High Value Manufacturing - Introduction

Thierry Dormal

SIRRIS – ADD

Agenda High Value Manufacturing – Nov. 15

14h30 Introduction Thierry Dormal (Sirris)

14h50 Cas concrets d’application des Matériaux à Gradient Fonctionnel (FGM) dans différents secteurs industriels Julien Magnien (Sirris)

15h10 L’allègement par les techniques additives: une nouvelle manière de

concevoir. Denis Gravet (Sirris)15h30 Pièces métalliques à porosité contrôlée fabriquées par 3D-Printing

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15h30 Pièces métalliques à porosité contrôlée fabriquées par 3D-Printing

Bruno Verlee (Sirris)15h45 Pause

16h00 Témoignages industriels: AEI, Flying Cam, Group T Formula Racing

16h45 Visites & échanges thématiques individuels

18h00 Drink

B2B – Session d’échanges thématiques

Conception orientée additive manufacturingLaser Cladding, Laser Melting, EBM, 3DP metal SIRRIS

Caractérisation microstructurale et thermophysique Ulg (MMS)

Caractérisation mécanique, fatigue,… CRM

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Caractérisation mécanique, fatigue,… CRM

Contrôle non-destructif, tomographie CEWAC

Mesure 3D, Imagerie thermique, mesure de déformations CSL / SIRRIS

TipTopLam partnership

Research centers and universities:

SIRRIS CSL ULg CRM CEWAC

Industrial partners:

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Industrial partners:

Techspace Aero, FN Browning, Sabca, Sonaca, Precimetal, Breuer, Flying Cam, Carat Duchatelet, Euro Heat Pipes, Secopra, Précical, Précision Liégeoise, Jtekt.

Objectives:

- Titanium, Stainless steel, Inconel, Aluminium materials- Combination of small details and high productivity- Solutions for FGM experimentation

WP1 Technology selection and installation

TipTopLam – Phase 1Technology selection & mastering

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WP1 Technology selection and installation

WP2 Real time process control

WP3 Building with Laser Cladding & Laser Melting

WP4 Analysis of microstructures and mechanical properties

WP5 Post-milling & post processing

TipTopLam – Phase 1Machines selection

Laser Cladding (Laser metal deposition): Optomec, Trumpf, Accufusion, POM, IrepaLaser…� Irepa EasyClad DuoClad

Laser Melting: EOS, MTT (MCP), ConceptLaser, Phenix,…

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EOS, MTT (MCP), ConceptLaser, Phenix,…� MTT (SLM Solutions)

Scanning 3D: ExaScan, Metris, GOM, Minolta,…� GOM + Metris head LC60D

PrincipleNo powder bedLocal deposition of fused metalPowder feeding in the laser beam

3 types of applications- Coatings: enhancement of hardness, wear resistance and anti-

Laser cladding

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- Coatings: enhancement of hardness, wear resistance and anti-corrosion- Repair of damaged expensive parts- Full 3D building of parts

Large range of materials available

FGM (dual feeding system)

Cladding head

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Laser melting process

© sirris 2010 | www.sirris.be | info@sirris.be | 9

- Powder bed system- Full melting of the powder- Full density

Pictures from ILT

MTT (SLM Solutions) SLM 250HL

- Laser Power: 400W

- Materials: Ti, Al, Inconel, CoCr, SS, Tool Steel

- Z axis: 350mm

- Pre heating build platform: - Pre heating build platform: up to 200°C

- AutoFAB Software (Marcam)

- Layer thickness: 30�m (20�m) up to 100�m

Laser melting - Quality controlTwo examples of Melting mastering problems

(from SLM/DMLS/Cusing manufacturers benchmarks!)

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Al-SiTi-6Al-4V

� Sirris works are based on process simulation and microstructure analysis� Density: > 99 % and a fine microstructure due to fast cooling� Competence required and efficient quality control as well

Projecteur de franges + 2 CCD- 2 Mpix/scan (1624 x 1236 pixels)- 3 volumes de mesure

3D Scanner GOM ATOS I

Volume de mesure

Résolution

(mm)

Précision

(mm)

500x400x400 0.3 0.05

250x200x200 0.15 0.02

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- Plateau tournant (100Kg max)- Référencement par micro-cibles (gommettes)

250x200x200 0.15 0.02

120x96x80 0.07 0.01

Avantages <> génération précédente:

- ESP3, ajustage continu des paramètres de chaquepoint du scan- productivité: 75000pts/s au lieu de 25000pts/s- stabilité car prisme statique, pas de miroir mobile - pas de préchauffage car compensation thermique

Scanner METRIS LC60D (adapté au FGM)

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- pas de préchauffage car compensation thermique

- bande de 60mm, profondeur de champ 60mm- Précision 15 �m (1σsphere fit)

- Summary of FGM cases and patents in the world

- Summary of ideas from industrial partners

- New format file required (STL � AMF)

- Selection of material combinations for FGM

TipTopLam – Phase 2FGM Functionally graded materials

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- Selection of material combinations for FGM

- Selection of gradient types (thermal, physical, mechanical)

- Sample testing, validation and microstructure analysis

ADD (1990 – 2012)• 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)

In-house additive technologies• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (2 Optoform)• 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal)

Sirris ADD capacities & competencies

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• 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal)• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser Melting (MTT/SLM Solutions) SLM 250 HL • EBM Arcam A2 (Titanium & CoCr)• Laser Cladding (Irepa Laser EasyCLAD)• 3D Printing of wax (Thermojet)• Makerbot Replicator & Fab@home

• 3D scanning & metrology (GOM, Metris, Wenzel)

Additive Manufacturing Additive Manufacturing –– EE--learning & Handbooklearning & Handbook

• KTRM Leonardo project

• Partners:

ASCAMM, SIRRIS, ASERM, iSmithers, Materialise, ULPGC, ITIA

• Handbook (220 pages) and e-learning courses (17 modules)

• Introduction

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• Introduction

• 13 AM Technologies

• Design and Analysis

• AM Materials

• Business models for AM

• Conclusions

Contact: Thierry Dormal thierry.dormal@sirris.be

Additive Manufacturing Additive Manufacturing

Merci pour votre attention

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Contact: Thierry Dormal thierry.dormal@sirris.be