MANUFACTURING. James W Sears, PhD. Eric Faierson, PhD and Korby Heinsen

Transcription

1 Quad City Manufacturing Laboratory Western Illinois University APPLICATIONS IN DIRECT METAL LASER MANUFACTURING James W Sears, PhD Exec. Director Quad City Manufacturing Laboratory (QCML) Eric Faierson, PhD and Korby Heinsen This work is funded under the cooperative agreement W15QKN with the Army Research, Development and Engineering Center (ARDEC) and Western Illinois University.

2 Outline Quad City Manufacturing Laboratory Introduction: Where did this come from? History of Metal Deposition Applications Prototypes: Castings, Metal Injection Molding, Qualification hardware Legacy parts Low Volume Manufacturing: Sports, Bio-Med, Defense, NASA Current Applications & Results at QCML Ti, IN 718, Al Summary

3 The Quad City Area QCML I-80 Quad Cities (all 17 of us) I-88 I-80 I-74 Rock Island Arsenal John Deere WWHQ

4 Rock Island Arsenal & QCML

5 Quad City Manufacturing Laboratory (QCML) The QCML is a Not-for-Profit fi (501c(3)) (3)) Research and Development Company imbedded within the Rock kisland darsenal Joint Manufacturing and Technology Center

6 Mission The Quad City Manufacturing Laboratory (QCML) provides integrated manufacturing solutions for the use of titanium, magnesium, aluminum, silicon carbide and other light advanced metal composite materials for Department of Defense and private industry. The primary mission of QCML is to provide local and regional job creation and retention for the Rock Island Arsenal s Joint Manufacturing and Technology Center (JMTC) and Quad City companies. Assist in application developments through advanced materials processing for incubation of new business for the Quad City region.

7 QCML - Vision The Technology and Talent Gateway Rock Island Arsenal John Deere Technology Efficiency Innovation Forward Looking Responsive Alcoa QCML Primary Mission Technology Development Titanium PM Advanced Metal Matrix Composites Near Net Shape Manufacturing Advanced Material Processing Community QCML Partnering Industry &Technology Titanium, Advanced MMCs, Castings Forgings, Adv. Materials (Nano, Mg, AlMgB, etc.),, Green Technologies, Many more QCML Educator s Forum Technology & Process Training Universities Community Colleges Small Business Incubation Industry RIA/JMTC Industry Knowhow Sustainable Jobs Talent Education Business Community

8 Equipment (Current & Future) LAM (Laser Additive Manufacturing) SPS (Spark Plasma Sintering) HIP (Hot Isostatic Pressing) DMLM (Direct Metal Laser Manufacturing) UAM (Ultrasonic Additive Manufacturing) FSW/FSP (Friction Stir Welding/ Friction Stir Processing) IBLC (Internal Bore Laser Cladding) Installed 11/11 Installed 9/16/11 Future 4/12 8 Future 4/12

9 History of Metal Powder Deposition Schoop - Spray Metallizing Brennan - Spray Metal Strips Singer - Spray Rolling, CSD, SSP Osprey - Spray Forming Breinan - LASERGLAZE (UTRC) Hull - Stereo lithography (.stl file) Deckard - SelectiveLaserSintering Sintering (DTM-SLS) 1990 s - LPD, DLF, DMD, LENS, LasForm, LAM, DMLS (DMLM) EBAM (Electron Beam Additive Manufacturing)

10 Direct Metal Laser Manufacturing

11 Direct Metal Laser Manufacturing Applications: (Limited by Imagination) Prototypes for: Castings, Metal Injection Molding, PM parts Tooling: Injection Molding (plastic and metal), Die Casting Legacy parts: Defense, Auto, Collectors, etc Low Volume Manufacturing: Sports, Bio-Med, Defense, Jewelry, Art, etc

12 Direct Metal Laser Manufacturing Part Design: Important to engage customers early on as possible to design for DMLM. Material Selection for Application Application dictates post process requirements Not a tool for everything

13 DMLM Titanium (Ti-6Al-4V) Parts: UAV Engine Parts M2 Carbine Parts Test Specimens

14 Titanium UAV Engine Parts

15 Titanium UAV Engine Parts

16 Titanium M2 Carbine Parts

17 EOS Ti-6Al-4V Powder EOSTi Ti-6Al-4V powder Mean particle size ~ 33 µm Oxygen content 1400 ppm

18 As Built Ti-6Al-4V Microstructure Transverse Longitudinal

19 As Built Ti-6Al-4V Properties Hardness (Hv) Transverse Top Transverse Middle- 316 Longitudinal Top Longitudinal Middle Fully Annealed Plate Oxygen Content 1500 ppm

20 Post HIP Ti-6Al-4V Microstructures Transverse Longitudinal

21 Post HIP Ti-6Al-4V Properties Hardness (Hv) Transverse Top Transverse Middle- 351 Longitudinal Top Longitudinal Middle Fully Annealed Plate Oxygen Content ** ** HIP gas contaminated 2200 ppm

22 Ti-6Al-4V Microstructure (X-ray) 800 Intensity(Co ounts) Hip Pre-Hip Al 6 Ti 19 - Aluminum Titanium AlTiH x - Aluminum Titanium Hydride Two-Theta Theta (deg)

23 DMLM IN718 part

24 DMLM IN718 part 24

25 EOS IN 718 Powder EOS IN 718 powder Mean particle size ~ 36 µm

26 As Built IN 718 Microstructure Transverse Longitudinal

27 As Built IN 718 Properties Hardness (Hv) Transverse Top Transverse Middle- 312 Longitudinal Top Longitudinal Middle *Typical hardness of stress relieved ed IN 718 is 330 Hv

28 DMLM Al-10Si-0.3Mg 0.3Mg Part

29 B-52 legacy Al part

30 B-52 legacy Al part

31 B-52 legacy Al part

32 EOS AlSi10Mg Powder EOS Al-10Si-0.3Mg powder Mean particle size ~ 29 µm

33 As Built Al-10Si-0.3Mg Microstructure Transverse Longitudinal

34 As Built Al-10Si-0.3Mg Properties Hardness (R B ) Brinell* Transverse Longitudinal *Typical hardness of AL 10Si Mg as listed by EOS is 120 (Brinell)

35 What is Next? One issue is the lack of alloys available for DMLM. The alloys we plan to develop for this technology include but are not limited to: Magnesium WE 43 Other Aluminum Alloys 4047, Al-bronze TiAl Ti Other sources of Ti-6Al-4V, IN 625, IN 718 Refractory alloys

36 Summary QCML is providing DMLM services, specializing in reactive alloys (Ti, Al, IN 718) QCML has demonstrated the ability to produce Ti- 6Al-4V, Al-10Si-0.3Mg 0.3Mg and IN 718 parts DMLM offers part complexity without tooling DMLM ideal for: Prototypes Tooling Legacy parts Low Volume Manufacturing

37 Near Net Shape Manufacturing NNSM 2012 Moline, IL April 11-13,

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