SIRRIS ADD department. Additive Manufacturing

Transcription

1 SIRRIS ADD department Additive Manufacturing

2 ADD capacities & competencies SIRRIS ADD ( ) 15 engineers and technicians Two locations: Liège (10 p.) and Charleroi (5 p.) In-house additive technologies Stereolithography (normal & hi-res) Paste polymerisation for ceramics and metals (2 Optoform) 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal) Laser sintering of polymeric powder (PA, ): P360 P390 Objet Connex 500: bi-material Laser Melting (MTT) SLM 250 HL for metal parts and inserts EBM Arcam A2 (Titanium & CoCr) Laser Cladding (Irepa Laser EasyCLAD) 3D Printing of wax (Thermojet) 3D scanning & metrology (GOM, Metris, Wenzel) 2

3 Optoform process Photopolymerisation of resin filled with - technical ceramics (alumina, zyrconium, SiC) - bioceramics (HAP, TCP) High viscosity material. Debinding and sintering step 3

4 Optoform SiC parts Porous scaffolds in Hydroxyapatite & TCP Testing on various scaffold 3D structures for bone integration Spine and maxillofacial surgery Macro-porosity ~= 500 µm HA parts 4

5 Bi-material Prototype OBJET Connex 500 3D Printing of 2 materials simultaneously: 500 * 400 * 200 mm Resolution 600 dpi Visual prototypes for look and feel (hard, flexible, coating, ) Bi-material but also composite materials. Biocompatible materials. 5

6 Laser Sintering of polymer powder sirris /12/2007 6

7 3D Printing metal 3D Printing of metal powder Stainless steel with bronze infiltration Debinding / infiltration or debinding / sintering No support high geometrical complexity Functional Prototypes or parts (unique part, short series) Metal parts with internal complex geometry (Lattice structure, lightweight structure, ) Artistic parts Mould inserts for thermoplastic injection with conformal cooling channels for optimization (cycle time reduction, ) 7

8 3D Printing metal - Prometal 8

9 3D Printing (Prometal) Art works Pierre Pourveur Evelyne Gilmont Alice Salmon (Sirris) Gil Bruvel Batsheba Wim Delvoye 9

10 3D Printing Prometal Post-milling 10

11 Laser melting - Full melting - Full density - Titanium, alu, steels, Inconel, Pictures from ILT 11

12 Laser melting applications 12

13 Electron Beam Melting - Arcam - Near net shape solution requiring post milling (HSM) - An high energy beam of electrons is generated in the Electron Beam Gun - The control system allow for an extremely fast beam translation with no moving parts - Vacuum melt process eliminate impurities and yields high strength properties of the material - High build temperature provide good form stability and low residual stress in the part - Low operating costs 13

14 Electron Beam Melting Arcam Excellent properties for: Strength Elasticity Fatigue Chemical composition Microstructure Released Materials Ti6Al4V Ti6Al4V ELI CoCr, ASTM F75 100% Density Lattice & Cellular Structures - Lattice and cellular structures allow combination of the excellent properties of solid metal with the extraordinary properties of a cellular or lattice structure. Material: Ti6Al4V Size: 25 x 65 x 180 mm Build time: 6 hours - Applications include: * structures for bone in-growth in medical implants, * lightweight designs component * filters * other applications where a cellular structure is advantageous 14

15 Electron Beam Melting - Arcam Applications Medical: Implants Prosthesis - Instruments Material: Ti6Al4V Size: 180 x 130 x 5 mm Build time: 12 hours Material: CoCr ASTM F75 Build time: 8 knees in 20 hours Material: Ti6Al4V ELI Build time: 16 cups in 24 hours 15

16 Laser cladding Principle No powder bed Local deposition of fused metal Powder feeding in the laser beam 3 types of applications - Coatings: enhancement of hardness, wear resistance and anti-corrosion - Repair of damaged expensive parts - Full 3D building of parts Large range of materials available FGM Coaxial nozzle (2D) Multi-jet nozzle (3D) 16

17 The principle Laser + central gaz (coaxial) Shape Gas Carrier gas + powder Track Meltpool Motion direction Substrate Heat Affected Zone Sirris info@sirris.be 11/05/

18 IREPA Laser system IREPA LASER Duo-CLAD (EasyCLAD) - 2 fiber lasers: IPG 300 W et 2000 W. - MesoCLAD nozzle for mm Up to 15 cm 3 /h - MacroCLAD nozzle for 2 mm. Up to 250 cm 3 /h - Layer thickness: µm - Machining center 5 axes imes(isel) with rotating plate - PowerCLAD (Delcam) 5 axes based on PowerMill et PowerShape - Shielding gas - Double powder feeding: Medicoat DUO. - Monitoring & process control (added by Sirris & CSL) 20/12/

19 Comparative study of metal additive manufacturing technologies DPrinting EBM Laser Cladding Laser Melting Productivity 3D Complexity Maximum size Precision Surface quality Internal struct (Lattices) Mech prop - density sirris

20 Comparative study of metal additive manufacturing technologies 3DPrinting EBM Laser Cladding Laser Melting Source Printhead Electron Beam Laser Laser Powder feeding Powder bed Powder bed Nozzle Powder bed Materials S Steel + Bronze Ti CoCr Ti steel Ti Alu Steels Inco Controlled porosity Yes No No No sirris

21 Controlled porosity with 3D Printing (Prometal) Investigation ways to manage the porosity: (not a macro porosity with lattice structures) Sintering parameters Composition of the powder mixture Addition of organic particules Only one solution: 3DP Prometal Applications: fluid control, filters, 21

22 Controlled Porosity: some details Materials: 316L Density: From 50 to 95% Open porosity: From 0 to 50% Pore diameters: From 5 to 35µm Permeability (Darcy law): From to m² Mechanical properties: Up to 100% of the prop. of 316L with a density around 95%. Ø 40mm Ø 300mm sirris 22

23 Hipermoulding project 4 injection moulds produced with & without conformal cooling channels 4 mm Drastic reduction of the cycle time (up to 35%) Enhancement of part quality Enhancement of tool lifetime Profitability up to euros/year (prod. 6 Mparts) 23

24 Topology optimization Stress verification Flying Cam example (Compolight project) Free space definition Efforts repartition STL file Smoothing or redesign based on the STL geometry Weight reduction with the same mechanical result

25 SIRRIS ADD Actual & Future developments LightWeight solutions 3D structures Controlled Porosity Medical applications Quality, Repeatability, Standards Sustainability Composites SiC+ alu, Connex digital materials Titanium, Inconel, aluminium Functionally Graded materials and porosity Nano particles incorporation 25