Multi-axis Simultaneous machining and AMulti-axis Simultaneous machining and A

IGSTC Workshop

IIC, Delhi

axis Simultaneous machining and ADDITIVE MANUFACTURING axis Simultaneous machining and ADDITIVE MANUFACTURING

IGSTC Workshop

IIC, Delhi-2014

5 AXIS MACHINING

MULTI-AXIS SIMULTANEOUS MACHINING

INTRODUCTION

POWDER BED BASED TECHNOLOGIES

5 AXIS MACHINING

NUMERICAL METHODS FOR TOOL PATH GENRATION

INTRODUCTION

METAL ADDITIVE MANUFACTURING

POWDER BED BASED TECHNOLOGIES

DEPOSITION BASED TECHNOLOGIES

APPLICATIONS

DESIGN FOR ADDITIVE MANUFACTURING ( DFAM )

NUMERICAL METHODS FOR TOOL PATH GENRATION

DESIGN FOR ADDITIVE MANUFACTURING ( DFAM )

Why Multi-axis Machining ?

To manufacture parts more efficiently

and accurately by eliminating extra set-

ups and fixturing.

Standard shorter tool can be used,

which results in ability to rough more

aggressively, while increasing tool life.

More preciseandcomplexsurfacescanMore preciseandcomplexsurfacescan

be finish machined using accurate tool

path control and easy tool access.

Fig. Compressor wheel

Scope- Optimization of 5 axismachining

aerospace and power generation industries.

Axis machining

5 Axis machine consists of

- 3 linear axes X, Y, Z

- 2 Rotary axes A or B or C

Fig . Standard Axis Convention

machiningprocess for intricate components from

.

5 Axis machine consists of

3 linear axes X, Y, Z

2 Rotary axes A or B or C

Fig . Example of 5 axis machine with axis convention [Ref-Hermle C30 U ]

Table / Table Table / Tool (Mill)

Both (A and C) rotary axes arein the table

One rotary axis(B) is inthe table. The other onthespindle(C)

Onein(C)

Axis Machine Configurations

thespindle(C) (C)

Table / Tool (Mill-Turn)

Tool / Tool

One rotary axis (A) isin the table, the other(C) on thespindle.

Both rotary axes (A and C) are in the tool

(C) on thespindle.

Most people believe that simultaneousmultiaxis

machine tool continuously while cutting,

combinationis considered to besimultaneous

Simultaneous Multi-axis Tool paths

Fig. Examples of simultaneous multiaxis tool path motions

multiaxis toolpaths must move all 5 axes of

cutting, when in fact a single rotary andlinear

simultaneousmultiaxis cutting motion.

Fig. Examples of simultaneous multiaxis tool path motions

1- Interpolation

Finding an arbitrary curve that fits (passes through) a set of given points.

This problem is encountered, for example, when trying to fit a curve to a set of

experimental values.

Types of interpolation techniques

• Lagrange polynomial

• Parametric cubic (Hermite)

Finding an arbitrary curve that fits (passes through) a set of given points.

This problem is encountered, for example, when trying to fit a curve to a set of

Mainly used to interpolate to given data, not

splinecurves do.

Parametriccubic spline connects two enddata

To define parametric cubic spline need twoend

points.

Parametriccubic spline curves not popular as

- Control of curves is not obviousbecause

changethe entire shape.

- Order of spline is constant (Cubic)

to design free-formcurves as Bezier andB

datapoints and utilizes a cubic equation.

enddata points and two tangent vectors atthe

Bezier and B-spline because

becausechange in end points or endvector

Synthetic Curves

2. Approximation Approximation approaches to the representation of curves provide a smooth shape that approximate the original points, without exactly passing through all of them.

Two Approximation methods are used

• Bezier Curves• B-Spline Curves

Approximation approaches to the representation of curves provide a smooth shape that approximate the original points, without exactly passing through all of them.

It is based upon approximationtechniques

techniques in curve design due to addedflexibility

Synthetic Curves – Bezier Curve

The order or degree of Bezier curve isvariable

defining it.

The Bezier curves are smoother because ithas

techniques. This is preferred overinterpolation

flexibility and intuitive feel.

variableand is related to the number ofpoints

hashigher order of derivatives.

Given n+1 control points, P0, P1, P2, ….., Pn, the Bezier curve is defined by the

following polynomial of degree n

0)()( =∑ PuBuPn

Synthetic Curves – Bezier Curve

0)()(0

,=∑=

PuBuPi

ini

Where,

P(u) is any point on the curve, Pi is a control point, P

Bi,n are polynomials (serves as basis function for the Bezier Curve)

Disadvantages

� Curve does not passes through control points which may be convenient to designers.

� Curves lacks local controls, it has global control nature.

� If one control point is changed whole curve changes.

, the Bezier curve is defined by the

10 ≤≤u 10 ≤≤u

is a control point, Pi = [x i yi zi]T

are polynomials (serves as basis function for the Bezier Curve)

Curve does not passes through control points which may be

Curves lacks local controls, it has global control nature.

If one control point is changed whole curve changes.

What is a spline?

� An interval [a..b] is subdivided intosufficiently

a=ξ1<…<ξl+1=b,

� On each such interval, a polynomial p of� On each such interval, a polynomial pj of

approximation.

� This can even be done in such a way that thepolynomial

resulting composite function s(x) that equals pj

derivatives.

� Such smooth piecewise polynomial functionis

Why B-splines?Why B-splines?

� They provides local control of curves .

� Ability to addcontrolpoints withoutincreasing

� B-spline has ability to interpolate as well

Interpolation helps to display engineeringresults

sufficiently small intervals [ξj.. ξj+1], with

of relatively low degree can provide a goodof relatively low degree can provide a good

polynomialpieces blend smoothly, i.e. so thatthe

j(x) for x∈[ξj ξj+1] , all j , has severalcontinuous

is called aspline.

increasingthe degree of curves.

as approximate a set of given data points.

results such as stressor displacementwhile

Given n+1 control points P0, P1, ……., Pn, the B

these control points is given as

n

=∑

Synthetic Curves – B spline

0, 0)()( PuNuP i

n

iki=∑

−

Where

• P(u) is any point on the curve

• Pi is a control point

• Ni,k(u) are the B-spline basis functions of degree k

• The parameter k controls the degree (k-• The parameter k controls the degree (k-and usually independent of the number of control points

• It should be noted that the range of u is not 0 to 1, but it varies with the number of control points and the degree of the curve

0 ≤ u ≤ ( (n+1) – (k-1) )

, the B-spline curve of degree (k-1) defined by

≤≤ max0 uu≤≤

spline basis functions of degree k

-1) of the resulting B-spline curve -1) of the resulting B-spline curve and usually independent of the number of control points

It should be noted that the range of u is not 0 to 1, but it varies with the number of control points and the degree of the curve

1) )

B spline in advanced Multiaxis M/c controller

Non-Uniform Rational B-Splines(NURBS)

functionsare mainly used inCAD/CAM/CAE

Interpolationfunctionmainlydeterminedby allInterpolationfunctionmainlydeterminedby all

Computingthe weight of control pointsevolves

sincewe interpolate one direction at a time.

(NURBS) and they are basically piecewisepolynomial

CAD/CAM/CAE to express sculptured or curved surfaces.

all setof dataata time.all setof dataata time.

evolvesset of linear systems of much smaller

B spline in advanced Multi-axis M/c controller

Cut Pattern – Guides the tool along withcutting

Tool Axis Control – ControlstheorientationTool Axis Control – Controlstheorientation

CutPattern

Tool Tip Control – Controls the geometryto

In addition to the above three majorcontrols,

additionalcollision control.

Thus modern machine tools offer almostlimitless

tool paths and geometrical compensation toachieve

cuttingdirections

orientationof thetool’s centeraxisasit follows theorientationof thetool’s centeraxisasit follows the

to which the tool tip is compensated.

controls, CAD/CAM system also offers

limitless possibilities to generate complex

achievedesired surfaces.

• Stereolithography –Patented by Charles Hull ( 1987 )• Stereolithography -Commercialized by 3D systems ( 1989 )

• FGM ( Fused Deposition Modelling ) – Stratasys( 1991 )• LOM ( Laminated object manufacturing ) – Helisys( 1991 )• SLS ( Selective laser sintering ) – From DTM corp. austin• SLS ( Selective laser sintering ) – From DTM corp. austin

• SLS (Selective laser sintering) from DTM corp. ( now part of 3D systems ) ( 1994 )• EOSINT M250 launched by EOS ( Electro optical systems )

• LAM (Laser additive manufacturing) Aeromet ( 1997-2005 • LENS (Laser engineered net shaping) Sandia national laboratory • DMD (Direct metal deposition) from POM ( 2000 )

• Euromold 2001 –metal sintering machine from Concept laser • EOSINT M270 from EOS, Germany• SLM 100 (Selective Laser Melting) from MTT group ( 2005 )

• EBM A2 (Electron beam melting) from ARCAM, Sweden ( 2007 )• ASTM F-42 committee defined additive manufacturing and it’s standards ( 2008 )• Global market for AM exceeded $1 billion ( 2009 )

• A workshop was held in the U.S. to form a roadmap for research in AM for the next 10• A group of companies led by Materialize formed a group to conduct collective marketing for AM ( 2010 )• SLM500 ( largest metal machine ) from SLM solutions Germany. ( 2012 )

Patented by Charles Hull ( 1987 )Commercialized by 3D systems ( 1989 )

( 1991 )( 1991 )

austintexas( now part of 3D Systems ) ( 1992 ) austintexas( now part of 3D Systems ) ( 1992 )

SLS (Selective laser sintering) from DTM corp. ( now part of 3D systems ) ( 1994 )EOSINT M250 launched by EOS ( Electro optical systems )

2005 )LENS (Laser engineered net shaping) Sandia national laboratory – commercialized to Optomec ( 1998 )

metal sintering machine from Concept laser Gmbh

SLM 100 (Selective Laser Melting) from MTT group ( 2005 )

EBM A2 (Electron beam melting) from ARCAM, Sweden ( 2007 )42 committee defined additive manufacturing and it’s standards ( 2008 )

A workshop was held in the U.S. to form a roadmap for research in AM for the next 10-12 years ( 2009 )A group of companies led by Materialize formed a group to conduct collective marketing for AM ( 2010 )SLM500 ( largest metal machine ) from SLM solutions Germany. ( 2012 )

Additive manufacturing (AM), also referred to as

3D printing, is a layer-by-layer technique of

producing three-dimensional (3D) objects directly

D Printing ( Additive manufacturing )

from a digital model

Tool-less manufacturing

Energy saving process

Less waste

Reduced time to market

ApplicationsApplications

Rapid prototyping and models manufacturing

Tool manufacturing

Direct part production ( Aerospace and defense components )

Maintenance and repair

Additive manufacturing (AM), also referred to as

dimensional (3D) objects directly

Rapid prototyping and models manufacturing

Direct part production ( Aerospace and defense components )

Fig. Additive manufacturing process

Factors Affecting Additive Manufacturing Process

�Materials that can be processed

Fig. Additive manufacturing processes classification

�Materials that can be processed

�Build volume and build speed

�Accuracy and surface finish

�The material properties and post treatment required

�Accessibility and safety related to complexity of operation

Factors Affecting Additive Manufacturing Process

Fig. Additive manufacturing processes classification

The material properties and post treatment required

Accessibility and safety related to complexity of operation

Fig. Stereolithography process

� Principal commercial providers: 3DSystems, Aaroflex, envisionTEC (non� Principal commercial providers: 3DSystems, Aaroflex, envisionTEC (non

laser stereolithography)

� Materials: Photo curing polymers using material like polypropylene, ABS,

PBT, rubber; development of ceramic-metal alloys.

� Typical resolution: 0.025 mm

Fig. Stereolithography process

3DSystems, Aaroflex, envisionTEC (non-3DSystems, Aaroflex, envisionTEC (non-

Photo curing polymers using material like polypropylene, ABS,

metal alloys.

Laminated Object Manufacturing

Laminated object manufacturing: 1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning prism. 5 Laser unit. 6 Layers. 7 Moving platform. 8 Waste

Laminated Object Manufacturing

Laminated object manufacturing: 1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning prism. 5 Laser unit. 6 Layers. 7 Moving platform. 8 Waste

A.M. of metals

Additive manufacturing of metals

Powder bed technologies

Laser based Electron beam based Laser based

SLS of EOS Germany

SLM Solutions (Germany)

SLM of MTT

ARCAM(Sweden)

LENS of Optomec

DMD of POM

Easyclad of

Irepalaser

A.M. of

Deposition technologies

Laser based Electron beam based Arc based

LENS of Optomec

DMD of POM

Easyclad of

EBFFF of NASA PTA Plasma

PAW

GMAW-P

GTAW-HT

Powder bed technologies

Fig. Basic principle of powder based technologies

Spreading powder on a wider area and sintering/ binding only where required

Only powder can be usedOnly powder can be used

Powder particles are coarse as they are mechanically spread (> 20µm)

Not readily amenable for FGM

Tools : SLS/SLM systems from EOS and MTT, EBM from ARCAM

Fig. Basic principle of powder based technologies

Spreading powder on a wider area and sintering/ binding only where required

Powder particles are coarse as they are mechanically spread (> 20µm)

Tools : SLS/SLM systems from EOS and MTT, EBM from ARCAM

Powder bed technology : Selective laser sintering ( SLS )

Fig. Selective laser sintering process ( SLS )

Principal commercial providers: SLS from EOS , SLM from Slm

Materials: Plastics - polystyrene, nylon, glass filled nylon, alumide Materials: Plastics - polystyrene, nylon, glass filled nylon, alumide

(aluminum/nylon blend)

Materials: Metals - aluminum, stainless steel, titanium, gold

Most accurate Z-resolution: 0.2mm for plastics, 0.02mm for metals

Powder bed technology : Selective laser sintering ( SLS )

Fig. Selective laser sintering process ( SLS )

SLS from EOS , SLM from Slm-solutions

polystyrene, nylon, glass filled nylon, alumide polystyrene, nylon, glass filled nylon, alumide

aluminum, stainless steel, titanium, gold

0.2mm for plastics, 0.02mm for metals

RENISHAW SLM SOLUTIONS

MODELS AM 250 SLM 500

BUILD 245 x 245 x 500 x 280 x 325 BUILD VOLUME

245 x 245 x300 ( 360 )

500 x 280 x 325 mm

BUILD SPEED5- 20

cm³ per hour

70cm³ per hour

LASER TYPEFiber laser200/400 W

2 Fiber laser (400/1000 W)

ADVANTAGESLow

maintenance High build volume,

ADVANTAGES maintenance cost

High build volume,High build rate

MATERIALSMaraging Steel, Stainless Steel,Cobalt Chrome,Aluminium AlSi10Mg

COST Rs.4

SLM SOLUTIONS EOS CONCEPT LASER

SLM 280 M280 M2 Cusing

280 x 280 x 350 250 x 250 x 325 250 x 250 x 325 280 x 280 x 350 mm

250 x 250 x 325 mm

250 x 250 x 325 mm

20 - 35cm³ per hour

13.5-20 cm³ per hour

10 - 20 cm³ per hour

Fiber laser 400/1000W

Fiber laser 200/ 400 W

Fiber laser 200/ 400 W

High build volume, Larger customer Random laser High build volume,High build rate

Larger customer base

Random laser scanning

Cobalt Chrome,Titanium Ti64,Nickel Alloy IN718 , IN625 ,

4-5 Crore

Electron beam technologies

�Tungsten filament

�EBM takes place in vacuum chamber

Process parameters

EB power : 7 KW

spot size : 1 to 4 mm

EB positional accuracy ±0.05 mm

�Prevents oxidation and contaminations

EB positional accuracy ±0.05 mm

Deposition rates : 55-80 cc/h

Accuracy: ±0.40 mm

Build up volume : max. 200 × 200 ×350 mm

Layer thickness : 0.050 – 0.200 mm

Fig. Electron beam melting

350 mm

Material Can Be Processed�Super alloys �Stainless steels�Tool steels �Aluminum�Titanium

Latest EBM Systems from ARCAM

Table Specifications of two ARCAM modelsTable Specifications of two ARCAM models

Deposition of metal only in the required areas

Features of deposition technologies

Powder as well as wire can be used

Higher deposition rates compared to powder based processes

Powder particles are fine, as small as a few µm

Readily amenable for FGM

ToolsTools

� LENS ( Laser engineered net shaping ) from OPTOMEC,

� DMD ( Direct metal deposition ) from POM,

� Easyclad and other Arc based processes .

Deposition of metal only in the required areas

Higher deposition rates compared to powder based processes

Powder particles are fine, as small as a few µm

Fig. Basic layout of deposition system

LENS ( Laser engineered net shaping ) from OPTOMEC,

DMD ( Direct metal deposition ) from POM,

Easyclad and other Arc based processes .

Deposition technologies

LENS from OPTOMEC DMD from POMDMD from POM EASYCLAD from Irepalaser

Lasers technologies

CO2 laser

ND : YAG laser

Fiber laser

Deposition technology : Laser engineered net shaping ( LENS )

Fiber laser

Process parameters

laser power : 0.5 to 3 KW

spot size : 1 to 4 mm

Heat affected zone : 0.12 to 0.65 mm

Deposition rates : 230 cc / h Deposition rates : 230 cc / h

powder utilization rates : up to 80%

Build up volume : max.900 x 900 x 1500

mm

Layer thickness : 0.1 to 1 mm

Deposition technology : Laser engineered net shaping ( LENS )

Materials � Stainless steels,

Fig. Basic layout and flow path of typical LENS system

� Stainless steels,� Tool steels (H13, P20, P21, S7, D2);� Nickel-based alloys (Inconel 600, 625, 690, 718)� Titanium alloys (Ti-6Al-4V);� Aluminium;� Copper and its alloys;� Stellite;� Tungsten carbide

Parameters LENS from OPTOMEC

Build up volume 900 x 900 x 1500 mm 2000 x 1000 x 750 mm

Deposition rates 20 – 230 cm3/h

Different laser based deposition systems

Deposition rates 20 – 230 cm3/h

Layer thickness 0.1 to 1 mm

Laser type IPG Fiber Laser1 to 4 KW diode/disk/fiber lasers

Tolerance ± 0.125 mm

Powder utilization up to 80%

Models MR7Models MR7850R

Materials Stainless steels, tool steels, nickelalloy, stellite, tungsten carbide.

-processing Part cutting, shot peening, heat treatment

DMD from POM

EASYCLAD from Irepa laser

2000 x 1000 x 750 mm 1500 x 800 x 800 mm

35 – 300 cm3/h 45 – 180 cm3/h35 – 300 cm3/h 45 – 180 cm3/h

0.1 to 1.6 mm 0.2 to 0.8 mm

fiber coupled diode/disk/fiber lasers

Monomode fiber laser750 - 4000W

± 0.127 mm -

40 to 70 % -

DMD 105D/505D , Magic LF6000,DMD 105D/505D ,DMD 44R/66R ,DMD IC 106.

Magic LF6000,CLADUnit,

MobilCLAD.

Stainless steels, tool steels, nickel-based alloys, titanium alloys, Copper and its alloy, stellite, tungsten carbide.

Part cutting, shot peening, heat treatment

• Defense

• Aerospace

• Oil and gas

Application fields

• Oil and gas

• Use of high performance alloys

• Small, complicated low volume parts

• Reduced buy to fly ( BTF ) ratio

• Difficult to process materials can be processed

Reasons

• Small to medium sized part manufacturing• Small to medium sized part manufacturing

• High performance part repairing

• Hybrid manufacturing

• Manufacturing defect repairing or Service repairs

Applications

Aerospace

Oil and gasOil and gas

Use of high performance alloys

Small, complicated low volume parts

Reduced buy to fly ( BTF ) ratio

Difficult to process materials can be processed

Small to medium sized part manufacturingSmall to medium sized part manufacturing

High performance part repairing

Hybrid manufacturing

Manufacturing defect repairing or Service repairs

Rotor produced on an EOS ( Inconel 718 )

Size: Ø 140 x 80 mm

Rocket Engine Impeller ( Ti6Al4V )

Size: Ø 140 x 80 mmWeight: 2,5 kgBuild time: 16 hoursARCAM EBM

Thin walled turbine combustion chamber, produced on EOSINT M 270, material EOS Nickel Alloy IN 718

Swirler (fuel injection nozzle) for gas turbine applications made from Cobalt Chrome

Fig. Direct part manufactured by LENS deposition system ( Ti

Gas thruster – Bell helicopter

Dual wall exhaust duct

Fig. Direct part manufactured by LENS deposition system ( Ti-6Al-4V )

Gear box spider ( Red bull )

+ LENS

Conventional manufacturing cost -$3500

Manufacturing cost by LENS -$2000 Manufacturing cost by LENS -$2000

Wall thickness 7.6 mm

Fig.5. Ti-6Al-4V Small Ribbed Bracket ( Optomec )

$3500

Inconel 718 Blisk airfoil repair

T700 engine blisk repair

Ti-6Al-4V bearing housing repair

Tungsten carbide cladded oil field tools

Defective forgings or castings can be repaired

Ti-6Al

Manufacturing defect repairing by deposition technologies

Laser repair ( LENS ) process is used

Fig. Repairing of undersized forgings

Defective forgings or castings can be repaired

6Al-4V atomizer drive plate ( Forging undersized )

Manufacturing defect repairing by deposition technologies

Laser repair ( LENS ) process is used

Fig. Repairing of undersized forgings

�

�

Hybrid Manufacturing by using deposition technologies

�

�

Fig. Ti-6Al-4V atomizer wheel with added boss

( Forging + additive manufacturing LENS )

Fig. Alloy 718 ring of GE aviation

Conventionnalmanufacturing + Additive manufacturing

Used for small feature addition ( flanges, pads, bosses )

Hybrid Manufacturing by using deposition technologies

Laser deposition based processes can be used

Initial raw material and machining cost can be saved

Fig. F119 fan section ( NASA )

Punch life before :

Punch life after :

Repairing cost :

Connecting rod punch ( after machining )

Repairing cost :

Lead time : 30 % less than new

Technical challenge : Severe wear and heat checking

H-13 and hard

Die after H13 deposition

H-13 and hard coating material deposited on forging die

Punch life before : 5000 cycles

Punch life after : 19,000 cycles

45 % of new

After deposition

45 % of new

30 % less than new

Severe wear and heat checking

13 and hard

Die after Nestelle C deposition

13 and hard coating material deposited on forging

Cost of 3D Printing

Complex bosses Cooled aerofoilsCooled aerofoils Internal cavities and oil ways

List of requirements

Structural optimization

� Redesigninging of components considering

capabilities of 3D printing

� Complex designs are possibleStructural optimization

Interpretation of results

New design in CAD

FE Analysis

� Benefits in terms of light weighting ( Strength /

mass optimization ) and some special functions

� Lattice and honeycomb like structures are possible

by using 3D printing

FE Analysis

Final design

Fig. Steps of DFAM

Redesigninging of components considering

capabilities of 3D printing

Complex designs are possible

Benefits in terms of light weighting ( Strength /

mass optimization ) and some special functions

Lattice and honeycomb like structures are possible

by using 3D printing

External lattice for heat dissipation

Design for additive manufacturing ( DFAM )

HC101 steel ( 7.7 gm/cm3 )918 gms

Ti64 alloy ( 4.42 gms/cm3 )326 gms

Design for additive manufacturing ( DFAM )

Mass : 870 gmsMaterial : Ti64

First class monitor arm

Mass : 285 gms

First class monitor arm

Mass : 370 gmsMaterial : Ti64Reduction : 57.4 %

Mass : 148 gmsReduction : 48 %

Material ProcessingTensile strength

( Mpa )

Wrought 950

Properties of 3D Printed metals

6Al-4VPowder bed /

deposited1100 / 1045

IN 718Wrought 1265

Powder bed / deposited

1241 / 1247

IN 625Wrought 965

Powder bed / 930 / 1052

Powder bed / deposited

930 / 1052

316 L-SS Wrought 585

Powder bed / deposited

625 / 678

Yield strength ( Mpa )

Elongation ( % )

Young's modulus( Gpa )

880 14 -

1000 / 1145 11 / 9 107 / 116

1075 18 -

1034 / 1088 18 / 21 170 / -

480 52 -

650 / 694 44 / 33 160 / -650 / 694 44 / 33 160 / -

380 45 193

525 / 515 ~ 43 ~177

Pre-processing 3D Printing

Pre and Post Processing Required

Reverse engg. Tools

Magics ( support editing ) Magics ( support editing )

software

Post-processing 3D Printing

�Support, part cutting

�Grinding, polishing

�Shot peening

�Heat treatment

�HIP treatment

Process: Simultaneous application of

hydrostatic pressure up to 500-1400 bar under

argon gas at temperatures between 400-1400

Application fields : Aerospace , defense , oil and gas, power generation, nuclear automotive

Benefits

Eliminates porosity in sintered parts

Removes fatigue crack initiation sites

Achieves homogeneous microstructure, eliminates

internal voids.

Typical tensile strength and ductility improvement is 5

% and upto 50 % respectively.

Achieves homogeneous microstructure, eliminates

Typical tensile strength and ductility improvement is 5

Applications of additive manufacturing

Fig. Range of applications of AMFig. Range of applications of AM

Fig. Metal powder bed type 3D systemsFig. Metal powder bed type 3D systems

Sr. no. Applications 3D systems market leaders

1. Polymer AM EOS ( Electro Optical Systems ), 3D systems

2. Tooling's EOS, Concept laser 2. Tooling's EOS, Concept laser

3. Dental EOS, Phoenix systems

4. Medical EOS, ARCAM, SLM Solutions

5. Aerospace EOS, RENISHAW, SLM Solutions, ARCAM

6. Auto EOS, SLM Solutions, RENISHAW, Concept laser6. Auto EOS, SLM Solutions, RENISHAW, Concept laser

7. Lifestyle EOS, Concept laser, Relizer

8. Repair LENS from Optomec and DMD from DM3D

3D systems market leaders

EOS ( Electro Optical Systems ), 3D systems

EOS, Concept laser EOS, Concept laser

EOS, Phoenix systems

EOS, ARCAM, SLM Solutions

EOS, RENISHAW, SLM Solutions, ARCAM

EOS, SLM Solutions, RENISHAW, Concept laserEOS, SLM Solutions, RENISHAW, Concept laser

EOS, Concept laser, Relizer

LENS from Optomec and DMD from DM3D

3D printing at GE and SAFRAN

�

Leap engine fuel nozzle

�

�

�

�

Fig. 3D printed LEAP fuel nozzle ( Cobalt-chromium alloy )

�Every LEAP engine has 19 fuel nozzles �Every LEAP engine has 19 fuel nozzles

( conventional nozzle is assembly of 20 parts )

�Single piece

�25 % lighter

�5 times durable than conventional

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