With Carbon into New Dimensions

Transcription

1 CARBOPRINT With Carbon into New Dimensions Additive Manufacturing with Carbon Materials and Post-Processing Technologies

2 2 With carbon into new dimensions made by SGL Group SGL Group The Carbon Company is a leading global manufacturer of carbonbased products. We have wide-ranging expertise in raw materials, advanced manufacturing processes, and longstanding application and engineering know-how. Focusing on the technological challenges of megatrends, like digitalization and individualization, we develop innovative carbon based solutions. With additive manufacturing we open new dimensions in respect to product design, performance and time-to-market.

3 Additive manufactured carbon components 3 CARBOPRINT Additive manufacturing with carbon materials and post-processing technologies Classical carbon based components are made by machining, which is a standard subtractive process. In contrast, additive manufacturing, such as 3D printing, is an innovative, material efficient, layer by layer process. It opens up new dimensions of design freedom. Together with our partners and customers we develop individual and new out of the box solutions for tomorrow. The CARBOPRINT family combines our comprehensive carbon material knowhow with additive manufacturing technology. In addition, our broad base of post-processing capabilities, such as metal, resin or silicon infiltration, delivers innovative material solutions for your applications. This set of competencies and capabilities is a unique starting point for rapid and economic production of prototypes and small series of carbon based components for various industries such as glass, metal and chemicals, as well as high-temperature and mechanical applications. Polymer infiltration CARBOPRINT M Metal carbon composites Metal infiltration CARBOPRINT C Carbon and graphite Silicon infiltration CARBOPRINT P Polymer carbon composites CARBOPRINT Si Ceramic carbon composites CARBOPRINT material family a

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5 Additive manufactured carbon components 5 Benefitting from unique carbon properties and additive manufacturing technology Advantages of additive manufacturing with binder jetting technology Complex design at no additional cost (e. g. realization of undercuts and/or cavities) Acceleration of developments and production launch of small series Use of materials suitable for industrial applications Capabilty to produce large industrial components Advantages of using carbon in additive manufacturing Carbon and graphite specific properties (e. g. low weight, electrical and thermal conductivity, mechanical strength, chemical and high-temperature stability, low thermal expansion) Porous body structures deliver ideal basis for new material designs via metal, polymer or silicon infiltration Intelligent functions are possible (e. g. heating and thermal management) Post-processing Types Typical properties Potential components None/ Carbon infiltration CARBOPRINT C Q Low density Q Open porosity Q Isotropic homogenous structure Q Casting cores Q Casting molds Q Preforms Polymer infiltration CARBOPRINT P Q Complex designs with improved mechanical properties Q Accelerated development Q Good gliding properties Q Electrical contacts Q Gliding elements Q Pump parts Q Electrodes Q Heat exchanger components Q Heaters Q Sealings Metal infiltration CARBOPRINT M Q High strength at elevated temperature Q Good electrical and thermal conductivity Q Casting molds Q Bearings Q EDM electrodes Silicon infiltration CARBOPRINT Si Q High hardness low wear Q High temperature resistance Q Good corrosion resistance Q Pump impellers and casings Q Burner nozzles Q Heat exchangers

6 6 CARBOPRINT C Carbon and graphite components Carbon and graphite powders are the basis for cost-efficient serial production of carbon and graphite based components. Their porous bodies are binded with chemically and thermally stable duroplastic binder systems all with help of SGL Group s established processes and know-how. The highly porous carbon structure of CARBOPRINT C bodies is an ideal basis for post-processing, such as infiltration with silicon, or impregnation with polymers and metals. Processable like additive manufacturing sands Freedom of (material) design CARBOPRINT C Lightweight low density, open porosity b Carbon powder as the basis material d Porosity of printed carbon delivers ideal basis for refinement Typical material data for our CARBOPRINT C Typical properties Units C1 Density g/cm³ 1.0 Open porosity % E-modulus GPa 2 Flexural strength MPa 5 Electrical resistivity Ωµm Thermal conductivity W/(mK) <1 CTE (at RT/150 C) µm/(mk) 5.5

7 Additive manufactured carbon components 7 CARBOPRINT P Polymer carbon composites Lightweight Porous carbon structure and low weight resins Heating functions Thermal properties of carbon and resins Electrical and thermal conductivity Adjustable and high conductivities possible CARBOPRINT P Temperature stability Heat resistant < 200 C CTE CTE lower than pure polymers New material designs Infiltration of carbon with polymers, i. e. resins Applications that require non-metallic materials will profit significantly from polymer carbon composites. This material is temperature resistant up to 200 C without creeping effects common among other polymers. Depending on the choice of polymer, properties such as mechanical or chemical stability can be adjusted to customer requirements. a Choice of polymer increases material design variability d Sample part infiltrated with polymers Typical material data for our CARBOPRINT P Typical properties Units P1 P2 Density g/cm³ E-modulus GPa 6 6 Flexural strength MPa Electrical resistivity Ωµm Thermal conductivity W/(mK) 40 <1 CTE (at RT/150 C) µm/(mk) 12 40

8 8 CARBOPRINT Si Ceramic carbon composites Lightweight Low density due to porous carbon structure and silicon Established manufacturing Key know-how in post-processing, i. e. infiltration CARBOPRINT Si Chemical stability Good oxidation and chemical resistance Ceramic carbon composites provide ideal properties when it comes to reliable function and longevity in harsh environments and at high temperatures. We bring decades of experience with ceramic composites to additive manufacturing, in order to provide our customers the opportunity to realize almost any design with ceramic carbon composites. CARBOPRINT SI components are made by siliconizing CARBOPRINT C bodies. Temperature resistance Up to 1200 C and against thermoshocks High hardness Strong resistance against abrasion Low CTE, high precision c Silicon used in our infiltration process d Pump impeller in CARBOPRINT Si Typical material data for our CARBOPRINT Si Typical properties Units Si1 Density g/cm³ 2.3 Open porosity Vol.-% <0.1 E-modulus GPa 35 Flexural strength MPa 60 Elongation at break % 0.25 Bending energy absorption Nmm 340 Electrical resistivity Ωµm 20 Thermal conductivity W/(mK) 50 CTE (at RT/200 C) µm/(mk) 3 Silicon carbide content wt.-% 25 Silicon free content wt.-% 35 Carbon content wt.-% 40

9 Additive manufactured carbon components 9 CARBOPRINT M Metal carbon composites Metal carbon composites are designed for purposes where the combination of metal and carbon properties are needed. They are suitable for applications in elevated temperature environments, where good electrical conductivity and/or where low friction is needed. Lightweight Lower density than that of pure metals Simplicity No specialized metal powder necessary Lower wear Good gliding properties Thermal & electrical properties adjustable combining carbon and metal advantages CARBOPRINT M Flexibility Available choice of metals depending on component function CTE Lower CTE than pure metals b Antimon for metal impregnation d Sample parts in CARBOPRINT M Typical material data for our CARBOPRINT M Typical properties Units M5 Density g/cm³ 3.0 E-modulus GPa 23 Flexural strength MPa 20 Electrical resistivity Ωµm 5 CTE (at RT/200 C) µm/(mk) 6 Carbon content Vol.-% 60 Metal content Vol.-% 30 Pores Vol.-% 10

10 10 Additive manufacturing technology and post-processing expertise combined From individual requirements to customized solutions. Project initiation Binder jetting technology Understanding the application requirements Connecting customer s design needs with material specifications Integrating additive manufacturing expertise and design Selecting composite and related post-processing options with resin, silicon or metal impregnation Processing the order with partner On-demand order management or long-term production c Customer design file in 3D-CAD format (source: ExOne GmbH) c Additive manufacturing process (binder jetting) building up the carbon body layer-by-layer CARBOPRINT family: typical material properties at a glance Typical properties Units CARBOPRINT C CARBOPRINT Si CARBOPRINT P CARBOPRINT M Density g/cm³ E-modulus GPa Flexural strength MPa Electrical resistivity Ωµm Thermal conductivity W/(mK) <1 50 <1 40 CTE (at RT 150 /200 C) µm/(mk)

11 Additive manufactured carbon components 11 If you want to combine the unique properties of carbon and graphite with the advantages of additive manufacturing technology, SGL Group will be your partner of trust. Our start into this new era of manufacturing has just begun. We encourage industrial partners with pioneer spirit, such as engineers and designers, to develop innovative carbonbased components with us to gain a significant competitive advantage. Join us on the discover journey to new carbon based dimensions! Post-processing steps Product refinement Infiltration with polymer or metal or silicon Finishing Delivery c Polymer infiltrated part c Metal infiltrated rings c Silicon infiltrated pump impeller Additive manufacturing of carbon CARBOPRINT C Optional: carbonization/redensification/graphitization Polymer infiltration Metal infiltration Silicon infiltration Polymer carbon composites CARBOPRINT P Metal carbon composites CARBOPRINT M Ceramic carbon composites CARBOPRINT Si

12 Contact SGL CARBON GmbH Werner-von-Siemens-Strasse Meitingen/Germany Phone pending trademark application of SGL CARBON SE /1 E Printed in Germany This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should therefore not be construed as guaranteeing specific properties of the products described or their suitability for a particular application. Any existing industrial property rights must be observed. The quality of our products is guaranteed under our General Conditions of Sale. Technology & Innovation SGL CARBON GmbH Werner-von-Siemens-Strasse Meitingen/Germany