LMD) - Selective Laser Melting (SLM) State-of-the-art State-of-research-and-development Case studies industrially implemented applications Seite 24

12 13 LMD of copper mould insert 500 FeCrV FeCr FeNi Cu 500 µm Hardness Härte [HV [HV 0,3] 0.3] layer substrate 0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 Abstand von der Oberfläche x [mm] distance from surface [mm] Surface hardness up to 450 HV Intermediate layer : FeNi Graded layer: FeCr + FeCrV Seite µ-lmd Cross section substrate Top view P= 14 W v= 500 mm/min Ø L = 60 µm Substrate: (stainless steel) Additive material 316L: Powder particle diameter: 1-9 µm Result: Homogenous track geometry Track width: 50 µm Track height: 7 µm Melting depth: 6 µm High dilution: > 40% Seite 26

13 14 µ-lmd: Potential applications Medical Science Electronic Industry Energy Sector SEM Fa. Angiomed X-ray 200 µm 2 mm Increasing X-ray visibility by cladding markers made of tantalum on nitinol stents Electronic switch Fa. Inovan GmbH Silver contact 4 mm Selective cladding of silver contacts on stainless steel switches Reduction of used precious material Gold contacts 1 mm Cross section Gold contacts for fuel cells 50 µm FZ Jülich J Seite 27 SLM of ceramics Ceramic materials Zirconium-based ceramics Density approx. 100% First demonstration parts manufactured Current R&D-focus: Avoidance of micro-cracks Seite 28

14 15 SLM of PEEK PEEK Density ca. 100% First demonstration parts manufactured Current R&D-focus: Development of machine components Reproducibility Seite 29 µ-slm Using reduced powder grain sizes in in combination with novel fibre lasers with high beam quality elemental structure resolution of: of: dcyl = dcyl µm, dhole = dhole µm µm could be beachieved dhole dcyl Seite 30

15 16 Combination of additive and ablative techniques Tool for micro injection moulding preform conventional manufactured generative process including cooling channels by SLM post processing: outer control: grindig inner control: laser ablation preform 12 mm SLM-part final part Seite 31 Content Process basics - Laser Metal Deposition (LMD) - Selective Laser Melting (SLM) State-of-the-art State-of-research-and-development Case studies industrially implemented applications Seite 32

16 17 Repair of HPT Case at several locations 300 mm Seite 33 Machine implemented at Rolls-Royce, Oberursel 1 kw lamp pumped Nd:YAG laser axis (turning table) Automated powder mass flow measurement Automated laser power and beam profile measurement (PRIMES) Seite 34

17 18 Cladding of aero engine components at KLM, Amsterdam Examples: housing flange (Inconel 718), rotating seals (17-4PH) Repair of flange and cross section Repair of sealing and cross section In cooperation with KLM Seite 35 Cladding of aero engine components at KLM, Amsterdam 6 Axes Stäubli Robot + turning table (tiltable) + long turning table 1 kw fibre coupled Nd:YAG laser Completely automated Sensing system for detecting position of components In cooperation with Rolan Robotics Seite 36

18 19 Laser cladding of gear components at Stork Gears & Services, Rotterdam Applications Petrochemical industry / offshore drilling Shipping Storage and transhipment Sugar industry Steel industry Energy companies Source: Stork Gears & Services Seite 37 Repair of gear components at Stork Gears & Services 2 kw fibre coupled diode laser from Laserline Discrete coaxial nozzle Turning table Robot system Typical layer thickness 0,5 mm Hardness HRC Replacement of: Chromium plating Thermal spraying In cooperation with Stork Gears & Services Seite 38

19 20 First Industrial Application of SLM - Dental Restaurations Application: reconstruction of of single teeth teeth Process steps: preparation model digitalization design (CAD) manufacturing (DLF) (DLF) control of of model ceramic cover cover Production start: start: Nov. Nov In cooperation with BEGOmedical AG Seite 39

20 21 Loading videostream and thanks a lot for paying attention! Seite 41