voestalpine Additive Manufacturing Center Singapore Pte Ltd
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1 voestalpine Additive Manufacturing Center Singapore Direct Metal Deposition, DMD. 30 th November
2 voestalpine Additive Manufacturing Center. Singapore Direct Metal Deposition» Company registered September 2016» Located on the Bohler Pacific site.» Operates from 5,000 sq ft. of the sites 77,000 sq ft.» Production» Design Office» Qualification Lab» 4 full time employees.» Investment planned for 3 DMD machines 2 30/11/2017 Direct Metal Deposition
3 voestalpine Additive Manufacturing Center. Singapore Laboratory» Powder Inspection» Density.» Particle Size & Distribution.» Flow rate.» Chemical composition.» AM Material Inspection» Sample Preparation.» Density Measurement.» Tensile Testing.» Hardness Testing.» Microstructure Evaluation.» Porosity Evaluation. 3 30/11/2017 Direct Metal Deposition
4 voestalpine Additive Manufacturing Center. Direct Metal Deposition 4 30/11/2017 Direct Metal Deposition
5 voestalpine Additive Manufacturing Direct Metal Deposition» DMG Mori Lasertec 65 3D. Closed loop process control of the laser build up combines laser deposition of metals with milling for the highest surface quality and part precision, (hybrid). PRODUCTION REPAIR SURFACE ENHANCEMENT 5 30/11/2017 Direct Metal Deposition
6 voestalpine Additive Manufacturing Direct Metal Deposition» DMG Mori Hybrid. Laser deposition of metal powders» Single or multiple metal layers» Low alloy, Stainless steels, Ni Alloys, Tungsten Carbide etc.» 5 axis CNC workstation, 400 x 500 mm footprint.» 600 Kg maximum component weight.» AS9100 on going PRODUCTION REPAIR SURFACE ENHANCEMENT 6 30/11/2017 Direct Metal Deposition
7 3D Build. ARTC picture» Majority of business to date in SS 316L. Other in 4140, 17/4PH and high alloys.» Sample build weekly for mechanical test program.» In house component build to generate examples ongoing as customer NDA s prevent publication of components. 7 30/11/2017 Direct Metal Deposition
8 3D Manufacturing Strategies Courtesy of BeAM 8 30/11/2017 Direct Metal Deposition
9 3D Manufacturing Strategies Courtesy of BeAM 9 30/11/2017 Direct Metal Deposition
10 3D Manufacturing Strategies - Plate» Near net shape closed die forging blank. 17/4 PH» Dimensions 12 x 6 x3» Weight 10 Kg.» Tolerance as deposited » Requirement for minimum distortion /11/2017 Direct Metal Deposition
11 3D Manufacturing Strategies - Plate ¾ Precut Base Plate Resulting in a flat component Base plate fixed to 180 degree rotating table 11 30/11/2017 Direct Metal Deposition
12 3D Manufacturing Strategies - Tube» Originally investment casting.» Purchased seamless tubing» Base and cap tooling to support build.» Skim OD to size» Build 3D geometries on OD» Machine working surfaces /11/2017 Direct Metal Deposition
13 Surface repair & Enhancement Removal of damaged functions & reconstruction by DMD Deposition of new surface (s) Machining for final surface Courtesy of BeAM 13 30/11/2017 Direct Metal Deposition
14 Surface repair & Enhancement Comparison Plasma (PS), thermal spraying (HVOF) and DMD (LC).» Stellite 6 as deposit material» DMD parts showed: Due to high cooling rate which results in a fine microstructure» Reduced roughness» Increased hardness» Better performance with regard to wear resistance 14 30/11/2017 Direct Metal Deposition
15 Surface repair & Enhancement Cobalt Alloy Cast Iron Tungsten Carbide Interface Mild Steel» Thermal spray combinations well known.» Performance of wrought + DMD material combinations to be developed» New material combinations are now available.» Surface grade deposition can be localised and with 3D geometries 15 30/11/2017 Direct Metal Deposition
16 voestalpine Additive Manufacturing Center Singapore Direct Metal Deposition R&D. 30 th November
17 Content» Direct Metal Deposition (DMD) Process Challenge» Raw Material» Process» DMD Material» Parts 17 30/11/2017 Direct Metal Deposition
18 Direct Metal Deposition (DMD) 18 30/11/2017 Direct Metal Deposition
19 DMD Process Development» Build DMD expertise» Ensure repeatability and reliability» Understand influence of process parameters» Optimize material performance» Increase machine efficiency 19 30/11/2017 Direct Metal Deposition
20 Raw Material Expertise Data collection:» Chemistry» Particle Size Distribution» Particle Morphology» Flowability Powder Handling:» Storage» Pre-conditioning» Shelf-Life AISI 4140 SS 316L 17-4 (PH) 20 30/11/2017 Direct Metal Deposition
21 Process Expertise 21 30/11/2017 Direct Metal Deposition
22 Design of Experiment» DoE to measure influence of process parameters on the powder material» Laser Power Input» Laser Scanning Speed» Powder Feed Rate» Process Gas Flow Rate» Weld Bead Overlap» Layer thickness 316L beads on 316L substrate 22 30/11/2017 Direct Metal Deposition
23 Single Beads Dilution = AA mm AA mm +AA cc Cross section 316L bead 23 30/11/2017 Direct Metal Deposition
24 Parameter Influences» Cladding height governed by laser scanning speed and powder feed rate 4D Response Contour of Clad Height [um] (MLR) 316L - single layers - screening Min Min 600 Min /11/2017 Direct Metal Deposition
25 Parameter Influences» Dilution governed by laser power input and powder feed rate 4D Response Contour of Dilution (MLR) 316L - single layers - screening Target Target /11/2017 Direct Metal Deposition
26 Automated Parameter Optimization Clad Height μm Clad Width μm Clad Angle degrees Penetration Depth μm Design Space (MLR) 316L - single layers - screening Clad Area Penetration Area Probability of failure (%) for Clad Height and Dilution - Optimizer Setpoint (R) μm 2 μm 2 Dilution % E Recommended process set point 26 30/11/2017 Direct Metal Deposition
27 Single Layers» 30%» 40%» 50% Increasing layer height; comparable penetration depth 316L single layers on 316L substrate 27 30/11/2017 Direct Metal Deposition
28 Defects Interrun inclusions due to non-optimized process parameters; 316L, 50x magnification Optimized process parameters; 316L, 50x magnification 28 30/11/2017 Direct Metal Deposition
29 Cubes» Material integrity» Repeatability and reliability» Material Performance 17-4 cubes on 316L substrate 29 30/11/2017 Direct Metal Deposition
30 AM Material Expertise Weld Heat Affected Zone AISI 4140 cubes on AISI 4140 substrate Substrate 30 30/11/2017 Direct Metal Deposition
31 Microstructure AISI 4140, wrought and tempered, 500x magnification AISI 4140, as printed, 500x magnification 31 30/11/2017 Direct Metal Deposition
32 Microstructure 316L, wrought and annealed, 500x magnification 316L as printed microstructure, 500x magnification 32 30/11/2017 Direct Metal Deposition
33 Interface 316L cube, printed on L printed on 4140, fusion zone, 50x magnification 316L printed on 4140, fusion zone, 500x magnification Tensile sample 33 30/11/2017 Direct Metal Deposition
34 Mechanical Properties Process No. Sample Orientation Yield Strength Tensile Strength Elongation Reduction of Area ASTM A276-17, S31606, annealed ksi ksi % % Min 25 Min 70 Min 40 Min 50 DMD, as printed 1 horizontal DMD, as printed 2 horizontal DMD, as printed 3 horizontal DMD, as printed 4 vertical DMD, as printed 5 vertical DMD, as printed 6 vertical Wrought, annealed 7 longitudinal Wrought, annealed 8 longitudinal /11/2017 Direct Metal Deposition
35 DMD Data Base» Establishing DMD material / mechanical properties in as printed and Heat Treated condition.» Material: In 718, In 625, 17-4, AISI 4140 (42CrMo4), SS 316L, Maraging Steel 1 (1.2709), Corrax, stainless tool steel.» Material Characterization: Microstructure, Porosity, Tensile, Charpy, Fatigue, Microhardness» Samples: Horizontal and vertical 35 30/11/2017 Direct Metal Deposition
36 Surface repair & enhancement» Wear resistant and corrosion resistant surface coatings (Stellite, WC in NiBase, )» Hard surface coatings with tailored hardness up to 64HRC as deposited (iron based, carbon free) Shafts for repair 36 30/11/2017 Direct Metal Deposition
37 Multi-Materials/ Functionally Graded Materials» Localised material selection within the component based on application needs» Sandwich structures» Functionally graded materials» Material cost saving» Enhanced performance of repaired parts /11/2017 Direct Metal Deposition
38 Printing Strategy Development Forging blanket, /11/2017 Direct Metal Deposition
39 Process Monitoring and Closed Loop Control 39 30/11/2017 Direct Metal Deposition
40 Part Integrity 40 30/11/2017 Direct Metal Deposition
41 Future Work» Comprehensive Material Database» Intimate Process Knowledge» Influence of Heat Treatment» Wear Resistant and Corrosion Resistant Coatings» Multi-material Parts 41 30/11/2017 Direct Metal Deposition
42 Summary» vamcs is building AM capabilities from raw material through DMD processing to finished parts» Material properties are cross-referenced with DMD process parameters and strategy» Process reliability and repeatability are key» Component requirements are translated into process parameters and printing strategy to ensure optimal part performance 42 30/11/2017 Direct Metal Deposition
43 voestalpine Additive Manufacturing The Next Steps» Target the repair market as an entrance to gain customer confidence.» Target non critical components. (No API, NACE, Maritime approvals).» Drilling components» Flow control» Pump impellors» Add second machine in 2018, non hybrid with build size ca. 1M x 1M.» Investigate opportunities in Titanium / Aluminum build via inert atmosphere.» Develop repair and restoration model moving into re-engineering & component design at the earliest opportunity /11/2017 Direct Metal Deposition
44 voestalpine Additive Manufacturing Vision Singapore Service Bureau Powder Process Mechanical Design Product, Repair Finished Characterisation Technology Properties Optimisation Surface Enhancement Products 44 30/11/2017 Direct Metal Deposition
45 Thank you Tanja Arunprasad T
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