increasing in additive manufacturing...• 4 x 500w lasers, each can address the whole build plate...
TRANSCRIPT
![Page 1: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/1.jpg)
10/06/2019
1
Increasing
productivity without
compromising quality
in Additive
Manufacturing
Marc Saunders
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10/06/2019
2
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
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About Renishaw
10/06/2019
Slide 3
World leading metrology & engineering company
Metrology Research Healthcare Additive
• FTSE 250 public company, UK headquarters
• Independent
• Strategic focus on breakthrough innovation
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Metal AM machine builder and user
10/06/2019
Slide 4
AM machine production
AM medical implants
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10/06/2019
5
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
![Page 6: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/6.jpg)
A new AM world is emerging
10/06/2019
Slide 6
• 20 – 35% CAGR forecasted
• Equipment sales set to triple
over next 5 years
• Strong growth in services
also predicted
• Industrial AM applications
are the main growth driver
• Metal AM is showing the
fastest growth
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10/06/2019
Slide 7
What’s driving industrial AM growth?
We can create parts that were not practical
or economical to make before
• Produce complex geometries to
improve part performance
• Consolidate multiple parts to
improve reliability and reduce
inventory
• Light weight – only build material
where it is needed
• Create fully customised components
• Parts can be manufactured directly
without tooling
• Enables rapid design iterations
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10/06/2019
Slide 8
High-value manufacturing
• Heat exchangers & thermal management
• Fluid transfer
• Structural parts where weight is critical
• Difficult-to-process, expensive materials
• Where extensive quality assurance is acceptable
• Customised or low / medium volumes
Mature applications
• Aerospace and turbo-machinery
• Healthcare
• Tooling
Applications where additive is more mature
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10/06/2019
Slide 9
How AM will grow – lower part costs
Volume
Unit cost
AM
marketHigh unit costs have
confined AM to low
volume, specialist
applications
Conventional
manufacturing
Additive
manufacturing
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Reducing AM part costs
will open up new market
opportunities
AM
market
expands
10/06/2019
Slide 10
How AM will grow – lower part costs
Volume
Unit cost
Conventional
manufacturing
Additive
manufacturing
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10/06/2019
Slide 11
Part cost-v-mass – subtractive manufacturing
Processing
costs dominate
Mass
Unit cost
Material costs
dominate
Minimum
mass
Minimum
cost
Subtractive
manufacturing
• Low-weight products are
expensive
• Material is too expensive to
remove
• Exotic alloys used to
minimize weight
• If we minimize processing
costs, material costs rise
• Minimum cost achieved by
balancing material and
processing costs
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10/06/2019
Slide 12
Typical market segmentation
Motorsport
Mass
Unit cost
Minimum
cost
Subtractive
manufacturing
Space
Aerospace
Automotive
Industrial
(static)Industrial
(mobile)
Minimum
mass
• Products often used in multiple
market sectors
• Same basic function,
performance, reliability
• Different value assigned to
weight and space claim
• Motorsport, space,
aerospace will pay more for
lighter products
• Automotive and industrial
sectors are more driven by
cost
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10/06/2019
Slide 13
In AM, a lighter part is a cheaper part
Mass
Unit cost
Minimum
cost
Subtractive
manufacturing
Additive
manufacturing
Minimum
mass
• In AM, we have a virtuous circle:
Lower part
mass
Lower part
cost=Productive AM
• The position and gradient of the
AM part cost-v-mass curve
depends on several factors:
• Material cost
• AM productivity
• Post-processing
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10/06/2019
Slide 14
Design for AM enables market disruption
Mass
Minimum
cost
Subtractive
manufacturing
Unit cost
Minimum
mass
An innovative AM product
design could serve the
whole market
• One product instead of many
• Simplified product
configuration & sales process
• Reduced inventories
• Streamlined servicing
DISRUPTION!
Productive AM
Single product suitable
for all market sectors
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AM is a business strategy
10/06/2019
Slide 15
• AM’s real impact is on competitive positioning:
✓ Product performance and efficiency
✓ Lower product costs
✓ Value-added services (e.g. personalisation)
✓ Responsiveness to changing demands
✓ New product development lead times
✓ Alternative production and distribution logistics
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10/06/2019
16
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
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Productive laser powder bed fusion
10/06/2019
Slide 17
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Higher productivity = lower part cost
10/06/2019
Slide 18
Faster laser powder bed fusion
• 4 x 500W lasers, each can address the whole build plate
• Efficient use of all lasers for any geometry – typically reducing build times by a factor of 3 to 4
• c. 50% increase in machine cost for 200 – 300% increase in productivity
• Machine component of part costs typically halved
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More lasers = more variables to control
10/06/2019
Slide 19
Multi-laser coordination challenges
• Laser-to-laser consistency – power & focus,
across the bed
• Laser cross-referencing – relative position
& stability
• Laser task assignment – load balancing
• Multi-laser interaction – relative position
w.r.t. gas flow
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Innovative optical system
10/06/2019
Slide 20
AM galvanometer mounting
• Compact mounting block for
8 motorized guiding mirrors
• All 4 laser beams enter build
chamber close together
• Each laser can address the
whole build plate – full
overlap
• AM mounting block includes
complex internal cooling
channels for optimum thermal
stability
RenAM 500Q
quad laser
overlap
Quad laser galvo
mounting
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Flexible use of multiple lasers
10/06/2019
Slide 21
Adaptable laser assignment
• Each laser can address the whole build plate
• Flexible assignment of lasers to each task
• Build with 1, 2, 3 or 4 lasers
• Select number of lasers to suit budget and
required build rate
Laser
assignment
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More lasers = more throughput
10/06/2019
Slide 22
4 x 500W lasers
3 x 500W lasers
2 x 500W lasers
1 x 500W lasers
Upgra
de a
fter
insta
llatio
n
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Dynamic focusing
10/06/2019
Slide 23
Laser
source
Dynamic
focussing
Galvo
mirror
F-theta
optic
✓ Programmable focus
✓ Adjust for thermal drift
✓ Fewer optical surfaces
x Fixed focus
x No adjustment
x More optical surfaces
Programmable focus
• Active focusing upstream of the
steering optics
• Programmable focus control –
can be different for each laser
• No F-theta lens – reduced
thermal lensing
• Enables compact galvo mounting
• Multiple lasers pass through
single window
Laser
source
Galvo
mirror
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Precise, stable laser cross-referencing
10/06/2019
Slide 24
Process plane
High precision z-axis
• Optical encoder with a
1nm resolution for high
accuracy positional
sensing
Kinematic recoater
• Kinematic recoater
ensures a precise and
repeatable working
plane
Narrow beam
spacing reduces
laser alignment
sensitivity to process
plane variation
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10/06/2019
25
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
![Page 26: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/26.jpg)
Multi-sensor
High-frequency data across a
range of wavelengths
• Infrared thermal sensor
• Near-IR plasma sensor
• Laser input energy
Synchronised with actual galvo
mirror positions to enable 3D
modelling and visualisation
10/06/2019
26
Real-time process monitoring
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Analysis software
• Collect and view process data
live as the build progresses
• View and compare data from
previous builds
• Software tools to change
thresholds and reveal
anomalous data
• Guide post process quality
assurance techniques
• Keep records by capturing
traceable process data
10/06/2019
27
Process monitoring data visualisation & analysis
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Understand - gain insight into process performance
Record - compare and store traceable process data
Improve - check quality during the build to optimise output
10/06/2019
28
Process monitoring benefits
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10/06/2019
29
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
![Page 30: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/30.jpg)
Effective gas flow
10/06/2019
Slide 30
• Inert Argon gas flow carries process emissions
away from melting zone
• Consistent conditions in all locations
• Effective handling of ‘dirty’ materials such as
maraging steel – reduced cleaning
Laminar flow of 2
m/sec across bed
High speed flow at
outlet effectively
removes emissions
High volume / low velocity gas
flow from chamber ceiling
suppresses recirculation
Single laser window
makes space for
ceiling perforations
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Tensile testingStress-strain curve
• The more ductile the material, the more easily it can withstand tensile stress
• Good ductility = good fatigue strength which is important for loading stress, shows lack of defects in the build
• Correct chemical composition and good ductility allows users the freedom to use heat treatment to tailor
mechanical properties as required.
10/06/2019
Slide 31
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High and consistent material properties
10/06/2019
Slide 32
Nickel super-alloy IN718
60 µm layer
Ti6Al4V Grade 5
60 µm layer
• Consistent melting conditions
• Lack of defects results in high ductility and fatigue performance
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10/06/2019
33
But what if we provoke poor melting conditions?
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10/06/2019
Slide 34
Multi-laser interaction mechanisms
Melting of a downwind laser can be affected by…
1. De-focusing by airborne condensate – leads to reduced intensity
2. Occlusion by airborne spatter – prevents energy reaching the bed
3. Incorporation of spatter in the component – large particles shield powder from laser energy
All mechanisms can result in lack-of-fusion porosity
De-focusing by airborne condensate Obscuration by airborne spatter Spatter incorporation
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Ductility & tensile strength variation with downwind distance
-40
-35
-30
-25
-20
-15
-10
-5
0
5
-200 -150 -100 -50 0
% L
os
s o
f d
ucti
lity
of
do
wn
win
d s
am
ple
Downwind distance (mm)
Downwind sample ductility vs. upwind
IN625-60um_AB IN718-30um_HT
Ti64-30um_HT Maraging Steel-50um_AB
-250
-200
-150
-100
-50
0
50
-200 -150 -100 -50 0
Lo
ss
of
UT
S o
f d
ow
nw
ind
sa
mp
le (
MP
a)
Downwind distance (mm)
Downwind sample UTS vs. upwind
IN625-30um_AB IN718-30um_HT
Ti64-30um_HT Maraging Steel-50um_AB
Impact of downwind
melting increases
with distance
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Fracture surfaces
• Classic ‘cup and cone’
ductile fracture
• No ‘lack of fusion’ defects
visible even at high
magnification
• Premature fracture
• ‘Lack of fusion’ defects
leading to localized
brittle failure
UPWIND DOWNWIND
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Melt pool analysis
• InfiniAM Spectral real-time melt pool monitoring
http://www.renishaw.com/en/infiniam-spectral--42310
• Downwind sample exhibits more variation in visible /
near-IR spectrum – evidence of hot spots due to
spatter passing through the laser beam
• Downwind sample exhibits lower average IR signal –
evidence of de-focusing and obscuration of the laser
beam
Downwind Upwind
Photo-diode 1
Visible / near IR
Photo-diode 2
Infra-red
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Multi-laser build strategies – multiple parts
1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4
Gas flow
Laser 1
Laser 2
Laser 3
Laser 4
Build in columns from left to right
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
Gas flow
Laser 1 Laser 2 Laser 3 Laser 4
Build in rows from back to front
Avoids downwind melting Downwind melting
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10/06/2019
39
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
![Page 40: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/40.jpg)
Minimising material costs by maximising powder re-use
10/06/2019
Slide 40
• Rapid inert atmosphere generation using vacuum
& Argon purge
• Sealed machine enables 0 ppm oxygen during
build
• Integral powder handling keeps powder under
inert atmosphere at all times
Powder is never exposed to oxygen or moisture
throughout the cycle
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Ti6Al4V re-use on RenAM 500Q
10/06/2019
Slide 41
• Series of builds, topping up
with new powder after each
• Oxygen and Nitrogen
remain with specification
limits
• Hydrogen drops from high
initial levels as powder
‘dries out’ with repeated
use
• Further data to be
presented at AMPM0
200
400
600
800
1000
1200
1400
Inte
rstitial ele
men
t con
cen
tra
tion (
pp
m)
Oxygen, Nitrogen and Hydrogen trends in Ti6Al4V
Oxygen Nitrogen Hydrogen
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10/06/2019
42
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software & support
Agenda
![Page 43: Increasing in Additive Manufacturing...• 4 x 500W lasers, each can address the whole build plate • Efficient use of all lasers for any geometry –typically reducing build times](https://reader033.vdocuments.mx/reader033/viewer/2022060419/5f16a6d626e60d2d856c8b48/html5/thumbnails/43.jpg)
Software productivity tools
10/06/2019
43
Build preparation software
Orientate, support, slice
and material development tools
In-process monitoring
Identify potential defects
Compare serialized builds
Productivity Management
Machine utilization and status
Data acquisition and analysis
PLAN CONTROL MONITOR
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AM process chain
10/06/2019
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Design for AM AM build Gauging Machining Inspection
Pro
cesses
To
ols
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Support for process development - AM Solutions Centres
10/06/2019
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• Try before you buy: develop your product
and process, acquire knowledge, build
your business case
• Global network of centres providing
facilities, machines, post-processing and
engineering support
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46
Boosting AM productivity and quality
Progression rather than revolution
• Better design for AM with a focus on disruption
• Lower cost AM parts enabling more business cases
• Faster builds
• Cheaper materials
• Higher yields / less waste
• Advanced processing techniques delivering tailored
material properties
• Enhanced process sensing and control
• Reduced reliance on post-process inspection
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Thank you
10/06/2019
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Renishaw.com/am-guide
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