Metal Additive Manufacturing Manufacturing

Metal Additive Manufacturing

Manufacturing & case

studies.

M.Sc. Miguel Godino Martinez

Agenda for today

1.What does Sirris do?

2.Why Metal Additive Manufacturing?

3.Which metal AM technology fits me?

4.Several metal AM case studies for aerospace

5.An innovative case study for the automotive sector

6.More case studies Miguel Godino

Process Engineer, Additive Manufacturing

[email protected] 2

What does Sirris do?

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What does Sirris do?

2485 SME’s (<250 employees)

2500 companies

115 big companies (>250 employees)

> WHAT ?

To help companies implement technological innovations > WHY ?

To reinforce the long-term competitive position of companies > TO WHOM ?

Belgian technology industry and at European level

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Within four domains of technology

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METALS

COMPOSITES

PLASTICS & HYBRIDS

COATINGS

NANOMATERIALS

ECO-MECHATRONICS

SENSORIZED FUTURE

MODEL BASED DESIGN

FACTORIES OF FUTURE

WORLD CLASS TECHNOLOGIES

ADDITIVE MANUFACTURING

SOFTWARE ENGINEERING

CLOUD COMPUTING

DATA INNOVATION

TEAM OF 20 INDEPENDENT EXPERTS, 25+ YEARS OF

EXPERIENCE

METALS, POLYMERS & CERAMICS

MORE THAN 10 Additive Manufacturing

TECHNOLOGIES IN-HOUSE

ADDITIVE MANUFACTURING AT SIRRIS

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http://www.sirris.be/nl/agenda/masterclass-design-additive-manufacturing-dag-1-2-0




Why metal additive

manufacturing?

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Some things to remember about metal AM…

Redesign, understand possibilities & limitations

of technology

Full chain from design, process/materials

optimization, AM technology & post treatments

Get CAD Design, Press print and done!

You are fully done by buying a metal machine

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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

Re-design Design, optimize, convert

Technology Selective Laser Melting and Electron Beam Melting

Orientation Right 3D position for the right process

Support Heat transfer and structural support

Manufacture Process parameters, material optimization

Thermal treatments Residual stresses

Post-finishing Surface finishing

Some things to remember about metal AM…

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Process chain example for additive manufacturing of metals


Advantages • ‘Reduced time design-to-manufacturing’

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CAD • Design your CAD

.STL conversion

and edit

• .STL is the format used for Additive Manufacturing

• Edit your part, redesign it, place support structures

Slice your part

• Slicing for a given layer thickness and hatching

Manufacture

• Depending on several factors, a normal built will take between 6-60h


Advantages

• Complex geometries possible

– Avoid welding and assembly steps for your part.

– Internal channels.

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‘Almost no geometrical constraints anymore’


Advantages • Reduce material

Only melt powder where needed to build the 3d part.

Powder not meltedpowder recupered & reused.

• Produce ‘overnight on Sundays’

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EOS center

Which metal additive manufacturing

technology fits me ?

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4 main metal additive manufacturing

technologies in a nutshell

1- Metal Binder Jetting ‘Similar to paper2D printing.

Able to produce big parts very fast by joining metal layers together thanks

to a binder. Gives a green part that needs to be sintered afterwards.’

2- Direct metal deposition/ cladding `A moving nozzle deposits and melt powder at the same time. Very useful

for difficult welding reparations. Naval industry.`

14 ILT, Fraunhoufer M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

3- Selective Laser melting Powder bed technology that melts

layer by layer using a laser beam.

Highly complex parts with a high

resolution, limited in size

4- Electron Beam Melting ‘ Powder bed technology that melts

layer by layer using an electron beam.

Highly complex metal parts limited in

size, fast.’

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4 main metal additive manufacturing

technologies in a nutshell

Video: Solid Concept

Video: Oak Ridge Lab M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

EBM (ARCAM A2 available at Sirris) SLM (SLM 250HL available at Sirris)

1. Re-Design 2. Technology 3. Reorientation

4. Support generation

5. Manufacture

6. Thermal treatments

7. Post-finishing

Electron beam source

High preheating Temperature

(~700C)

Need less supports

Less as-built thermal stresses

Difficult for building internal channels

Laser beam source

Low preheating Temperature (<200

C)

More need of supports

Finer resolution

Wider material pallet (Al,Ti,Inox,tool steel…)

16 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

picture: EOS

http://www.sirris.be/

A more detailed comparison: Some numbers

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SLM EBM

Size building

chamber

(mm)

typical 250 x 250 x 350 Ø 210 x 350

up to 500 x 280 x 325 Ø 350 x 380

Layer thickness (µm) 30 to 90 50 to 90

Min wall thickness (mm) 0.2 0.6

Accuracy (mm) +/- 0.1 +/- 0.3

Build rate (cm³/h) 5 - 20 80

Surface roughness (µm) 5 - 15 20 - 30

Type of parts High resolution, difficult

for massive parts

More massive parts, less

detailed.

1. Re-Design 2. Technology 3. Reorientation


5. Manufacture

6. Thermal treatments

7. Post-finishing


1. Re-Design 2.

Technology

3. Reorienta

tion


5. Manufacture 6. Thermal treatments

7. Post-finishing

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‘Need of support structures for EBM and SLM technologies’

Support goal Importance

for SLM

Importance

for EBM

Hold part against thermal stresses-

avoid delamination *** *

Conduct the heat away-thermal

transfer ** **

Physically hold the surfaces >45

over the powder bed *** *


© sirris | www.sirris.be | [email protected] |

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4/16/2015

1. Re-Design 2.

Technology

3. Reorienta

tion



7. Post-finishing

‘Supports will decrease the quality of the surface’


>45°

© sirris | www.sirris.be | [email protected] |

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1. Re-Design 2.

Technology

3. Reorienta

tion



7. Post-finishing

‘So orient the part in the way that less supports will be

needed’


mailto:[email protected]




•Diffusionless martensitic β→α’

martensitic acicular

•diffusion β→α phase transformation

‘Aluminium Alloys compared to casting: Some data’

AlSi10Mg, SIRRIS data

SLM SLM CAS

T +

AGE

CAS

T +

AGE

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1. Re-Design 2.

Technology

3. Reorientat

ion


5. Manufacture

6. Thermal

treatments

7. Post-finishing


Lightweight and aerospace

case studies

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Case1. Redesign for Additive Manufacturing: A satellite part

Initial part

Initial Mass ~ 457 g

Targeted reduction by

AM ~ 200 g!

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‘Unlock the potential of Topology Optimization thanks to the

design freedom of Additive Manufacturing’

Volume space

Initial part

Non-modifiable

areas Load cases

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After Topol iteration and FEA analysis

240g< 457g x2 weight saving !

Size and massivity Suitable to be produced by Additive Manufacturing

Final part

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An innovative case study for

the automotive industry

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A cylinder head. An innovative solution for the

automotive industry

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‘Lighter, complex and faster from design to

manufacturing than conventional production’ M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

Everything start with the redesign to get the

most of the technology

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Correct orientation, correct support structures

• Powder is less conductive than molten metal.

• So supports are built below massive zones to dissipate

the heat and avoid over-melting.

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Part after removing supports

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3D Scan comparison

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More applications

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Drillers AET-BMT

‘Smart drilling machines made of Titanium using EBM’

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Why metal additive

manufacturing?

Production cycle reduced up to 70%

Maintenance cost reduced 80%

Save of weight: high strenght vs weight

ratio.

Integration of functions


Laser collimator: simplifying the assembly

and adding performance

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Orthopedics, customized implants by Metal additive

manufacturing

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‘Production of complex patient specific implants’

Play on porosity, roughness and randomness lattices to replicate bone

conditions and promote cell growth


picture: ARCAM

Miguel Godino

Process Engineer in Additive Manufacturing of Metals

[email protected]

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Metal Additive Manufacturing Manufacturing

Business

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