MANUFACTURING FLAGSHIP

CSIRO Metallic Additive Manufacturing High Performance Metal Program

Chad Henry | Metallic Additive Manufacturing

Sept 2014

Comprehensive Overview and Findings on 3D Printing for Construction CMIC 2014

Lab 22 - The Australian 3D Printing Centre for Innovation and Production

(d)

• CSIRO has an open house policy to Industry and for R&D

• De-risk to aid in Industry Adoption and Growth • Access our capital equipment • Access our trained operators

• Trial and Learn Metallic AM

• Access us for assistance on Developing Business Cases and Positive ROI’s • Access us for assistance on design (or re-designing) to take advantage of 3DP

Design Freedoms • Access us for assistance on material science solutions • Learn first-hand

• Technologies (next slides)

• Powder Beds – E-Beam and Laser • Powder Spray – 3D Deposition, Cold Spray, and Laser Cladding • Sand Printing – For Metallic Castings

Arcam Model A1 - Electron Beam Melting (EBM) - Powder Bed - Vacuum - Elevated Temp - Low Distortion - Excellent Properties - Model A1 - 200mm x 200mm x 180mm - Materials - Ti and Ti Alloys - CoCr - Nickel Alloys (Inconel) - Steel Alloys - Others??? - CSRIO Level 3 Training

E-Beam AM Equipment

Concept Laser M2 cusing • Laser fusion powder bed • 250 x 250 x 280 (mm) chamber build volume • 400W beam power • Very good part roughness Ra 9-12mm, Rz 35-

40mm (Ti-64) • <55cm3/h build rate (Ti-64) • Inert gas environment • Standard LaserCUSING materials include:

Stainless steel 1.4404 / CL 20ES Aluminium alloy AlSi12 / CL 30AL Aluminium alloy AlSi10Mg / CL 31AL Titanium alloy Ti6Al4V / CL 40TI Titanium alloy Ti6Al4V ELI / CL 41TI ELI Hot-forming steel 1.2709 / CL 50WS Rust-free hot-forming steel CL 91RW Nickel-based alloy Inconel 718 / CL 100NB Cobalt/chrome alloy remanium star CL

• Moderate residual stress • Prototyping, design, customising, light-

weighting

Optomec LENS MR-7 • IPG Fibre Laser “blown powder” • 300 x 300 x 300 (mm) chamber build volume • 500W beam power • Two powder feeder (layered composition profiles) • Part roughness Ra 20-50mm (Rz 150-300mm) • 22cm3/h build rate (Ti-64) (much higher build rates for

other LENS variants • High purity inert gas (O2 ≤ 10 ppm) • High residual stress • Optomec materials: *Non-standard Materials used in R&D

• Repair, prototyping, design, customising, light-weighting, alloy design, composite materials

Titanium Nickel Tool Steel

CP Ti, Ti 6-4, Ti 6-2-4-2

Ti 6-2-4-6*, Ti 48-2-2*,

Ti 22AI-23Nb*

IN625,IN718,IN690*, Hastelloy

X*, Waspalloy, MarM247*,

Rene 142*

H13, S7, A-2*

Stainless Steel Refractories Composites

13-8, 17-4, 304, 316, 410,420,

15-5PH*, AM355*, 309*, 416* W*, Mo*, N* TiC*, WC, CrC*

Cobalt Aluminum Copper

Stellite 21 4047 GRCop-84*, Cu-Ni*

Plasma Giken PCS-1000

Cold Spray Technologies

CGT Kinetiks 4000

Voxeljet

Manufacturing with Lasers & Asset Maintenance

High power laser facilities 4 kW fibre delivery diode laser Various beam shapes and sizes Closed loop temperature control Multi-axis robot Twin hopper powder delivery PTA system Provision for in-situ alloy deposition and/or

hardfacing

Services • R&D and procedure development for wear

resistant surface build up • Extensive knowledge in understanding in-service

wear modes • Expertise in low cost alloy selection and

development for crack-free deposition • Multi-physics modelling to predict cracking and

service life • Power generation, petrochemical, coal and

mineral processing, food processing

Fit-for-service assessment • Wide range of wear testing facilities for QA

(unique!) • All tests simulate field conditions for laboratory

evaluation

Courtesy Dr. Rob Sharman, GKN Aerospace

Must Understand ... One Size Does Not Fit All

Material

Build Volume

Rate

Design and Unitization

Unique Shapes/Details (free)

Surface Finish

Inspection

Laser vs.

E-Beam vs.

Solid State

Powder Bed vs.

Powder Spray vs.

Wire Fed

Product Requirements Manufacturing Processes

Production

Prototyping (form, fit, function)

Tooling

Rapid Design

Shop Aids

All for ...

Ti

Ni

Al

Metallic Additive Manufacturing Roadmap

Database for Production

•Ti 6Al 4V

Low Cost Feedstock

Distortion Control Management

In Situ Inspection Methods

Microstructure Manipulation

Additional Material Data

•Titanium, Steel or ?

Novel Titanium Materials

Wire Powder

(Bed or Spray)

Properties and Databases for Production

Ex Situ Powder Bed

Powder Manipulation

In Situ Modelling & Management

In Chamber Inspection Methods

Microstructure Manipulation

Novel Metallic Alloys

Additional Materials

Decrease final Component Cost

Increase the Application Space

Meltless Additive Manufacturing

Cold Spray

Additive Manufacturing Repair Coatings

Near Net Shape

Ti Pipe Seamless Continuous

Ti Bike Frame

Ti Coupler

Composite Dies

Defects Repair

Corrosion Resistant

Electroplating Replacement

Design Modification

Wear Resistant

Biofowling

Composite Coatings

Bulk

Billet

Forging Pre forms

Reclamation

Materials

Metals & Alloys: Ti, Ni, Fe, Cu, Al, Sn Ceramics + Metals: Al + TiB2 Polymers

CSIRO Additive Manufacturing ... The 2+1 Strategy

Modelling and Simulation

Feedstock and Powder

New Material Development

Distortion Management

Novel Sources

Physical Modification

The AX - Powder Flow

Industry Engagement

AM Network

Build, Consult, SIEF

Derived from Casting and

Welding

Derived from Cold Spray,

TiRO, and Alloys Processing

3D Printing for the Construction Industry My Findings (Based on Digging Around on the Web)

Companies 3D Printing for Construction

- Contour Crafting (upcoming slides)

- Suzhou Yingchuang Science and Trade Development Co (upcoming slide)

- Shanghai WinSun Decoration Design Engineering

- DUS Architects

- WikiHouse

My Findings (Based on Digging Around on the Web)

Materials

- From Waste (Plastic, Construction, Industrial, Glass)

- Sand, Gravel, Dirt (with Water and Binder)

D-Shape (Sandstone)

- Printed Hollow (for Reinforcement, Insulation, Plumbing, etc)

- Printing Construction Hardware (Fasteners, Connectors, etc)

Arup (3DP Metallic Nodes for Lightweight Material Construction)

3D Printing for the Construction Industry

My Findings (Based on Digging Around on the Web)

Printers

- Material and Deposition Technologies – hard part

G.tecz

- Frames and Movement Programming – easy part

BetAbram

3D Printing for the Construction Industry

Contour Crafting http://www.contourcrafting.org/

Contour Crafting http://www.contourcrafting.org/

Suzhou Yingchuang Science and Trade Development Co

http://constructionglobal.com/video/33/3D-Printer-Constructs-10-Buildings-in-One-Day-from-Recycled-Materials

Titanium Technologies and Lab 22 Achievements • Since Sept of 2012, Lab 22 has 3D printed over 700 pieces in titanium from over 150 files

for 52 entities in 130 total Arcam EBM builds. That is an average of 1.5 builds per week. Of these, 54% have been for industry, 21% have been for R&D, and 25% have been for marketing, media, and education. In 2012 we hosted 134 visitors, in 2013 it was 216, and at the end of the first quarter of 2014 it was over 100 (total >450).

• MPs - Adam Bandt, Julie Bishop, Anna Burke, Greg Combet

• EVP of the Lockheed Martin F-35 Joint Strike Fighter Program, Tom Burbage

• Lab 22 Chosen to be a Preferred Service Provider for Arcam EBM

• AM Fish Anchors Implemented (upcoming slide)

• AM Bicycle with Flying Machine (upcoming slide)

• AM Mining Drill Bit Holders

• AM Bugs (upcoming slide)

• AM Orthotic Horse Shoes

• AM Design Optimisation via student projects (upcoming slide)

• AM of Aero Engine Demonstration with SIEF (upcoming slide)

• AM Network (upcoming slide)

Rapid Design Iteration

Manufacture all of the design candidates at once in a single build.

Inexpensive physical testing was employed to make decisions.

Making the Business Case with Flying Machine

Three Conditions Together Made the Product Marketable Design Change for Every Customer Possible

Off-The-Shelf Tubing

The Novelty http://www.flyingmachine.com.au/2014/01/3d-printed-titanium-bike-of-the-future/ http://www.youtube.com/watch?v=_gOd3w69kh4

Topology and Design Optimisation

Same Performance ... Less Weight

Iteration 1 Iteration 6 Iteration 9 Iteration 13

Iteration 16 Iteration 20 Iteration 25 Iteration 29

SIEF Aero-engine AM Project with Monash University

I like big bugs ...

Sciaky DM Process (and CSIRO Modeling and Simulation)

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Sciaky DM Process and CSIRO Modeling and Simulation

Electron Beam Freeform Fabrication (EBFFF) is an additive manufacturing (AM) process that works efficiently with a variety of weldable alloys.

Residual stress and shape distortion are inherent features of AM, particularly at high deposition rates, as a result of the large thermal gradients.

Fabricated parts are stress-relief heat treated both during and after deposition to help relieve stresses, which adds to cycle time and the overall cost.

CSIRO has established and implemented modelling techniques to predict distortion and stresses during and after deposition by EBFFF as a first step towards developing an active distortion management system.

The model can be employed in a predictive mode to investigate the effects of various tool paths and process parameters on the (post-manufacturing) part distortion and residual stress.

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FEA Model of a T-shaped part - Substrate plate: 600 mm long, 12.5 mm thick, 100 mm wide - Deposit: 51 mm tall, 11.8 mm wide, single bead - Process parameters:

• Speed: 12.7 mm/s • EB power: 4.3 kW for preheat and 8.6 kW for deposit • 18 layers per side; each layer is 2.83 mm high • Substrate and wire have initial temperature of 30°C

Model of the part

12

.5

T-shaped part built by EBFFF

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Neutron Diffraction Used to Improve Results

200 MPa

- 135.2 MPa

- 94 MPa

235 MPa

Prediction

Residual Stress by ND (ANSTO)

The predictive tool has been recently refined further by using an updated material model.

The predicted stress distribution is in excellent agreement with residual stress measurements by neutron diffraction at ANSTO.

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Significance of the Predictive Tool

Cost saving ‒ The predictive tool can perform virtual EBFFF. We can run a series of

Design of Experiments (DoE) without having to consume materials and cost

‒ The tool can predict the expected distortion when deposition is made on a pre-bent plate or when insulated clamps are used

‒ Combinatorial effects such as the effect of combining a substrate preheat with half the building speed and insulated clamps can be predicted.

Provides insight into the evolution of thermal and stress distribution during and post build

Identifies critical moments when defects such as cracks and/or excessive distortion may occur

The application of the predictive tool can be extended to large deposition (wire or blown powder) and other AM processes

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Selected DoE Results

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Future Today

50% of the cost in operation is labour 20% is depreciation (i.e. Cost of the unit)

If the equipment cost comes down and labour gets more productive Powder becomes the mostly costly component of AM

$ $

Operational Cost Considerations of Additive Manufacturing – Why work on materials?

Where is “Cheap” Titanium Powder???

Armstrong Process – Cristal

FFC Process – Metalysis

TiRO

Alloys

CSIR

New Zealand

Hydride DeHydride

ADMA

China

Powder, Particles and Aggregate

Size

Size Range

Flow

Density

Alter Either or Both: - Improve the Inexpensive Powder - Alter the AM Equipment Operating Parameters

CSIRO Powder Manipulation

50

25

>1000 600 – 1000

400 – 600

250 – 400

150 – 250

100 – 150

75 – 100

45 – 75

25 – 45

< 25

E-Beam AM

Laser AM, Cold Spray

Weight pct

Particle Size in mm

Before

After

Powder hopper 25 kg of Ti each

Rake regulator

Powder table

Build tank

Rake

Optical Camera

Heat shield

Universal Powder Bed External laboratory bench-top unit to allow for studies of how low cost input material actually behaves without being encumbered by a full AM system.

Cold Spray Technology

CSIRO has developed a new solid-state additive manufacturing process using Cold Spray Technology to produce bulk 3D forms and coatings from powder feed stock that is both metallic and non-metallic.

Process and applications

• During cold spray, powder particles (typically 10 to 50 µm) are accelerated to high velocities (200 to 1200 m.s-1) by a supersonic compressed gas jet at temperatures well below their melting point. As the particles impact the surface they undergo large plastic deformations, consolidating to produce localised forge bonding, at spray rates up to several 100 g/min.

• The deposition efficiency is also very high, above 95% in most

cases.

• The technology is more efficient, cost effective and environmentally friendly and can be applied to the aerospace, biomedical, oil and gas, power generation, motor sport, petrochemical and electronics industries.

• Our 3D simulation outcomes has proved to be highly cost effective for optimization of the cold spray parameters.

Research at CSIRO

Preforms, Billet and Pipe

Coatings on polymer and metal

3D manufacturing of bulk billet and preforms

Repair and modification techniques for lightweight aerospace alloys

Improved biocompatible coatings for medical implants

Thick metallic coatings for thermally sensitive substrates

Ballistic protection composite coating for defence and space application

Anti-fouling coatings for marine application

Advantages of Cold Spray

Solid-state deposition - no melting therefore no solidification defects

No vacuum required for oxygen

sensitive materials such as Ti Environmentally friendly process Cost effective - capital and

operation

Cold Sprayed CP Ti

Conventional CP Ti

Cold Spray for Pre-forms

Continuous Billet Production

CSIRO has the capability to produce 45 kg/hr of product via cold spray

MISSION – Coordinate additive manufacturing for Australia.

The Additive Manufacturing Network is ... - Public with participation from academia, industry, and government welcome. - To be self governed once established. - Well poised to be a self supporting national asset.

GOAL – Market globally Australian additive manufacturing capability, for both technology R&D and production for profit in industry. - Publish who has what equipment and corresponding capabilities. - Create confidence in global customers investigating Australian potential. - Collaborate efficiently for new Australian business, creating greater total revenues in which to participate. - Connect those with a need to those with a solution.

The Additive Manufacturing Network The hub for all things additive.

Per the mission statement: co·or·di·nate (verb) - The act of harmoniously combining and interacting items to function effectively.

GOAL – Facilitate communication within Australia on additive manufacturing. - Use a network infrastructure, including focused working groups, to conduct regular face-to-face and web meetings. - Understand others’ roadmaps and strategies. - Coordinate and be efficient on resolving issues. - Achieve a comprehensive and non-redundant R&D project portfolio within the country. - Accelerate the deployment of technologies to industry.

Status - A survey of industry was taken and interest existed. - Kickoff Meeting - Inaugural Committee of 10. - Now Partnered with (i.e. handed over to) AMTIL.

For further information, please contact: Chad Henry CSIRO Additive Manufacturing Operations Manager Titanium Technologies Stream Leader Gate 7 Normanby Road, Clayton 3168 VIC Australia +61 3 9545 7844 (office) chad.henry@csiro.au

Thank you CSIRO Manufacturing Flagship High Performance Metal Industry ore to more Chad Henry Metallic Additive Manufacturing +61 (03) 9545 7844 chad.henry@csiro.au

FUTURE MANUFACTURING FLAGSHIP