Increase of Productivity by Using Adaptive LPBF Process Strategy 3D Valley Conference

Transcription

1 Increase of Productivity by Using Adaptive LPBF Process Strategy 3D Valley Conference Anders Such, Tobias Pichler Fraunhofer ILT Christoph Korbmacher MAN Energy Solutions Aachen

2 AGENDA 1 2 Short Introduction of LPBF at Fraunhofer ILT Increase of Productivity by Adaptive LPBF Process Strategy Slide 2

3 AGENDA 1 2 Short Introduction of LPBF at Fraunhofer ILT Increase of Productivity by Adaptive LPBF Process Strategy Slide 3 intern

4 Laser Powder Bed Fusion Definition and Naming Direct Metal Laser Sintering (DMLS) Laser-powder bed fusion (L-PBF) Selective Laser Melting (SLM ) LaserCUSING Same Process Laser Metal Fusion (LMF) Metal Additive Manufacturing Selective Laser Melting (SLM TM ) Direct Metal Printing (DMP) Seite 4 intern

5 Laser Powder Bed Fusion at Fraunhofer ILT Group structure Laser Powder Bed Fusion Process Technology Application Machine Technology High Temperature Preheating Polymer Processing Processing Strategies for new exposure concepts Feasibility Studies Product Development Process Development for Standard AM Materials (e.g. IN718, Ti64, AlSi10Mg) Post Processing High Power LPBF Processing Strategies for Commercial Systems Using new Laser Beam Sources (green, blue, diode, VECSEL ) Exposure Concepts Component Development Machine Modifications Conceptual Studies Assessment of LPBF Machines and Periphery Seite 5 intern

6 AGENDA 1 2 Short Introduction of LPBF at Fraunhofer ILT Increase of Productivity by Adaptive LPBF Process Strategy Slide 6

7 R&D Cooperation Leads to Series Production Additive Manufacturing of Guide Vane Segment R&D cooperation between MAN Energy Solutions and Fraunhofer ILT Duration of development:3-5 Years Monolithic design: Conventional design: 13 parts AM design: 1 part Reduction of manufacturing costs Increase of part performance Approval for series production: April 2017 Seite 7

8 Evolution Steps Additive Manufacturing of Guide Vane Segment Geometry for conventional manufacturing Geometry for Additive Manufacturing Evolution step 1 Evolution step n 1-row Guide Vane Segment 6-row Guide Vane Segment 12-row Guide Vane Segment Complexity Slide 8

9 Current State Additive Manufacturing of Guide Vane Segment Identification of a possible business case Detailed calculation and validation of the business case Test of pilot series in a prototype gas turbine Current state Basic developments for Additive Series Manufacturing Process development Part development Qualification of supplier for Additive Series Manufacturing Know-how transfer Manufacturing of pilot series Additive Series Manufacturing Buy Make ??? Slide 9

10 Increase of Productivity Fields of Action Multi scanner High power Low cost Lightweight design Machine Design Fields of action to High detail resolution High build-up rate increase productivity LPBF Heat Treatment Process Production Machining Slide 10

11 Approach Adaptive LPBF Process Strategy Part analysis LPBF process strategies Fitting surface Machining necassary 3D functional surface LPBF process with high surface quality necassary»conventional«same build-up strategy for whole part Build-up strategy is designed according to the surface requirements»skin-core«build-up strategy independent from local part requirements»adaptive«build-up strategy adapted to local part requirements Slide 11

12 Overall Working Procedure Adaptive LPBF Process Strategy Correlation between process parameters and material properties Combination of various process parameter sets in one component Adaptive LPBF process strategy applied on a guide vane segment Correlation between process parameters and geometrical properties Correlation between manufacturing chain with the focus on LPBF and non-machining post processing and geometrical properties Slide 12

13 Working Procedure Adaptive LPBF Process Strategy Correlation between process parameters and material properties Combination of various process parameter sets in one component Content of this presentation Adaptive LPBF process strategy applied on a guide vane segment Correlation between process parameters and geometrical properties Correlation between manufacturing chain with the focus on LPBF and non-machining post processing and geometrical properties Slide 13

14 Layer thickness D s [µm] Working Procedure Correlation between Process Parameter and Material Properties Manufacturing Analysis Density and type of Defects M ax. TruPrint 1000 SLM 280 HL M achine TruPrint Laser Pow er P L [W] Melt pool geometry EBSD analysis Slide 14

15 Machine and Material Experimental Setup SLM 280 HL Twin Laser: 2x Single Mode 400 W Laser spot size: d s 80 µm Max. scan velocity: : v s,max = 10 m/s Building volume: 280 x 280 x 365 mm³ TruPrint 3000 Laser: 1x Single Mode 500 W Laser spot size: d s 100 µm Max. scan velocity: v s,max = 3 m/s Build volume: Ø300 mm x 400 mm Powder Material: Inconel IN718 Particle size: µm Supplier: Oerlikon Metco Slide 15

16 Inter gas flow Data Preparation (SLM280 HL) and Metallographic Preparation Experimental Setup Arrangement of specimens Scan strategy Metallographic preparation Powder deposition 1 15 Layer n Q1 Q2 z 8 Q Q4 21 Layer n + 1 y x Slide 16

17 Powder deposition Data Preparation (TruPrint3000) and Metallographic Preparation Experimental Setup Arrangement of specimens Scan strategy Metallographic preparation 1 Q1 15 Q2 Layer n z Q3 Q4 Layer n + 1 y x Powder deposition Slide 17

18 LPBF Basics Correlation between Process Parameter and Material Properties Volume energy E v E v = P L D s v s y s Melt track energy E s E s = P L v s Theoretical build-up rate v th V th = D s v s y s Slide 18

19 Layer thickness D s [µm] Working Procedure Correlation between Process Parameter and Material Properties Manufacturing M ax. TruPrint 1000 SLM 280 HL M achine TruPrint Laser Pow er P L [W] Slide 19

20 Dichte ρ [%] Density SLM280 HL, D s = 40 µm, P L = 400 W Volumenenergie E v [J/mm³] D s = 40 µm, P L = 400 W, y s = 60 µm D s = 40 µm, P L = 400 W, y s = 80 µm D s = 40 µm, P L = 400 W, y s = 100 µm ,0 100,0 100,0 99,8 99,8 99,8 99,6 99,6 99,6 99,4 99,4 99,4 99,2 99,2 99,2 99, , , Slide 20

21 Melt track energy Es [J/m] Density SLM280 HL, D s = 40 µm, P L = 400 W > 99,8% > 99,5% > 95% 95% D s = 40 µm, y s = 100 µm D s = 40 µm, y s = 80 µm 600 D s = 40 µm, y s = 60 µm Volume energy Ev [J/mm³] Slide 21

22 Melt track energy Es [J/m] Density SLM280 HL, D s = 40 µm, P L = 400 W > 99,8% > 99,5% > 95% 95% ΔEs Slope: ΔE P L s vs = ΔE P V L = y s D s vs ys Ds 200 ΔEv Volume energy Ev [J/mm³] Slide 22

23 Streckenenergie Es [J/m] Density SLM280 HL, D s = 40 µm, P L = 400 W y s,max 1200 E s,max > 99,8% > 99,5% > 95% 95% E s,max 600 E V,min E s,min E V,min 0 E s,min Volumenenergie Ev [J/mm³] Slide 23

24 Melt track energy Es [J/m] EBSD SLM280 HL, D s = 40 µm, P L = 400 W > 99,8% > 99,5% > 95% 95% Volume energy Ev [J/mm³] Slide 24

25 Layer thickness D s [µm] Working Procedure Correlation between Process Parameter and Material Properties Manufacturing M ax. TruPrint 1000 SLM 280 HL M achine TruPrint Laser Pow er P L [W] Slide 25

26 Melt track energy Es [J/m] Density SLM280 HL, D s = 20 µm, P L = 200 W y s,max 1200 E s,max > 99,8% > 99,5% > 95% 95% 600 E s,max E V,min E V,min Volume energy Ev [J/mm³] E s,min Slide 26

27 Melt track energy Es [J/m] Density SLM280 HL, D s = 120 µm, P L = 400 W 1200 E V,min E s,min E V,max E s,max E s,max > 99,8% > 99,5% > 95% 95% 400 E V,min E V,max 200 E s,min Volume energy Ev [J/mm³] Slide 27

28 Melt track energy Es [J/mm] Density D s = 20 µm vs. D s = 40 µm vs. D s = 120 µm D s = 120µm P L = 400 W 600 D s = 40 µm P L = 400 W D s = 20 µm P L = 200 W Volume energy Ev [J/mm³] Slide 28

29 Melt track energy Es [J/mm] Density D s = 20 µm vs. D s = 40 µm vs. D s = 120 µm D s = 120µm P L = 400 W 600 D s = 40 µm P L = 400 W D s = 20 µm P L = 200 W Volume energy Ev [J/mm³] Slide 29

30 Layer thickness D s [µm] Working Procedure Correlation between Process Parameter and Material Properties Manufacturing M ax. TruPrint 1000 SLM 280 HL M achine TruPrint Laser Pow er P L [W] Slide 30

31 Melt track energy Es [J/mm] SLM280 HL vs. TruPrint3000 Density TruPrint3000 D s = 120 µm P L = 400 W Theoretical build-up rate [mm³/s] TruPrint3000 D s = 40 µm P L = 400 W SLM280 HL D s = 120µm P L = 400 W Volume energy Ev [J/mm³] SLM280 HL D s = 40 µm P L = 400 W Slide 31

32 Working Procedure Adaptive LPBF Process Strategy Correlation between process parameters and material properties Combination of various process parameter sets in one component Adaptive LPBF process strategy applied on a guide vane segment Correlation between process parameters and geometrical properties Correlation between manufacturing chain with the focus on LPBF and non-machining post processing and geometrical properties Slide 32

33 Guide Vane Segment Current State Adaptive LPBF Process Strategy Exposure time [hh:mm]: 26:14 Segment (34335 mm³) Vane support (27225 mm³) 25,3% 26,7% Magics support Solid support (36908 mm³) 20,8% 27,2% Process parameter used for the entire component: Machine: SLM280 HL Layer thickness: D s = 20 µm Laser power: P L = 200 W Slide 33

34 Exposure time T [hh:mm] Guide Vane Segment Exposure Time Adaptive LPBF Process Strategy :14 25% % 10 21% 10:42 35% 7: Segment Supports 27% 65% D s = 20 µm; P L = 200W D s = 20 µm; P L = 200W D s = 20 µm; P L = 200W D s = 120 µm; P L = 400W 47% 53% D s = 40 µm; P L = 400W D s = 120 µm; P L = 400W Slide 34

35 Summary and Outlook Adaptive LPBF Process Strategy Summary Es-Ev diagrams were introduced to describe and to compare various process windows A high layer thickness leads to high process efficiency and allows build-up rates up to >12 mm³/s A large laser spot is advantageous for a high layer thickness and leads to a higher process robustness Adaptive LPBF process strategy is a promising approach to increase productivity Outlook Applied to a guide vane segment, LPBF process strategy reduces the exposure time to more than 50% Results of the interaction between LPBF and non-machining finishing in terms of geometry properties will be presented on ICTM Conference 2019 Implementation of adaptive LPBF process strategy in production for additive series manufacturing Slide 35

36 BACKUP: NEW AGENDA Slide 36