GIRAUD Rémi ERASTEEL Metallic powder for additive manufacturing
INTRODUCTION ERAMET IN BRIEF ERAMET Group 12800 employees 2897 M turnover in 2016 ERAMET Engineering (100 %) ERAMET Research (100 %) ERAMET Alloys ERAMET Manganese ERAMET Nickel 4800 employees 949 M 5000 employees 1439 M 2500 employees 595 M ERASTEEL AUBERT & DUVAL
INTRODUCTION Two companies, Aubert & Duval and Erasteel, with a common management One of the leaders in large dimension closed die forgings One of the main worldwide producers of high performance steels and superalloys One of the worldwide leading companies in high speed steels Worldwide leader in gas atomized powders European actor in recycling of catalysts, metallic oxides and batteries 4 800 employees 949 M Turnover in 2016 Page 3-15 juin 2017
INTRODUCTION 3 production sites Pearl Micro fine powders for Additive Manufacturing Metafesnch (France) ASP & Pearl stainless steel powders for HIP & Additive Manufacturing (new) Ti powder pilot plant (Metafensch) Ni powders & PM HIP parts WORLD LEADING PRODUCER OF GAS ATOMIZED POWDERS A LONG EXPERIENCE OF POWDER PRODUCTION SINCE 1969 6 ATOMIZATION UNITS IN 3 COUNTRIES THE 2 WORLD LARGEST GAS ATOMIZERS IN SWEDEN Page 4-15 juin 2017
POWDER PRODUCTION AND ADDITIVE MANUFACTURING J.M. Capus 2010 Page 5-15 juin 2017
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Gas Atomization : Steel powder for HIP and AM (under devpt.) Powder Pearl manufactured at Söderfors, Sweden Big batch size(10 à 12t): MOQ to be defined Gas atomisation with slag Low content of oxygen and nitrogen High cleanliness powder Atomization gas : nitrogen Typical grades: 316L, 17-4PH, 420, High Speed Steel https://www.youtube.com/watch?v=ldp1sqnjwcc Page 6-15 juin 2017
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Gas atomization VIM : Superalloys powder for MIM, AM and HIP Powder Pearl Micro manufactured at Irun, Spain EN9100 accreditation Advantages of Vacuum Induction Melting : Low content of oxygen, nitrogen and hydrogen, Useful for reactive elements(al, Ti, etc.) High cleanliness powder Plant dedicated to fine powder Atomization gas : Azote or nitrogen Powder size on demand: D50 between 20 and 70 µm Typical grades : Ni718, Hastelloy X, Ni625, etc https://www.youtube.com/watch?v=x2bttqwov6a Page 7-15 juin 2017
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Pearl Micro Ni718 POWDER SIZE 10 53 µm Pearl Micro Hx Page 8
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Gas atomization process Atomization EIGA : Titanium powder for AM (under devpt.) Advantages of Electrode Induction Melting : Low content of oxygen, nitrogen and hydrogen, Useful for reactive base such as Ti High cleanliness powder (no ceramics) Atomization gas : Argon or nitrogen Typical grades : TA6V, TiAl, etc As atomized TA6V Page 9-15 juin 2017
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Processes overview Part size HIP Forging Closed-die forging Page 10-15 juin 2017 Additive manufacturing Press&Sinter Casting MIM Part number
POWDER PRODUCTION AND ADDITIVE MANUFACTURING Powder bed fusion or Direct Energy Deposition https://www.youtube.com/watch?v=gjbkxvku39y - In case of pipe and/or nozzle: Flowability, morphology, size, moisture - Ability to make regular and dense layers : Flowability, morphology, PSD, moisture, apparent density, - Parts microstructure and density : Oxygen content, chemical elements influence Page 11-15 juin 2017
POWDER CHARACTERIZATION Particles Size distribution Size by sieving Sieving : ISO 2591 1 ASTM B 214 Better for coarse particles Laser diffraction : ISO 13320 ASTM B 822 Better for fine particles Size by Laser diffraction Particle equivalent diameter Page 12-15 juin 2017
POWDER CHARACTERIZATION Characteristic densities Apparent density: ISO 3923 1 or ASTM B 212 Hall funnel ISO 3923 1 or ASTM B 417 Carney funnel ISO 3923 2 or ASTM B 329 Scott volumeter Flowability decrease Tap density: ISO 3953 and ASTM B 527 Hall / Carney funnel Scott volumeter Page 13-15 juin 2017
POWDER CHARACTERIZATION Flowability ISO 4490 or ASTM B 213 Hall funnel ASTM B 964 Carney funnel ISO 13517 Gustavsson funnel Note : Flowability is not always a relevant parameter, spreadability could be a more interesting parameter but there is no standardized test up to now. Alternative test method unstandardized and/or unusual Hausner Ratio define as tap density / apparent density Angle of repose or angle of avalanche Page 14-15 juin 2017
CONCLUSIONS Aubert&Duval and Erasteel have 50 years of experience in gas atomization for various market (Aeronautic, Power, tooling, ) With capacity of Ni and Co based superalloys (Spain) Atomization tower for steels around 10 tons (Sweden) Development of capacity for titanium alloys (France). Fully involved in the ramp-up of Additive manufacturing: EPMA member(www.epma.com/am) International standardization member: Leader of joint group ISO-ASTM Additive manufacturing Technical specifications on metal powders future ISO ASTM 52907 Development of new facilities in adequacy with the market Strong R&D implication through collaborative projects (AMANDE, Sofia, etc) Page 15-15 juin 2017
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