developedatSandiaNationalLaboratory NewMexico USAdevelopedatSandiaNationalLaboratory,NewMexico,USAandcommercialised byOptomec,USA

presented byPS h IITKhPSaha IITKharagpur

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Motivationbehinddevelopmentp Fullydense functionalmetallic components. Pickand placematerialcomposition totailorp plocalizedmaterialcharacteristics withinapart.

Repairandoverhaul technologiestoextendthelifeofcomponentsinagingaircraft ship vehicles andweaponcomponentsinagingaircraft,ship,vehicles,andweaponsystems. Convetional repairtechniquessuchasMIGorTIGweldinginduce

excessiveheatandalargeHEATAFFECTEDZONE(HAZ)excessiveheatandalargeHEATAFFECTEDZONE(HAZ)destroyingusefulnessofthepart.

Highcostofscrappingormaintainingcriticalparts,especially,whendrawingsdonotexist,whendrawingsdonotexist,

Partsdeemednonrepairableduringtheirrepairprocess Fabricate sparepartasandwhenrequiredfromitsoriginalCADdesign ratherthankeepingahugeinventoryoriginalCADdesign,ratherthankeepingahugeinventory.

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Schematic of the LENS processSchematicoftheLENSprocess

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LENSProcessstepsp Acomponentisfabricatedbycreatingamoltenpoolthroughfocusingalaserbeam ontoasubstrate.

Metalpowder particlesaresimultaneouslyinjectedintothepooltoaddmaterial.

Usingcomputercontrol thesubstrateismovedbeneath Usingcomputercontrol,thesubstrateismovedbeneaththelaserbeam intheXYplane,depositingathincrosssectionofpredeterminedCADgeneratedgeometry.Af d i i f l h d i i h d Afterdepositionofalayer,thedepositionhead(consistingofapowderdeliverynozzleandfocusinglensassembly)isincrementedinthepositiveZdirection,ll i i f h l f h allowinggenerationofthenextlayerofthepart.

Depositionoflayersisrepeateduntilthedesiredthreedimensionalcomponenthasbeenlayeradditivelyformed.dimensionalcomponenthasbeenlayeradditivelyformed.

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Powderdeliverynozzle

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ConstructionofthinwalledstructurewithfournozzleConstructionofthin walledstructurewithfournozzlepowderdeliverysystem

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NdYAGlaservs.CO2 laser Sinceitisundesirable

tovaporizemateial asitisdeposited opticalitisdeposited,opticalabsorptionofmaterialiscriticalforeffectiveutilizationoflaserenergy.

Withtheexceptionofcopper allofthecopper,alloftheelementalmetalsshowninthegraphhavesignificantlyg yabsorptionattheNdYAGlaserwavelengthascomparedtoCO2laserlaser.

Fiberlaserat1070nmhassimilarabsorptionasthatofNdYAGlaser11/11/2013 7PSaha

CapabilitiesofLENSprocessp p Abilitytobuildfullydense shapes Closedloopcontrol ofprocessforaccuratepartfabrication

Abilit t t il dd iti t t f t i f d Abilitytotailoreddeposition parameterstofeaturesizeforspeed,accuracy,andpropertycontrol

Compositeandfunctionallygraded materialdeposition ThreeaxisandfouraxissystemsforcomplexpartfabricationThree axisandfour axissystemsforcomplexpartfabrication Withthistechnology,materialsthateithercannotbe cast andthermo

mechanicallyprocessed,orthatcannotbeconsolidated successfullybypowdermetallurgy,canbeformed.

d f l h l d l l ll Widevarietyofmaterials that,atminimum,include:stainlesssteelalloys(316,304L,309,174),maraging steel (M300),nickelbasedsuperalloys(Incodesignations625,600,718,690),toolsteel alloys(H13),titaniumalloy(6Al4V),andotherspecialtymaterials( 4 ), p y

Highcoolingrate(102 103 K/s)leadsto finermicrostructure Mechanicalproperties similarorbetter thantraditionalprocessing

methods

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VaryingCompositiony g p Multiplepowderdeliverynozzlesarecapableofvaryinglocalcompositionvaryinglocalcomposition.

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Different Build Styles with VaryingDifferentBuildStyleswithVaryingCompositionpDependingonthedesigncriterionofapart,materialcompositioninLENScanbevariedthroughcompositioninLENScanbevariedthrough compositematerialdeposition thepowdercompositionremainsconstantfordistinctbuildpregions,and

functionallygradedmaterial(FGM) depositionthepowdercompositioniscontinuouslychanging

FGMrequiresaheavierinteraction betweenthepowderfeedercontroller andtheLENSmotioncontrollercontroller.

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(a)AcompositeconsistsofdistinctregionsofAandB (b)CompositesmaybeconstructedbyfirstdrawingallofregionAandthen (c)drawingallofregionB,allowingpowderfeederstobereconfiguredbetweencompositions. (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild. (e)eachdepositionvectorinanFGMbuildwillhaveauniquepowderfeederprofile.

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PowderFeederCharacterization

PowderFeederSetUp(Feeder,Screw,Feedlinelengthetc.)

Powderistransportedfromapowderhoppertothegasstream Ascrewfeeddevice usesanopenthreadedshafttometerpowderintoan

argoncarriergasstreamargoncarriergasstream Asinglecarriergaslineisdividedintotwodistinctflows,passedthrough

thefeedersandthenrecombinedintoasingleline. Mixingofthetwopowders occursnaturallyintherejoinedargonstreamg p y j g

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Forcomposites,thechiefcriterionforsuccessfuldepositionisthatthepowderfeedersprovidethedesireddepositionisthatthepowderfeedersprovidethedesiredpowdercompositionforagivenperiodoftime.Thesystemcaneffectivelypauselongenough forpowdery p g g pcompositionstobealteredandreachsteadystate.

ForFGMs,thereisasignificanttimelagbetweenaskingforagivencompositionandwhenthatcompositionisactuallyi j di h l lb i i l H injectedintothemoltenpoolbecomescritical.Hencethoroughcharacterizationofpowderfeederisneeded.

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OPTOMECs FOPTOMEC sLENS850SYSTEM

Features 1100Wcontinuous

NdYAGlaserd G ase Fiberopticbeam

delivery 18x18x42build 18 x18 x42 build

envelop 4th and5th axis:rotary

andtiltstagesandtiltstages Controlargon

atmospherewithoxygensensoroxygensensor

FilteringsystemforparticulatecontrolCCD i i CCDvision

Glovebox Power220V3phasePower220V3phase

100A11/11/2013 14PSaha

S 8 0 ifi iLENS850systemspecifications

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Materials deposited using the LENSMaterialsdepositedusingtheLENSProcess

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Measured tensile values for LENS vMeasuredtensilevaluesforLENSv.forged/annealedspecimensg / p

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ApplicationsofLENSpp ToolingapplicationsforInjectionMoldToolingandDie

Casting whereLENS'canimprovecycletimesby50%andg p y y 5extendmoldlife. Conformalcoolingchannelsarepossible.

RepairandOverhaul applicationsduetosmallHeatAffectedZone(HAZ) allowingforhigheryieldandsuperiorpartrepairsZone(HAZ),allowingforhigheryieldandsuperiorpartrepairs.

Functional"PrototypingandSmallLotManufacturingmadepossibleduetoproducingfullydensemetalpartswith

di h i l i (hi h h&d ili ) outstandingmechanicalproperties(highstrength&ductility),notfoundwithRapidPrototypingsystems

MaterialResearch :improvementofpropertiesinexistingp p p galloysandcomposites;developmentofnewalloysandcomposites.LENS'abilitytoprovidemultiplematerialgradientdepositionoffersuniquematerialresearchoptionsdepositionoffersuniquematerialresearchoptions.

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Applicationspp

Building Up of Turbine Blade Finished TurbineBuilding Up of Turbine Blade by LENS

Finished Turbine Blade

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Applicationspp

H13 Tooling

Thin Walled Housing

H13 Tooling

Impeller

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Six Inch Tall Thin Walled Part Substrate Included in Part

Housing Finished Housing11/11/2013 21PSaha

ToolingPartsbyLENSProcessg y

Injection Molding Injection Mold CavityInjection Molding Core

Injection Mold Cavity

Conformal Cooling Channel

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ToolingPartsbyLENSProcessg y

Trimming DieTrimming Die

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Insuchaninjectionmold,ah d l lhardtoolsteelmaybeselectivelyplacedinregionsh i whereexcessive

wearwouldbeanissue,yetthebulkofthemoldcouldofthemoldcouldbemadeofamaterialwithabettercoefficientbettercoefficientofthermalconduction.)

Injectionmoldingdies(coreandcavity,CADimageandFinalj g ( y, gfabricatedparts)withcopperchillerblockandthreedimensionalconformalcoolingchannel.11/11/2013 24PSaha

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ProcessessimilartoLENSProcess

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C ll d M l B ild UP (CMB)ControlledMetalBuildUP(CMB)(Developed at Fraunhofer IPT, Aachen Germany)(DevelopedatFraunhofer IPT,AachenGermany)

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Di M l D i i (DMD)DirectMetalDeposition(DMD)(Developed at University of Michigan, USA)(DevelopedatUniversityofMichigan,USA)

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Comparison of Direct MetalComparisonofDirectMetalFreeformProcesses

Process Deposition Type Accuracy Horizontal

Layer Thickness Deposition Rate Materials

SLS L i i Hi h N/A N/A S lSLS Laser sintering High N/A N/A Steel, copper, Solder

SDM Droplet based and cladding

N/A, Machined finish

Variable 30g/min Stainless steel, INVAR

Welding Welding 0.2-0.5 mm Up to 50 mm N/A, High Steels, Numerous

Droplet based freeform fabr

Droplet based N/A N/A 25-150 m dia. droplets

Bi-Sn

LENS Cladding 0.02mm, Z: 0 4mm

0.13-0.38 mm N/A, Low SS, Ti alloys, Numerous0.4mm Numerous

DLF Cladding 0.075-0.125 mm 0.075-0.125 mm 1-2g/min SS, P20, Numerous

DMD at Michigan Cladding N/A 0 254 mm 0 1 4 1 cm3/min H13 AlDMD at Michigan Cladding N/A 0.254 mm 0.1-4.1 cm3/min H13, Al, Numerous

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