Fabrication additive par procédé CLAD : principes, performance et exemples d applications

Transcription

1 Fabrication additive par procédé CLAD : principes, performance et exemples d applications Additive Manufacturing with CLAD process: principles, performances and application examples. Didier BOISSELIER Jérôme WURSTHORN Philippe ACQUIER / IREPA LASER NOGENT - 29 Novembre 2016 IREPA LASER Laser Technological centre in France Industrial laser applications and developments in the field of material processing More than 30 years of experience. 42 people. Products : feasibility, technical and economic studies, training, industrialization, R&D, 20 lasers in the lab : YAG, Fiber, diode, Femto, with multiaxis workstations and robot analysis means: laser beam analyzer, 3D profilometer (ALICONA), metallographic, Expertise and fine characterization : Main activities: Welding and surface treatment Micro-machining Training. And additive manufacturing 3 CLAD machines + future SLM machine 1

2 KEY COMPONENTS CLAD OF CLAD Process PROCESS Construction by Laser with Additive and Direct Process Software Machine Process Track width 1 2,2mm Accuracy ±0,2mm Build up rate 120 cm 3 /h MACHINE : MAGIC FALAFEL FUI Project (Fabrication Additive Laser et Faisceau d Electrons) MAGIC = "Machine Aeronautique Gaz Inert CLAD " 5 axis machine : XYZ + BC Working space : 3D (CLAD) : 1500x840x800 mm3 Max load : 300 kg Gas enclosure : Volume : 12 m 3 O2<40 ppm, H2O<60 ppm 2 lasers : Fibre 500 W + Diode 2 kw 2 CLAD heads 2

3 MACHINE : BIOCLAD Y X BioCLAD: Enceinte gazeuse (1m 3 ) 02 < 40 ppm et H2O < 50 ppm 5 axes continus: X400 x Y250 x Z200 + B±110, Cn360 Charge maxi: 50 kg CNC : Power Automation 5 axes 1 buse Laser QCW 600/6000 (mode continu ou impulsionnel) Système de distribution de poudre à plateau vibrant Z C B LASER CLADDING Layer thickness 0,5 2 mm Track width 3 5mm Efficiency > 90% Dilution < 5% VS CLAD Layer thickness 0,2 0,7 mm Track width 0,3 3 mm Efficiency 20-90% Dilution 5% 20% 3

4 APPLICATION POTENTIAL OF THE CLAD TECHNOLOGY MATERIALS WELDABILITY materials grade State of CLAD development Low carbon steel Parameters ok Steels Alloy steel (low Ceq) Parameters ok Tool steel (CPM10V, M2) Cladding ok SS304L, 316L Parameters ok Stainless APX4 Parameters ok steels 17-4 Ph Parameters ok SS440, Setup in progress Inco 718, 713 Qualified on aero Inco 625, 738 Parameters ok Ni base Nimonic C263, 75 Parameters ok alloys Rene 77, 142 Parameters ok Waspalloy Qualified on aero CMSX4 Setup in progress Ti6Al4V Parameters ok Ti base Ti6Al2Sn4Zr2Mo (6242) Qualified on aero alloys CpTi Parameters ok Co base Stellite 6, 12, 21, 25 Cladding ok Al alloys Al alloys (Si, Mn, Mg ) Difficult to process Cu alloys Cu alloys (Zn, Sn, Al, Ni, ) Difficult to process Au alloys Au alloys Difficult to process W Difficult to process Others WC Ok with Ni matrix Mo Setup in progress CLAD results 4

5 METALLURGICAL AND MECHANICAL PROPERTIES Very low level of pores (<0,01%) Fine microstructure (rapid solidification) Mainly for weldable materials (Ti and Ni alloys, SS, ) Local or global gas shielding for oxidization prevention, mainly on Ti alloys Low dilution of the first layer on substrate NDT TOMOGRAPHY Very few pores detected: Ø µm 25 November

6 Mechanical properties: tensile testing of Ti6Al4V Ductile failure mode no significant defect Tensile testing results E (Gpa) R0,2 (Mpa) Rm (Mpa) A% (x10) forging (AIMS ) casting (IGC ) longitudinal direction Z direction POTENTIAL OF CLAD PROCESS Repairing of worn or damaged CLAD Fonctionality adding on existing valued Manufacturing of functionnal Preform manufacturing to be machined 6

7 EXAMPLE : PART REPAIRING SEALING RING ROTATION SPEED: TR/MIN Repairing of the worn knife edges of sealing Collaboration with a company specialized in engine maintenance Company : Chromalloy France 100 people Essentially repairing for Pratt & Wittney : PW100/ PT6/ JT15 APU (901) REPAIRING 6 references of repaired and qualified > 1200 repaired and returned to flight First piece began its second cycle repair in August µ m With courtesy 7

8 POTENTIAL OF CLAD PROCESS Repairing of worn or damaged CLAD Fonctionality adding on existing valued Manufacturing of functionnal Preform manufacturing to be machined EXAMPLE: FUNCTIONALITIES ADDING Screw rotor Flange 8

9 POTENTIAL OF CLAD PROCESS Repairing of worn or damaged CLAD Fonctionality adding on existing valued Manufacturing of functionnal Preform manufacturing to be machined TRUMP : PREPARATION Subpart built up with CLAD process Subpart built up with SLM process by Material : Nickel Based alloy (Nimonic C263) Manufacturing started on SLM subpart Part adaptation to the process: Thickness variation eliminated Modification of the cones geometry Corner radius added for the mounting lugs 9

10 TRUMP: PRODUCTION Material Ni based alloy (Nimonic C263) Wall thickness Construction duration Deposited mass of Nimonic 0.8 mm Total : 3h46min (2h46 + 1h) 520 g Powder catchment efficiency 21% Average build up rate 18 cm 3 /h Roughness Powder to be recycled Ra g Industrial demonstrator: airduct Ti64 FUI FALAFEL 2014 IREPA LASER Dassault Aviation Courtesy SLM subpart made by Hybrid process SLM + CLAD Feedback: Part model evolution Dialogue: Designer manufacturer 10

11 BIG PART MANUFACTURING Before machining After machining Technical data: Material : stainless steel 316L Weight : 25kg (with 11kg baseplate) Øext tube : 430mm wall thickness : 2.5mm Deposited material : 14kg Manufacturing time : 20H POTENTIAL OF CLAD PROCESS Repairing of worn or damaged CLAD Fonctionality adding on existing valued Manufacturing of functionnal Preform manufacturing to be machined 11

12 EXAMPLE : PREFORM + MACHINING Mounting bracket Manufacturing Start with a plate : 250x60x10 mm3 Wall dimension : 250x55x7 mm3 (460g) Cycle duration : 49min PCE = 64% - 120cm3/h Machining Minimum machined thickness : 0.3mm! Overthickness VS distortion Material : TA6V EXAMPLE : PREFORM + MACHINING Application example: Traditional machining cm Kg Final part 27 Kg Features added by CLAD cm Kg 12

13 CONCLUSIONS Construction by laser of in true material additive process : material feeding direct process : from CAD to part high quality : no cracks, extra low level of porosities, high mechanical resistance : fine microstructure control of the deposited materials: Multi-material construction Localized deposition of expensive materials set up possible for fine repairing, on high value added No size limitation Able to build up on complex surface (not only flat) Slicing 3D Powder to be used = injected powder Performance of the process: MesoCLAD : 1 up to 10 cm 3 /h MacroCLAD : 10 up to 200 cm 3 /h THANK YOU FOR YOUR ATTENTION Didier BOISSELIER db@irepa-laser.com 13