Cold Spray Additive Manufacturing: from the Laboratory to the Market

Transcription

1 Cold Spray Additive Manufacturing: from the Laboratory to the Market North American Cold Spray Conference 2016 Edmonton Canada December 1, 2016 Stefan Gulizia - Research Team Leader CSIRO MANUFACTURING

2 Outline CSIRO a snap shot CSIRO Cold spray Titanium Additive Manufacturing Technologies :- 1. CSIRO Cold spray facilities 2. Modelling Capabilities 3. Low cost Titanium powder production 4. Billet and preform Technology 5. Continuous pipe manufacture 6. Print Roller Technology 7. Low cost Invar 36 tooling for carbon fibre part manufacture 8. Aero engine casing 9. Spark Plasma Sintering of Cold Sprayed Ti-6Al-4V Summary Q&A

3 CSIRO today: a snapshot Australia s national science agency One of the largest & most diverse in the world staff over 55 locations Ranked in top 1% in 14 research fields spin-offs based on our IP & expertise active licences of CSIRO innovation Building national prosperity and wellbeing

4 CSIRO Delivers via Business Units AGRICULTURE BIOSECURITY DIGITAL PRODUCTIVITY AND SERVICES ENERGY FOOD AND NUTRITION LAND AND WATER MANUFACTURING MINERAL RESOURCES OCEANS AND ATMOSPHERE

5 We pull resources from the overall pool of 5,000 dedicated employees of CSIRO. The Program taps into the skills of 100 CSIRO scientists and engineers. We strive to assist industry to be more efficient and affordable. Manufacturing High Performance Metals Technologies Electrochemical Systems Metal Production & Interface Design (Team) Metal Forming & Novel Materials High Temperature Metal Processes Materials and Processes (Team) Additive Manufacturing and Deposition Surfaces & Ceramics Simulation Lab 22 Australia s Centre for Additive Innovation Titanium - Scandium - Magnesium - Alloy Design - Corrosion Battery Design & Modelling Sheet - Wire - Extrusions - Billet - Powder Prep Metallic Additive Manufacturing & Cold spray - Thermal Assisted Techs

6 Cold Spray Additive Manufacturing Research Capabilities

7 CSIRO Cold Spray Capabilities CSIRO has state of the art Cold Spray research facilities in Melbourne established 2002 Cold Spray equipment CGT Kinetiks 3000 & 4000 Series Plasma Giken PCS 1000 with high deposition rate Low powered portable Cold spray Cu, Al, Zn Australia s Centre Cold spray Additive Manufacturing $10M Govt. funding AM & Deposition Team:14 research staff, 4 PhDs, 1 Post doc, 2 visiting scientists CGT Kinetiks 3000 & 4000 Plasma Giken PCS 1000

8 Capabilities 1. State-of-the-art fully Automated Cold spray systems 2. PIV Tecna particle velocity, Flir IR Camera 3. Full Materials Characterisation; SEM, EDX, FIB,TEM, XRD, LOM, Mastersizer 4. Australian Synchrotron & Centre of Nano-fabrication 5. LAB 22 Centre of Excellence in Additive Manufacturing ARCAM, Concept laser, Optimet, Voxlejet

9 Modelling & Simulation To understand complicated deposition events in the rapid, solid state 3D additive manufacturing process A cost effective approach to optimise process parameters To develop future cold spray systems tailored for a particular industry 9 Presentation title Presenter name

10 Validation of 3D Multicomponent Model According to: Substrate temperature Particle velocity using Particle Image Velocimetry (PIV) Particle location on surface of substrate (current) 10 Presentation title Presenter name

11 PIV Validation Experiment vs 3D model CP titanium particle size distribution for PIV and the 3D model Comparison of the PIV measurements (Zahiri et al., 2009 and Wong et al., 2011) with 3D model results at 550 C, 1.4 MPa for helium and nitrogen. 11 Presentation title Presenter name

12 Example 1: Visualisation of the Cold Spray Whole Flow Field for 3D Additive Manufacturing CP Titanium cold spray whole flow field at 800C and 3Mpa for a commercially available cold spray nozzle (a) Temperate and (b) velocity. 12 Presentation title Presenter name

13 Cold Spray Additive Manufacturing Creating a New Titanium Industry in Australia

14 Development of New Titanium Manufacturing Industry in Australia '000's of Tonnes Per Annum Our research is concerned with manufacturing parts directly from low cost powder using Cold Spray technology From ore to product Titanium Minerals Mine Production Rutile Ilmenite

15 There ARE other Titanium Powders Armstrong Process Cristal FFC Process Metalysis Alloys CSIR Hydride DeHydride ADMA China ~$15/kg They all require shaping and sizing for Cold spray application

16 90 CSIRO Powder Manipulation Technology (PMT ) Unusable powder Additive Manufacturing 30 Volume (%) 10 Wt. % 70% 50% 30% Before After % Particle Diameter (µm.) 0 >1000 >600 >400 >250 >150 >100 >75 >45 >25 < 25 Particle Size (mm)

17 Cold Spray Additive Manufacturing Titanium Billet/Preform Manufacture

18 Low Cost Titanium Billet/Preform Processing Route Titanium Sponge Gas atomised Powder $$$ HDH Powder $$ CSIRO PMT sponge-derived Powder $ Cold Spray AM Billet & Preform Forging Extrusion Rolling HIP

19 Continuous Billet Production CSIRO has the capability to produce >30 kg/hr of product via cold spray

20 Cold Spray Manufacture of Round CP-Titanium Billet Advantages: Direct production of titanium billet from powder bypasses the traditional route of ingot manufacture Product has excellent microstructural uniformity

21 Ti-6Al-4V Round Billet - Density uniformity Ti-6Al-4V powder D10 = 6.0 µm D50 = 12.2 µm D90 = 22.3 µm Cold sprayed billet, top surface machined Billet produced using Plasma Giken cold spray system; 900 C, 5MPa. Porosity variation to within 3.5 % Red line indicates porosity determined by bulk density measurement (Archimedes method)

22 Deposition efficiency Deposition Efficiency Deposition efficiency = mass of deposit / mass of powder sprayed Generally ~ 97% for CP titanium For Ti-6Al-4V, slightly lower 100% 98% 96% 94% 92% 90% 88% 86% 84% 82% 80% Gas atomised grade 2 titanium Hydride-dehydride grade 4 titanium Feedstock powder Gas atomised Ti-6Al-4V Deposition efficiencies measured during manufacture of Ti billet

23 Tensile Testing of Hot Rolled & Annealed Samples After rolling the samples were heat treated at 950 C for 2 hours under argon At least 12% elongation in all hot rolled samples UTS = MPa Rolled 955 C + annealed 950 C, 2h

24 Microstructure After Hot Isostatic Pressing (HIP ing) CP titanium, as-sprayed CP titanium, canned and HIP d Commercial purity (grade 2), Ti powder Cold sprayed using a CGT Kinetiks 4000 system (800 C, 3.5MPa) HIP d at 920 C, 100MPa for 2 hours

25 Mechanical Properties after Hot Isostatic Press (HIP) Commercial purity Ti powder

26 IP Landscape CSIRO has successfully used Cold spray technology as an Additive Manufacturing technology We have protected our IP via National phase PCT: o Cold spray billets and pre-forms Our powder manipulation technology IP is also protected under a National Phase PCT: o Powder Manipulation

27 Cold Spray Additive Manufacturing Continuous Titanium Pipe Manufacture

28 Titanium Pipe Production Technology Cold Spray Utilizing either fixed length mandrel or using FTT s continuous process. For larger scale production the continuous method is the most suitable process.

29 Cold spray Additive Manufacture of Continuous Titanium Pipe Continuous Additive Manufacture of Titanium pipe via Cold Large variation in pipe size and schedule can be manufacturing Seamless design Robust jig design Small equipment footprint

30 Titanium Printing Roller

31 Anilox Printing Rollers Anilox Rollers are a fluid (e.g. ink) transfer roller used in the flexographic printing process Wear resistance is achieved by coating metal rolls with chromium oxide (Cr 2 O 3 ) using plasma spray A cell pattern is then engraved into the Cr 2 O 3 surface by laser Flexographic printing process from Trungale, J. P. (1997). The Anilox Roll. Heart of the Flexo Process. Jelmar. Plasma Spray Gun used for Cr 2 O 3 coating

32 2.5 year project between Melbourne-based company Kinetic Elements and CSIRO, and ongoing collaboration since Kinetic Elements are commercialising the titanium anilox roller under the name Tiaurum made from titanium (Ti), looks like gold (aurum) Titanium deposited by cold spray, followed by Laser treatment of anilox roller Laser treatment of the titanium surface

33 The Titanium Roller The laser treated titanium surface has proven wear resistance from printing press trials Titanium roller with 300LPI cell pattern Deposition efficiency of cold spray of titanium 96-97% Great improvement over plasma spray of Cr 2 O 3 (< 45%) Damaged roller surface can be repaired by cold spray Plasma sprayed Cr 2 O 3 coatings need to be completely stripped & re-sprayed 3D map of roller surface topology

34 Acknowledgements: Anselm Oh, Peter King, Andrew Urban, Saden Zahiri, Mark Styles & Darren Fraser, Christian Doblin CSIRO Muhammad Faizan-Ur-Rab PhD student Swinburne University JingJing Sun PhD student RMIT University Thank you Stefan Gulizia - Research Team Leader CSIRO Manufacturing t e Stefan,gulizia@csiro.au w