Introduction to Additive Manufacturing Aberdeen, May 2017 www.voestalpine.com
Don t try to use AM for parts which are dedicated to other manufacturing technologies! AM is only economically if you can add value to the part! 2 Additive Manufacturing Introduction
Would you try to mill this part cast this part Source: huber-metallgaeu.de Source: http://www.fischer-group.com adhere this part cast this part Source: http://www.mirap.ch 3 Additive Manufacturing Introduction
Technical advances material properties 4 Additive Manufacturing Introduction Source: Renishaw
voestalpine Additive Manufacturing approach Be the Solution provider (one stop shop) within Additive Manufacturing Technologies for powder and parts Powder development Powder production Customer consulting Design AM-Parts Heat treatment & post processing Parameter development for different applications & Additive Manufacturing Center 5 Additive Manufacturing Introduction
Create an international Additive Manufacturing Competence Network Innovation Hub in Europe Powder production units (Sweden & Austria) Focus: Tool steels & Special alloys voestalpine Additive Manufacturing Center Eifeler Lasertechnik Activities in ASIA voestalpine Additive Manufacturing Center Singapore voestalpine Technology Institute (Asia) in Taiwan Activities in NAM Tooling focus in Ontario, CA Prepare operations in Houston 6 Additive Manufacturing Introduction
In the area of Additive Manufacturing there are several different processes for metal applicable Powder bed processes Direct Metal deposition processes Powder bed fusion Laser, e.g. Trumpf, Concept Laser, EOS, SLM Solutions Powder bed fusion Electron beam, Arcam Metal powder based binder jetting, ExOne Blown powder based Metal wire based Laser metal deposition, e.g. Trumpf Metal powder application technique, Hermle Electron beam, Sciacky Rapid plasma deposition, Norsk Titanium Laser metal deposition Each of this processes has advantages/disadvantages and so on focus on different applications 7 Additive Manufacturing Introduction
Different technologies within voestalpine Powder bed processes Direct Metal deposition processes voestalpine Additive Manufacturing Center Blown powder based Eifeler Lasertechnik voestalpine Additive Manufacturing Center Singapore Metal wire based Böhler forgings Eifeler Lasertechnik 8 Additive Manufacturing Introduction
Additive Manufacturing names a process which builds up parts layer-upon-layer (I) (II) Definition Additive Manufacturing is defined as the process of joining materials to make objects from 3D model data, usually layer upon layer (Definition by ASTM). (III) Process of layerwise manufacturing (I) lowering the building platform (II) recoating with new layer of powder (III) exposing with laser beam 9 Additive Manufacturing Introduction
Development & production of high quality metal powders at Böhler Edelstahl & Uddeholm Atomising rigs at Böhler & Uddeholm Facts Production started 2016 In total a yearly capacity of roughly 80 tons of metal powder will be available for AM & PM VIM with max. batch size of 200-250kg Atomization with inert gas Flexible production plant open for customized solutions (chemistry) Atomization of broad range of steel and Ni-Base alloys possible 10 Additive Manufacturing Introduction
Powder is powder really? =? Shape Particle size distribution Hollow structure Humidity Oxygen content Chemistry Flowability 11 Additive Manufacturing Introduction
Material properties - Uddeholm Corrax Mechanical properties Polishability Impact toughness [J] Modulus [N/mm²] Yield Strength - Rp0,2 [N/mm²] Tensile Strength - Rm [N/mm²] Conventional 17.6 200.000 1.600 1.700 Built vertically 18.7 199.867 1.640 1.701 Built horizontally 22.06 197.992 1.560 1.653 AM Hardness up to 50 HRC in aged condition and 7,624 g/cm3 density. Mechanical properties similar to conventional material! Polishability better than conventional material!! 12 Additive Manufacturing Introduction
AM-Machine capabilities @ vamc Materials Inconel 718 17-4 PH 1.2709 Corrax/CX, 316L 13 Additive Manufacturing Introduction Trumpf truprint 1000 Building Chamber: Ø100 x 100mm Laser Power: 175 Watt Heating: Not available SLM Solutions 280HL Building Chamber: 280 x 280 x 350mm Laser Power: 700 Watt & 1000 Watt Platform Heating: 200 C 600 C for reduced platform (Ø90mm) EOS M290 From June Building Chamber: 250 x 250 x 325mm Laser Power: 400 Watt Platform Heating: 200 C
The AM process needs to be tailored to specific product requirements in a lengthy development process Complexity of AM production process Implications As of today, there is no complete set of design, layout, material, machine and process rules Practitioners need to tailor the production process to each specific object Adaptations, such as the use of new material, require up to one year of development time 14 Additive Manufacturing Introduction Source: Roland Berger
State of the art @ eifeler Lasertechnik GmbH Laser cladding/deposition 15 Additive Manufacturing Introduction
Operational characteristics of laser beam deposition 3 beam nozzle technology coaxial powder supply Process: creating of a local melt pool low melting of material surface powder is melting in melt pool metallurgical bond with base material through heat dissipation --> molten material solidified to corrugated cladding lines 16 Additive Manufacturing Introduction
Application areas for the laser deposition technology Repairing of parts or tools Preventive wear protection Contour changing of surfaces Creation of adjusted functional layers 17 Additive Manufacturing Introduction
Examples of contour changing - forming tools, automobile side panel 18 Additive Manufacturing Introduction
Cladding of a punch surface part: punch for hot working base material: hot working steel additional metal: Iron basis alloy hardness: 56 + HRC layer thickness: 1 3 mm 19 Additive Manufacturing Introduction building of sandwich structure inside good thermal conduction / outside higher hardness good corrosion properties
Singapore Company registered 2016 Joint activities with DMG Mori to develop applications vamcs to manufacture 3D components for customers within the Asia Pacific region DMG Mori Lasertec 65 3D 20 Additive Manufacturing Introduction Laser deposition of metal powders Stainless steels, Ni Alloys, Tungsten Carbides etc. 5 axis CNC workstation 400 x 500 mm footprint; up to 600kg component weight. Powder deposition up to 1kg / hour Production, Repair & Coating
DMG Mori Application Drillhead Material: 316L (1.7225) / Alloy 718 Coated material: Tungsten Carbide 316L 3 Construction of base body Milling and drilling of cooling channels Alloy 718 Tungsten carbide Laser Deposition Welding: 13 Hrs. ULTRASONIC+Processing: 4.5 Hrs 21 Additive Manufacturing Introduction Construction of cutting blade Source: DMG Mori Coating + Finishing (Incl. loops of Inserts)
DMG Mori Application Vacuum Tube Build on curve Requirements: Building vacuum tube with inner tubes for heat exchanger Material used: Stainless Steel 316L Branch: Oil and Gas Cycle time: 3 hours Conventional: Impossible 22 Additive Manufacturing Introduction Source: DMG Mori
Design & Manufacture tools & components Direct metal deposition 23 Additive Manufacturing Introduction, BEAM
Additive Manufacturing has to offer a lot of benefits which needs to be exploited flexible production / design freedom temperature / flow optimization separation/mixing of liquids/gaseous less assembly/ monolithic design less time-to-market porous structures/ ventilation fast deployment of design changes integration of functions/sensors lightweight 24 May 17 Additive Manufacturing Introduction Source: DMRC, voestalpine
Technology Showcase: Additive Manufacturing - Tooling 25 Additive Manufacturing Introduction
26 Additive Manufacturing Introduction Source: Fraunhofer, Renishaw, APWorks, FIT, Sandvik, Arup
For further information please contact Armin Wiedenegger Strategy & Business Development Additive Manufacturing GmbH Hansaallee 321, 40549 Düsseldorf, Germany mobile: +49 (151) 105 402 51 tel.: +49 (211) 522-2332 armin.wiedenegger@voestalpine.com 27 Additive Manufacturing Introduction