Metal Additive Manufacturing Myths:

Transcription

1 Metal Additive Manufacturing Myths: The truth about powder reuse and its effect on mechanical properties Andrew Carter Senior Manufacturing Engineer 1 STRATASYS DIRECT MANUFACTURING

2 30 Years of Additive Applied. Headquarters: Eden Prairie, MN and Rehovot, Israel Over 1,200 Granted or Pending Additive Manufacturing Patents Globally $668 Million Revenue (2017) Publicly Traded On Nasdaq (SSYS) Over 30 Technology and Leadership Awards 2 STRATASYS DIRECT MANUFACTURING

3 ABOUT STRATASYS DIRECT MANUFACTURING Stratasys Direct Manufacturing is one of the largest providers of 3D printing and advanced manufacturing services. 7 U.S. manufacturing facilities 9 Manufacturing technologies 500+ employees Certifications: ISO 9001, AS9100 ITAR registered 3 STRATASYS DIRECT MANUFACTURING

4 MANUFACTURING FACILITIES Valencia, CA Poway, CA Tucson, AZ Phoenix, AZ Eden Prairie, MN Austin, TX Belton, TX 4 STRATASYS DIRECT MANUFACTURING

5 OUR TEAM Our experienced team of project and applications engineers are committed to your success with: Design support for advanced manufacturing Technical direction and recommendations Material, technology and build optimization for quality, speed and affordability 5 STRATASYS DIRECT MANUFACTURING

6 TECHNOLOGIES ADDITIVE CONVENTIONAL 6 STRATASYS DIRECT MANUFACTURING

7 SECTION TWO Additive Metal Production 7 STRATASYS DIRECT MANUFACTURING

8 ADDITIVE METAL CAPACITY 2 Facilities (Austin, TX & Belton, TX) 17 DMLS MACHINES 11 EOS M280 S 4 EOS M290 s 1 EOS M400 1 EOS M Fully supported Machine Shops Dedicated Quality Lab Cutup Metallography Flow Bench, Hydrostatic Tester CMM 8 STRATASYS DIRECT MANUFACTURING

9 ADDITIVE ALLOYS Current Offering SS 17-4 PH* SS316L AlSi10Mg Ti 6-4 Gd5* CoCr INCONEL 625* INCONEL 718* (API-Std avail.) MONEL K500 *Powder chemistry ordered to meet respective AMS standards.* Standard Text = Performance Super Alloys Bold Text = Quick Turn Alloys IN625: -45um +10um, Unused Materials are batched and blended to ensure full traceability SS17-4: -45um +10um, Recycled All materials are kept in airtight, color-coded containers Sourced directly from multiple established atomizers. 9 STRATASYS DIRECT MANUFACTURING

10 ADDITIVE MANUFACTURING IS MOSTLY CONVENTIONAL Stratasys Direct, In-house Heat Treating Vendor Radiographic Testing Vendor DMLS Powder Removal Cutup Metallography HIP Dimensional Inspection CMM, Faro, Surface Roughness Radiographic Inspection X-ray, CT scan This is the only Additive Step In-process Inspection SHT, PHT Performance Inspection Hydrostatic Pressure, Air Effective Area Stress Relief Post Machining Outsourced operations are executed by strategic partners where SDM programs take priority. Plate-Part Separation Part Serialization Dimensional Inspection Radiographic Inspection Performance Inspection 10 STRATASYS DIRECT MANUFACTURING

11 THE TRUTH ABOUT LEADTIMES Stratasys Direct Mfg. Approved Vendor Task DMLS Powder Removal & Inspection Stress Relief Plate Part Separation & Component Serialization HIP & Heat Treat Post Machining Inspection Typical RP Lead Time 11 STRATASYS DIRECT MANUFACTURING

12 SECTION TWO The truth of powder recycling - its happening 12 STRATASYS DIRECT MANUFACTURING

13 Powder handling is an after thought (by the machine manufacturers') Here is how its being done by the OEM s EOS Recommended method M280-M290 + = 13 STRATASYS DIRECT MANUFACTURING

14 Powder handling is an after thought (by the OEM s) Here is how its being done by the OEM s EOS Recommended method M400 s 14 STRATASYS DIRECT MANUFACTURING

15 Powder handling is an after thought (by the OEM s) Here is how its being done by the OEM s EOS Recommended method M400 s 15 STRATASYS DIRECT MANUFACTURING

16 Powder handling is an after thought (by the OEM s) Machine Manufacturer Additive Industries AddUp GE (Concept Laser) 3D Systems EOS Rennishaw SLM Solutions Trumphf Velo3D Powder Handling Internal Mixed External Internal & External External Internal Mixed External Internal No equipment manufacturer is concerned with material traceability. 16 STRATASYS DIRECT MANUFACTURING

17 MANUFACTURING SCENARIO 17 STRATASYS DIRECT MANUFACTURING

18 MANUFACTURING SCENARIO Blend Composition 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Theoretical Blend Composition Over 30 Recycles Build 31 Build 26 Build 21 Build 12 Build 11 Build 6 Build 1 % of Original Batch Times Recycled SDM Recycles 100% material The majority of powder has been recycled. No test method is identified to qualify recycled powder 18 STRATASYS DIRECT MANUFACTURING

19 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE Machine Powder ID # SI1476 Powder SI1991 SI2001 SI1160 Composition 1 3 SI1849 SI1989 SI2006 SI Start Production 4 machines producing product, 4 powder evolution ID # s 19 STRATASYS DIRECT MANUFACTURING

20 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE SI1476 SI1991 SI2001 SI SI1849 SI1989 SI2006 SI Start Production execute 4 builds and refresh with virgin each time 20 STRATASYS DIRECT MANUFACTURING

21 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE SI1476 SI1991 SI2001 SI SI1849 SI1989 SI2006 SI Unplanned Maintenance & Increase customer demand 6 machines producing product, swapped material between two machines, 6 powder evolution ID numbers. 21 STRATASYS DIRECT MANUFACTURING

22 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE SI1476 SI1991 SI2001 SI SI1849 SI1989 SI2006 SI Unplanned Maintenance & Increase customer demand execute 3 builds on all machines 22 STRATASYS DIRECT MANUFACTURING

23 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE SI1476 SI1991 SI2001 SI SI1849 SI1989 SI2006 SI Full Production All machine capacity dedicated to producing product, 8 powder evolution ID numbers 23 STRATASYS DIRECT MANUFACTURING

24 POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE SI1476 SI1991 SI2001 SI SI1849 SI1989 SI2006 SI Full Production execute 5 more builds across all machines 24 STRATASYS DIRECT MANUFACTURING

25 MATERIAL RECYCLING STATION Sometimes simplicity is best. 25 STRATASYS DIRECT MANUFACTURING

26 MATERIAL TRACEABLITY 26 STRATASYS DIRECT MANUFACTURING

27 MECHANICAL DATA STRATASYS DIRECT MFG HAS IT IN625 CoCr IN718 Blends were kept to a single system. Blends were transferred between systems to meet production demands. Virgin material compared material from different lots and different machines. Elevated Temperature Tensile Results IN718 & IN625 Sampled from multiple machines at varying levels of reuse. 27 STRATASYS DIRECT MANUFACTURING

28 Additive IN625 Property Study Study: 7 EOS M280 Machines, 2 Material Providers, 8 Material Lots, >55 Builds per Data represents 385 production builds over an 8 month period. Testing Included: 210 tensile bars (tests performed approx. every 4 builds), 14 Chemical, 20 Metallography Data Analysis: All data submitted to Battelle Comparisons: Build Location Machine to Machine Powder Composition Material Provider AMS 7000: Process Control Document (PCD) Class B - Material Chemistry and PSD Mechanical Testing: Nadcap & A2LA Accredited Test House 28 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

29 POWDER EVOLUTION / LIFE CYCLE SI Vertical Tensile Properties Times Recycled UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend 100% Strength (ksi) % 80% 70% 60% 50% 40% 30% 20% 10% 0% Age of Oldest Powder (days) 29 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

30 TENSILE PROPERTIES OVERLAID ONTO POWDER COMPOSITION SI Vertical Tensile Properties Times Recycled UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend 100% Strength (ksi) % 80% 70% 60% 50% 40% 30% 20% 10% 0% Age of Oldest Powder (days) 30 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

31 INTRODUCTION OF SEPARATE POWDER LOTS SI Vertical Tensile Properties Times Recycled UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend 100% Strength (ksi) % 80% 70% 60% 50% 40% 30% 20% 10% 0% Lot 30 Lot 32 Lot 33 Lot 34 Lot 35 Age of Oldest Powder (days) 31 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

32 MICROSTRUCTURE OVER TIME SI Vertical Tensile Properties Times Recycled UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend 100% Strength (ksi) A B C 90% 80% 70% 60% 50% 40% 30% 20% 10% 0.0 0% Age of Oldest Powder (days) 32 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

33 MICROSTRUCTURE OVER TIME A SI1849 (xy) - Vertical Tensile Properties 8e-3in B (xy) 8e-3in Times Recycled UTS (ksi) Yield (ksi) Elongation C (xy) (%) RA (%) % Virgin % Original Blend 8e-3in 100% Strength (ksi) A B C 90% 80% 70% 60% 50% 40% 30% 20% 10% 0.0 0% Age of Oldest Powder (days) 33 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

34 MICROSTRUCTURE DIFFERENT ORIENTATIONS A (xy) 8e-3in B (xy) 8e-3in C (xy) 8e-3in A (xz) 8e-3in B (xz) 8e-3in C (xz) 8e-3in 34 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

35 MATERIAL CHEMISTRY OVER TIME SI Vertical Tensile Properties Times Recycled UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend 100% Strength (ksi) % 80% 70% 60% 50% 40% 30% 20% 10% 0% Age of Oldest Powder (days) Percent 35 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

36 MATERIAL CHEMISTRY OVER TIME SI1849 & SI Chemistry SI1991 Sup. 1 SI1849 Sup 1 Limit Weight (%) Times Recycled Cr Mo Fe Nb+Ta Powder Age (days) Al 36 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

37 MATERIAL PROVIDER COMPARISON Yield Strength Material Provider Comparison, Yts Ultimate Strength Material Provider Comparison, Uts 35% 28% 21% 14% 7% 0% 25% 20% 15% 10% 5% 0% Yield Strength (ksi) Provider 1 YTS, Avg = 53.3ksi σ = 0.769ksi Provider 2 YTS, Avg = 53.0ksi σ = 0.756ksi Ultimate Tensile Strength (ksi) Provider 1 UTS, Avg = 124.0ksi σ = 0.731ksi Provider 2 UTS, Avg = 127.2ksi σ = 0.577ksi Material Provider 1, n = 180 Material Provider 2, n = STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

38 MATERIAL PROVIDER COMPARISON Strength (ksi, Msi) % 0.59% Material Provider - Mechanical Property Comparison Supplier 1 Supplier 2 n = 180, % 1.09% 11.41% 4.72% 6.47% 1.71% 5.51% 4.73% 100% 90% 80% 70% 60% 50% 40% 30% Percent % 10% 0.0 UTS Yield Mod Elongation RA Tensile Property 0% 38 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

39 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 1 machine Times Recycled 39 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

40 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 2 machines Times Recycled 40 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

41 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 3 machines Times Recycled 41 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

42 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 4 machines Times Recycled 42 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

43 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 5 machines Times Recycled 43 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

44 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 6 machines Times Recycled 44 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

45 Machine to Machine Consistency Strength (ksi) Material Strength vs. Times Recycled, 6 machines, 2 atomizers Times Recycled 45 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

46 MATERIAL PROVIDER COMPARISON The different chemistries produced by different suppliers produced statistically different ultimate tensile strength. Supplier Material Chemistry Supplier 1 (% by Weight) Supplier 2 (% by Weight) Al Cr Mo Nb+Ta Fe STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

47 MATERIAL PROVIDER COMPARISON IN625 Chemistry SI1991 Sup. 1 SI1849 Sup 1 SI1991 Sup. 2 Limit 22.5 Weight (%) Powder Age (days) Cr Mo Fe Nb+Ta Al 47 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

48 MATERIAL PROVIDER COMPARISON IN625 Chemistry SI1991 Sup. 1 SI1849 Sup 1 SI1991 Sup. 2 Limit Weight (%) Cr Mo Fe Nb+Ta Al Powder Age (days) 48 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

49 OUT OF THE 220 BARS, 2 APPEARED DIFFERENT SI Vertical Tensile Properties Build Build UTS (ksi) Yield (ksi) Elongation (%) RA (%) % Virgin % Original Blend Times Recycled % % 80% Strength (ksi) FR FL FL BL 70% 60% 50% 40% 30% % 10% 0.0 0% Age of Oldest Powder (days) 49 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

50 METALLOGRAPIC COMPARISON, BUILDS & z y x z y x Stress Relieved, Additive IN625 (100x) Solution Heat Treated, HIP ed, Stress Relieved, Additive IN625 (100x) 50 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

51 CONCLUSION ADDITIVE IN625 Stratasys Direct Manufacturing s mission to control, track, and develop the AM production process has lead to vertical integration of multiple post process operations and inspection techniques providing the industry with: An efficient and economic powder management process Increased confidence in DMLS material/part quality Increased customer confidence Insight into powder lifecycle Evidence process variation at the additive system level is reduced via certified heat treatments 51 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

52 Additive CoCr Property Study 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) >50 times recycled 52 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

53 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI1849 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 53 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

54 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI1849 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 54 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

55 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI1849 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 55 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

56 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI1849 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 56 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

57 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI2001 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 57 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

58 MANUFACTURING STUDY SAMPLING 90 room temperature tensile blanks from: 2 material provides 6 different machines 51 bars sampled before corrective action (17 builds) 39 bars sampled after the corrective action (39 builds) 6 different powder evolutions Powder Evolution Num. Machine Before or After Corrective Action 8 SI1476 Before 9 SI1991 Before SI2001 SI1476 SI1849 SI2006 Before After Before After 14 SI1848 After 15 SI1991 After 58 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

59 STUDY OUTCOMES COMPARISONS: Before and after the corrective action Machine to Machine Material Provider Material Blend Composition (times recycled) PROVOCATIVE THEORIES: Heat treating is a key factor to reducing process variation Laser based powder bed deposition process window is larger than previously believed. 59 STRATASYS DIRECT MANUFACTURING IN625 CoCr IN718 High Temp

60 INITIAL RUN CHART ALL DATA AT A GLANCE 250 Additive CoCr Room Tensile Results UTS YTS 200 Strength (ksi) Time (days) 60 STRATASYS DIRECT MANUFACTURING

61 INITIAL RUN CHART FIRST OBSERVATION 250 Additive CoCr Room Tensile Results UTS YTS 200 Strength (ksi) Time (days) 61 STRATASYS DIRECT MANUFACTURING

62 MECHANICAL PROPERTIES 30% 25% Ultimate Tensile Strength Pre Corrective Action Post Corrective Action n=59 n=31 40% 35% 30% Yield Strength Distributions Pre Corrective Action Post Corrective Action n=59 n=31 20% 25% 15% 20% 10% 15% 10% 5% 5% 0% % 62 STRATASYS DIRECT MANUFACTURING

63 TENSILE RESULTS SEGMENTED BY POWDER EVO. NUMBER 250 Additive CoCr Tensile Results Strength (ksi) Time (days) 63 STRATASYS DIRECT MANUFACTURING

64 TENSILE RESULTS SEGMENTED THREMAL TEREATMENT 250 SCRAPPED AFTER STRESS RELIEF Additive CoCr Tensile Results Strength (ksi) SCRAPPED AFTER SR + HIP Time (days) 64 STRATASYS DIRECT MANUFACTURING

65 TENSILE RESULTS ONLY REPRESENTING FULLY HEAT TREATED MATERIAL. 250 Additive CoCr Tensile Results Strength (ksi) Time (days) 65 STRATASYS DIRECT MANUFACTURING

66 MECHANICAL PROPERTES VS. THERMAL CONDITION Mechanical Properties % 3.91% SR SR, HIP, SHT 50% Strength, Modulus (ksi, Msi) % 4.02% 7.00% 6.78% 44.69% 13.78% 40% 30% 20% 10% Percent Elongation & Reduction of Area 0 UTS YS Mod Elong. Tensile Property 0% 66 STRATASYS DIRECT MANUFACTURING

67 CHEMICAL RESULTS Composition (% by weight) Cobalt Chrome Chemistry 30% Cr 27% % Mo 5% % Ni 0.00% % C 0.08% % 0.00% Ni Time (days) 67 STRATASYS DIRECT MANUFACTURING

68 CHEMICAL RESULTS Composition (% by weight) 30% 27% 7% 5% 0.50% 0.00% 0.23% 0.08% 0.20% 0.00% Cobalt Chrome Chemistry PRODUCTION HALT LOST OPPORUNTIY TIME Cr Mo Ni C Ni Time (days) 68 STRATASYS DIRECT MANUFACTURING

69 NON-CONFORMANCE - REVISITED Issue: Lack of fusion 0.125IN Location: The interface between contour and hatch. Non Conformance: Lack of Fusion 0.050IN Change in process parameters: ~60% increase in deposition speed ~50% increase in laser power 0.27 W/m 2 energy density (or flux) 9 part build to a 10 part build 69 STRATASYS DIRECT MANUFACTURING

70 BEFORE CORRECTIVE ACTION VS. AFTER CORRECTIVE ACTION Ultimate Tensile Strength Yield Strength Distributions 25% Pre Corrective Action n=29 Post Corrective Action n=31 30% Pre Corrective Action n=29 Post Corrective Action n=31 20% 25% 15% 20% 15% 10% 10% 5% 5% 0% 0% STRATASYS DIRECT MANUFACTURING

71 MATERIAL MANAGEMENT REVISITED Powder Composition 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Theoretical Batch Composition Over 30 Recycles Build 31 Build 26 Build 21 Build 12 Build 11 Build 6 Build 1 % of Original Batch Times Recycled SDM Recycles 100% material The majority of powder has been recycled. No test method is identified to qualify recycled powder 71 STRATASYS DIRECT MANUFACTURING

72 TIMES RECYCLED 200 Ulitmate and Yield Strength vs. Times Recycled Strength (ksi) Times Recycled 72 STRATASYS DIRECT MANUFACTURING

73 CONCLUSIONS ADDITIVE COBALT CHROME Heat treatment is the larger factor in additive metal mechanical properties than previously beleived. An ~60% increase in deposition speed through a reduction of 0.27 W/m 2 along with an 11% increase of deposited material had negligible affect on mechanical properties. Stratasys Direct recognizes a corrective as an opportunity to increase manufacturing efficiency to provide the customer product faster at a reduced priced. Stratasys Direct now provides industry with internal tensile specification minimums for CoCr. 73 STRATASYS DIRECT MANUFACTURING

74 ADDITIVE API IN718 STUDY WHAT IS ADDITIVE API IN718? API American Petroleum Industry API Standard 6A718 Nickel Base Alloy 718 (UNS N07718) for Oil and Gas Drilling and Production Equipment. Chemistry Metallography Tensile Impact Hardness 74 STRATASYS DIRECT MANUFACTURING

75 MANUFACTURING STUDY PARAMETERS Machine Systems: M280, M290, M400 Builds Per Machine: 3 (1 with 100% Virgin Material, 2 with highly recycled material) Locations on Build Plate: 5 Samples at each location: 2 tensile, 4 (2 z, 2 y ) impact, 2 microstructure Total Tested Sample Size: 90 per mechanical property, 11 metallurgical samples 75 STRATASYS DIRECT MANUFACTURING

76 BUILD LAYOUT 76 STRATASYS DIRECT MANUFACTURING

77 BUILD LAYOUT BL BR C FL FR 77 STRATASYS DIRECT MANUFACTURING

78 BUILD LAYOUT BL BR C FL FR 78 STRATASYS DIRECT MANUFACTURING

79 BUILD LAYOUT BL BR C FL FR 79 STRATASYS DIRECT MANUFACTURING

80 BUILD LAYOUT BL BR C FL FR 80 STRATASYS DIRECT MANUFACTURING

81 BUILD LAYOUT BL BR C FL FR 81 STRATASYS DIRECT MANUFACTURING

82 PROCESSING API SPEC ED HEAT TREATMENTS Additive Manufacturing Stress Relief Plate Part Separation (Saw) HIP Machining (Per ASTM E8 cylindrical bars Per ASTM E23 notched izod) Testing (Per ASTM E8 cylindrical bars, per at NADACAP facility) Solution Heat Treatment (1825F for 60min) Precipitate Heat Treatment (1425F for 8hrs) 82 STRATASYS DIRECT MANUFACTURING

83 Testing Standards and Study Comparisons Mechanical Properties: Tensile, ASTM E8 (gage length 4x gage diameter) Impact, ASTM E23 Mechanical Property Comparisons: Machine Systems Build Locations Material Recyclability Orientation Dependent Izod Impact Microstructure Comparisons: XY and YZ grainsize Additive API IN718 vs. Wrought API IN STRATASYS DIRECT MANUFACTURING

84 MACHINE SYSTEM COMPARISON TENSILE RESULTS Machine Comparison, Tensile Properties produce on EOS M280's, M290 s, & M400's % 0.42% 0.40 % M280 M290 M400 n=30 n=30 n=30 100% 90% Strength, Modulus (ksi, MSI) % 0.69 % 0.84 % 3.75% 7.10% 3.88% 3.66% 3.46% 2.28% 7.87% 6.06% 4.35% 80% 70% 60% 50% 40% 30% 20% Percentage 10% 0 UTS YS Mod Elong. RA 0% 84 STRATASYS DIRECT MANUFACTURING

85 BUILD LOCATION COMPARISON TENSILE PROPERTIES Build Location Comparison, Tensile Properties % Strength, Modulus (ksi, Msi) % 0.49% 0.42% 0.35% 0.47% BL BR C FL FR n=18 n=18 n=18 n=18 n= % 0.79% 0.74% 0.83% 0.72% 3.77% 3.83% 4.67% 4.09% 8.09% 4.05% 1.79% 4.19% 2.39% 2.16% 6.67% 4.12% 8.38% 5.58% 4.54% 90% 80% 70% 60% 50% 40% 30% 20% Percentage 10% 0 UTS (ksi) YS (ksi) Modulus (Msi) Elong. (%) RA (%) 0% 85 STRATASYS DIRECT MANUFACTURING

86 TENSILE PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER Virgin vs. Highly Recycled Material - Tensile Properties Strength, Modulus (ksi, Msi) % 0.47% 0.72% 0.64% 100% Virgin Powder Highly recycled Powder (>15X) n=30 n= % 5.54% 2.88% 3.32% 7.42% 5.49% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% Percentage 0 UTS YS Modulus Elongation Reduction of Area 0% 86 STRATASYS DIRECT MANUFACTURING

87 TENSILE PROPERTIES AS A FUNCTION OF TIMES RECYCLED Additive API IN718 Tensile Properties as a Function of Powder Recycling. UTS YS Mod. Elong. RA 100% 90% Strength, Modulus (ksi, Msi) % 70% 60% 50% 40% 30% 20% 10% 0% Times Recycled Elongation, Reduction of Area (%) 87 STRATASYS DIRECT MANUFACTURING

88 NOTCHED BAR IMPACT Reported Measurements: Absorbed Energy (ft-lbs): difference in energy of the striking unit at the instant of impact. Lateral Expansion Measurement (mils): the sum of material expansion on both sides of the sample perpendicular to the striking direction. Percentage of shear fracture (%): difference between total fractured area and the area of unstable fracture region. Lateral Expansion: Larger of A2 or A4 plus the larger of A1 and A3. Percent of Shear Fracture: A*B/total fracture region All impact testing was performed at -75F per API specification. *Figures from ASTM E23, Standard Test Methods for Notched Bar Impact Testing of Metallic Materials. 88 STRATASYS DIRECT MANUFACTURING

89 MACHINE SYSTEM COMPARISON IMPACT 30 Absorbed Energy Fracture Plane XY Energy (ft-lbs) % % 4.84% 5 0 M280 M290 M400 Machine System Vertical-sample Fracture Plane XY 89 STRATASYS DIRECT MANUFACTURING

90 BUILD LOCATION COMPARISON IMPACT 30 Absorbed Energy Fracture plane XY Energy (ft-lbs) % 5.02% 4.38% 4.42% 3.83% 5 0 BL BR C FL FR Build Location Vertical-sample Fracture Plane XY 90 STRATASYS DIRECT MANUFACTURING

91 IMPACT PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER 30 Absorbed Energy as a Function of Material Recycling Fracture Plane XY Energy (ft-lbs) Vertical-sample Fracture Plane XY Times Recycled 91 STRATASYS DIRECT MANUFACTURING

92 VERTICAL VS HORIZONTAL IMPACT PROPERTIES Vertical Horizontal Energy (ft-lbs) % 4.48% 5 0 Horizontal Sample (Fracture plane xz) Vertical Sample (fracture plane XY) Horizontal-Sample Fracture Plane XZ Vertical-sample Fracture Plane XY 92 STRATASYS DIRECT MANUFACTURING

93 HORIZONTAL DIRECTIONAL IMPACT PROPERTIES A B D C Notch Location Fracture Direction A X+ B Z- C X- D Z+ Energy (ft-lbs), Lat. Exp. (mils), % shear Fracture (%) % 5.41% 6.64% 4.48% A B C D A B C D 93 STRATASYS DIRECT MANUFACTURING

94 ADDITIVE API718 METALLOGRAPHY XY vs. ZY XY has a higher frequency of equiaxed grains than ZY Wider range of duplex grain structure in the ZY plane. XY ZY 94 STRATASYS DIRECT MANUFACTURING

95 CONCLUSTIONS ADDITIVE API IN STRATASYS DIRECT MANUFACTURING

96 SECTION Three Elevated Temperature Tensile Results IN718 and IN STRATASYS DIRECT MANUFACTURING

97 FRAMING THE SCOPE OF THE STUDY Metallic Materials Properties Development and Standardization (MMPDS) Handbook A source of accepted A, B, and S basis allowables for metallic material and fasteners. It is recognized by the FAA, DoD, and NASA Properties at Elevated Temperature: At temperatures above room temperature generally result in a decrease in strength and an increase in ductility. Data is plotted as percentages of room temperature allowable property against temperature. 97 STRATASYS DIRECT MANUFACTURING

98 IN718 EXPECTED BEHAVIOR Expected Behavior of Solution-treated and Aged IN718 % of Room Temp. UTS and YTS, AMS5662 A Basis ( in) Bar % of Room Temp. Modulus, AMS 5662 & 5663 A Basis ( in) Bar Percentage of Room Temperature Property 120% 100% 80% 60% 40% 20% 0% Room Temp. Temperature (deg F) 98 STRATASYS DIRECT MANUFACTURING

99 IN718 FIRST GLANCE Temperature Effect on the Tensile Strength of Additive solution-treated and aged IN718 % of Room Temp. UTS and YS, AMS 5662 ( in) Bar UTS, Additive Solution Treated and Aged IN718 Strength (ksi) YS, AMS 5662 & 5663 A Basis ( in) Bar YS, Additive Solution Treated and Aged IN Temperature (deg F) 99 STRATASYS DIRECT MANUFACTURING

100 EXPECTED BEHAVIOR OR ADDITIVE IN Temperature Effect on the Tensile Strength of Additive solution-treated and aged IN718 UTS & YS, AMS 5662 & 5663 A Basis ( in) Bar YS, AMS 5662 & 5663 A Basis ( in) Bar Expected Behavior of Additive IN718 UTS UTS, Additive Solution Treated and Aged IN718 YS, Additive Solution Treated and Aged IN718 Expected Behavior of Additive IN718 YS Strength (ksi) Temperature (deg F) 100 STRATASYS DIRECT MANUFACTURING

101 EXPECTED BEHAVIOR OR ADDITIVE IN718 Temperature Effect on the Elongation of Additive solution-treated and aged IN718 Modulus, AMS 5662 & 5663 A Basis ( in) Bar Modulus, Additive Solution Treated and Aged IN Expected Behavior of Additive IN718 Modulus Modulus (Msi) Temperature (deg F) 101 STRATASYS DIRECT MANUFACTURING

102 SMALL (0.16 ) VS. LARGE (0.25 ) DIAMETER BARS Strength, Modulus (ksi, Msi) ASTM E8, Round Bars, gage length 4X gage diameter " diameter bars room temp 0.16" diameter bars room temp 0.25" diameter bars 1000F 0.16"diameter bars 1000F Ultimate Tensile Strength Yield Strength Modulus 102 STRATASYS DIRECT MANUFACTURING

103 ADDITIVE IN718 TENSILE PROPERTIES AS A FUNCTION OF Room 1000F Strength (ksi) UTS YS Strength (ksi) UTS YS Times Recycled Times Recycled 103 STRATASYS DIRECT MANUFACTURING

104 ADDITIVE IN718 METALLOGRAPHY Tested 6 Samples for Grain Size in the XY and XZ planes. Every sample (regardless of orientation) has an average grainsize ASTM No. 3.5 to 4.5. z y x Precipitation Hardened, Solution Heat Treated, HIP ed, Stress Relieved, Additive IN718(100x) 104 STRATASYS DIRECT MANUFACTURING

105 A COMPARISON OF DIFFERENT THERMAL PROCESSING 250 Temperature Effect of UTS and YS of additive IN718 processed with two different heat treatments 200 Heat Treat 1 UTS Strength (ksi) Heat Treat 2 UTS Heat Treat 1 UTS Expected Behavior Heat Treat 2 UTS Expected Behavior Heat Treat 1 YS Heat Treat 2 YS Heat Treat 1 YS Expected Behavior Heat Treat 2 YS Expected Behavior Temperature (deg F) 105 STRATASYS DIRECT MANUFACTURING

106 IN625 EXPECTED BEHAVIOR Temperature Effect on Ultimate and Yield Strength of IN625 % of Room Temperature UTS % of Room Temperature YS Percentage of Room Temperature Properties 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Room Temp Temperature (deg F) 106 STRATASYS DIRECT MANUFACTURING

107 ADDITIVE IN625 AT FIRST GLANCE Temperature Effect on Ultimate and Yield Strength of IN UTS, AMS 5666 Bar S Basis Allowables UTS, Additive IN625 YS, Balloted AMS7000 IN625 YS, AMS 5666 Bar S Basis Allowables YS, Additive IN Strength (ksi) Temperature (deg F) 107 STRATASYS DIRECT MANUFACTURING

108 ADDITIVE IN625 TENSILE PROPERTIES AS A FUNCTION OF RECYCLING Ultimate Tensile and Yield Strength of Additive 1400F Strength (ksi) Strength (ksi) Strength (ksi) Times Recycled Times Recycled Times Recycled Si1849 SI1991 Material Properties are consistent regardless of the time recycled. 108 STRATASYS DIRECT MANUFACTURING

109 CONCLUSIONS ELEVATED TEMPERATURE TENSILE The elevated temperature tensile response of additively produced nickel base super alloys is similar to the expected behavior or wrought materials. Recycling of feedstock material has little to no influence on room or elevated temperature properties of IN718 and IN625. The appropriate heat treating is required to achieving expected behavior in tensile response at elevated temperatures. Stratasys Direct Manufacturing, committed to promoting the wide spread adoption of Additive Manufacturing as a viable means of producing end-use critical components makes these manufacturing studies available to industry. 109 STRATASYS DIRECT MANUFACTURING

110 CONCLUSIONS 110 STRATASYS DIRECT MANUFACTURING

111 CONCLUSION 111 STRATASYS DIRECT MANUFACTURING

112 THANK YOU Andrew Carter Senior Manufacturing Engineer Stratasys Direct Manufacturing Austin, TX STRATASYS DIRECT MANUFACTURING