GIRAUD Rémi ERASTEEL. Metallic powder for additive manufacturing

Transcription

1 GIRAUD Rémi ERASTEEL Metallic powder for additive manufacturing

2 INTRODUCTION ERAMET IN BRIEF ERAMET Group employees 2897 M turnover in 2016 ERAMET Engineering (100 %) ERAMET Research (100 %) ERAMET Alloys ERAMET Manganese ERAMET Nickel 4800 employees 949 M 5000 employees 1439 M 2500 employees 595 M ERASTEEL AUBERT & DUVAL

3 INTRODUCTION Two companies, Aubert & Duval and Erasteel, with a common management One of the leaders in large dimension closed die forgings One of the main worldwide producers of high performance steels and superalloys One of the worldwide leading companies in high speed steels Worldwide leader in gas atomized powders European actor in recycling of catalysts, metallic oxides and batteries employees 949 M Turnover in 2016 Page 3-15 juin 2017

4 INTRODUCTION 3 production sites Pearl Micro fine powders for Additive Manufacturing Metafesnch (France) ASP & Pearl stainless steel powders for HIP & Additive Manufacturing (new) Ti powder pilot plant (Metafensch) Ni powders & PM HIP parts WORLD LEADING PRODUCER OF GAS ATOMIZED POWDERS A LONG EXPERIENCE OF POWDER PRODUCTION SINCE ATOMIZATION UNITS IN 3 COUNTRIES THE 2 WORLD LARGEST GAS ATOMIZERS IN SWEDEN Page 4-15 juin 2017

5 POWDER PRODUCTION AND ADDITIVE MANUFACTURING J.M. Capus 2010 Page 5-15 juin 2017

6 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Gas Atomization : Steel powder for HIP and AM (under devpt.) Powder Pearl manufactured at Söderfors, Sweden Big batch size(10 à 12t): MOQ to be defined Gas atomisation with slag Low content of oxygen and nitrogen High cleanliness powder Atomization gas : nitrogen Typical grades: 316L, 17-4PH, 420, High Speed Steel Page 6-15 juin 2017

7 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Gas atomization VIM : Superalloys powder for MIM, AM and HIP Powder Pearl Micro manufactured at Irun, Spain EN9100 accreditation Advantages of Vacuum Induction Melting : Low content of oxygen, nitrogen and hydrogen, Useful for reactive elements(al, Ti, etc.) High cleanliness powder Plant dedicated to fine powder Atomization gas : Azote or nitrogen Powder size on demand: D50 between 20 and 70 µm Typical grades : Ni718, Hastelloy X, Ni625, etc Page 7-15 juin 2017

8 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Pearl Micro Ni718 POWDER SIZE µm Pearl Micro Hx Page 8

9 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Atomization EIGA : Titanium powder for AM (under devpt.) Advantages of Electrode Induction Melting : Low content of oxygen, nitrogen and hydrogen, Useful for reactive base such as Ti High cleanliness powder (no ceramics) Atomization gas : Argon or nitrogen Typical grades : TA6V, TiAl, etc As atomized TA6V Page 9-15 juin 2017

10 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Processes overview Part size HIP Forging Closed-die forging Page juin 2017 Additive manufacturing Press&Sinter Casting MIM Part number

11 POWDER PRODUCTION AND ADDITIVE MANUFACTURING Powder bed fusion or Direct Energy Deposition - In case of pipe and/or nozzle: Flowability, morphology, size, moisture - Ability to make regular and dense layers : Flowability, morphology, PSD, moisture, apparent density, - Parts microstructure and density : Oxygen content, chemical elements influence Page juin 2017

12 POWDER CHARACTERIZATION Particles Size distribution Size by sieving Sieving : ISO ASTM B 214 Better for coarse particles Laser diffraction : ISO ASTM B 822 Better for fine particles Size by Laser diffraction Particle equivalent diameter Page juin 2017

13 POWDER CHARACTERIZATION Characteristic densities Apparent density: ISO or ASTM B 212 Hall funnel ISO or ASTM B 417 Carney funnel ISO or ASTM B 329 Scott volumeter Flowability decrease Tap density: ISO 3953 and ASTM B 527 Hall / Carney funnel Scott volumeter Page juin 2017

14 POWDER CHARACTERIZATION Flowability ISO 4490 or ASTM B 213 Hall funnel ASTM B 964 Carney funnel ISO Gustavsson funnel Note : Flowability is not always a relevant parameter, spreadability could be a more interesting parameter but there is no standardized test up to now. Alternative test method unstandardized and/or unusual Hausner Ratio define as tap density / apparent density Angle of repose or angle of avalanche Page juin 2017

15 CONCLUSIONS Aubert&Duval and Erasteel have 50 years of experience in gas atomization for various market (Aeronautic, Power, tooling, ) With capacity of Ni and Co based superalloys (Spain) Atomization tower for steels around 10 tons (Sweden) Development of capacity for titanium alloys (France). Fully involved in the ramp-up of Additive manufacturing: EPMA member( International standardization member: Leader of joint group ISO-ASTM Additive manufacturing Technical specifications on metal powders future ISO ASTM Development of new facilities in adequacy with the market Strong R&D implication through collaborative projects (AMANDE, Sofia, etc) Page juin 2017

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