ADDITIVE MANUFACTURING Presentation

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1 ADDITIVE MANUFACTURING Presentation

2 Index LMD WAAM 2

3 1.Laser Cladding (LMD)

4 Laser Cladding o Laser Material Deposition (LMD) Both, the substrate and filler material are melted with a laser. Generally, filler material is injected as a powder stream by a nozzle Wire feeders can be also applied. TECHNOLOGY REQUIRED EQUIPMENT Laser: Usually solid state or diode laser. Powder feeder: Lower mass rates than plasma spray systems. Nozzle: Powder injection into the melt-pool. Kinematics: Machine-tool or Robot to guide the nozzle. 5 axis interpolation ability highly recommended. MATERIALS Superalloys (Ni, Ti, ). Tool steels. Stainless steels. Ceramic materials. Structural steels. Aluminum alloys.

5 Hybrid Machine ZVH 45/L1600 MULTIPROCES 5 axis multiprocess machine, integrating capabilities machining, additive manufacturing and welding. MILLING TURNING LASER CLADDING

6 MECHANICAL DESIGN ZVH 45/ L1600 ADD+PROCESS Milling / turning and laser cladding capacities in a moving column machining center TURNING, MILLING AND ADDITIVE MANUFACTURING Laser fiber up tothe head Pick-up for head Integration of laser equipment Optical isolation: glass + cabinet Manual powder recovery solut ion

7 EQUIPMENT APPLICATIONS A C B DESCRIPTION High productivity 5-axis machining center, with fixed table and mobile column architecture and with the capability of executing the following manufacturing processes: - Turning with horizontal and vertical plate - 5-axis machining with A+B and B+C axes - Additive manufacturing by Laser Cladding - 2D and 3D laser cutting and welding, surface treatments This machine is intended for use in the following sectors: aeronautics, automotive, railway, machinery, moulds and dies, oil&gas and valves and pumps. - Machining of long or bulky parts along the whole extent of the table in 3+2 or 5 continuous axes and horizontal and vertical turnings. - Machine operation in pendulum work cycle to produce medium/long series, avoiding loading/unloading downtimes, giving life to machining without interruption. - Repair of high added value parts. - Surface coatings. - Hybrid manufacturing additive+machining. - 2D and 3D laser cutting and welding, surface treatments. Diferentes set-ups para mecanizar piezas para diferentes sectores

8 2. WAAM TECHNOLOGY

9 WAAM: Wire Arc Additive Manufacturing Based on arc welding The substrate and the filler materials are melted by the arc transfer between the electrode of the torch and the substrate material. The material is injected as a wire. There are different systems for generating the arc (TIG, MIG, PAW, CMT). Required equipment Conventional welding equipment: PAW, TiG, MIG, CMT Torch Wire feeder and positioner Kinematic: Machine-tool or robot Application High added value parts repairing Manufacturing of components or parts of components with high material waste Big size part manufacturing Hybrid manufacturing. Materiales Superalloys (Ni, Ti, ). Stainless steels Structural steels Aluminium alloys

10 INTEGRATION IN SIEMENS CONTROL PLASMA TECHNOLOGY (HARDWARE/SOFTWARE) RETROFFITING 5 AXIS MACHINE FOR WAAM TECHNOLOGY SPECIAL CHAMBER FOR TITANIUM APPLICATION (ARGON GAS USED)

11 WAAM: ADDITIONAL EQUIPMENT Simulation Support Monitoring Process. Internal Signals (Intensity, Wire Feed Speed, Voltage) Pyrometer, Welding Camera, Laser Scanning Adaptive control taking into account Geometry of the bead, Process parameter Quality and NDT 3d Reconstruction David SLS-3

12 Applications in AM Coating Customization Repair Hybrid Manufacturing

13 WHY AM IN IBARMIA? NEW MARKETS FOR IBARMIA? Applications AERONAUTIC Manufacturing of some specific turbine component s. Repairing of t urbine blades. MOULD AND DIE Repair of defects during machining or inservice. Anti-wear coatings on tool steels. ENERGY Manufacturing of some specific turbine component s. Repairing of t urbine blades. HYBRID MANUFACTURING Repairing of Damaged Impeller

14 Responsible for Additive Manufacturing in Tecnalia R&I. Dipl. Eng. Alfredo Suárez, graduated in Mechanical Engineering by Tecnun (University of Navarre) in Since 2007 is responsible for Non-Conventional technologies in Tecnalia R&I, focus in AWJ Technology where he is managing several projects related with Non-Conventional technology. Furthermore, he is involved in the development of the hybrid machine (AWJ + Conventional milling) for aeronautic industry in collaboration with MTorres, machine builder. From 2014, responsible as well, for Additive Manufacturing technology (mainly laser and plasma technologies), where is in charge of several national project and European project, as AMAZE project, furthermore, he is involved in the Hybrid machine development within Ibarmia machine builder. Contact details: Alfredo Suárez Project Manager Advanced Manufacturing Area alfredo.suarez@tecnalia.com M Industry and Transport Division

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