metal additive manufacturing myths - map your show · 2018-10-02 · metal additive manufacturing...

1 STRATASYS DIRECT MANUFACTURING

Metal Additive Manufacturing Myths:

Andrew Carter | Senior Manufacturing Engineer

The truth about powder reuse and its effect on mechanical properties


Over 1,200Granted or Pending Additive Manufacturing Patents Globally

$668 Million Revenue (2017)

Publicly Traded On Nasdaq (SSYS)

Over 30 Technology and Leadership Awards

Headquarters: Eden Prairie, MN and Rehovot, Israel

30 Years of Additive Applied.


Stratasys Direct Manufacturing is one of the largest providers of 3D printing and advanced manufacturing services.

• 7 U.S. manufacturing facilities

• 9 Manufacturing technologies

• 500+ employees

• Certifications: ISO 9001, AS9100

• ITAR registered

ABOUT STRATASYS DIRECT MANUFACTURING


• Valencia, CA

• Poway, CA

• Tucson, AZ

• Phoenix, AZ

MANUFACTURING FACILITIES

• Eden Prairie, MN

• Austin, TX

• Belton, TX


Our experienced team of project and applications engineers are committed to your success with:

• Design support for advanced manufacturing

• Technical direction and recommendations

• Material, technology and build optimization

for quality, speed and affordability

OUR TEAM


TECHNOLOGIES

ADDITIVE

CONVENTIONAL


Additive Metal Production

SECTION TWO


ADDITIVE METAL CAPACITY

• 2 Facilities (Austin, TX & Belton, TX)• 17 DMLS MACHINES

• 11 EOS M280’S• 4 EOS M290’s• 1 EOS M400• 1 EOS M400-4

• 2 Fully supported Machine Shops• Dedicated Quality Lab

• Cutup Metallography• Flow Bench, Hydrostatic Tester• CMM


ADDITIVE ALLOYS

Current OfferingSS 17-4 PH*SS316LAlSi10MgTi 6-4 Gd5*CoCrINCONEL™ 625*INCONEL™ 718* (API-Std avail.)MONEL™ K500

*Powder chemistry ordered to meet respective AMS standards.*

Standard Text = Performance Super Alloys

Bold Text = Quick Turn Alloys

Sourced directly from multiple established atomizers.

IN625: -45um +10um, Unused

SS17-4: -45um +10um, Recycled

All materials are kept in airtight, color-coded containers

Materials are batched and blended to ensure full traceability


ADDITIVE MANUFACTURING IS MOSTLY CONVENTIONAL

Stress Relief

Plate-Part Separation

Part Serialization

In-process Inspection

HIP

SHT, PHT

Dimensional Inspection

RadiographicInspection

Performance Inspection

Stratasys Direct, In-house

Powder Removal

This is the only Additive Step

Dimensional InspectionCMM, Faro, Surface Roughness

Radiographic InspectionX-ray, CT scan

Performance InspectionHydrostatic Pressure, Air Effective Area

Heat Treating Vendor Radiographic Testing Vendor

Post Machining

Outsourced operations are executed by strategic partners where SDM programs take priority.

Cutup MetallographyDMLS


THE TRUTH ABOUT LEADTIMES

Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

DMLS

Powder Removal & Inspection

Stress Relief

Plate Part Separation & Component Serialization

HIP & Heat Treat

Post Machining

Inspection

Typical RP Lead Time

Stratasys Direct Mfg.

Approved Vendor


The truth of powder recycling - “its happening”

SECTION TWO


Here is how its being done by the OEM’s …

EOS Recommended method M280-M290

Powder handling is an after thought… (by the machine manufacturers')

+ =


Here is how its being done by the OEM’s …EOS Recommended method M400’s

Powder handling is an after thought… (by the OEM’s)


Here is how its being done by the OEM’s …EOS Recommended method M400’s




Machine Manufacturer Powder Handling

Additive Industries InternalAddUp Mixed

GE (Concept Laser) External3D Systems Internal & External

EOS ExternalRennishaw Internal

SLM Solutions MixedTrumphf ExternalVelo3D Internal

No equipment manufacturer is concerned with material traceability.


MANUFACTURING SCENARIO


MANUFACTURING SCENARIO

• SDM Recycles 100% material

• The majority of powder has been recycled.

• No test method is identified to qualifyrecycled powder

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Blen

d Co

mpo

sitio

n

Times Recycled

Theoretical Blend Composition Over 30 Recycles

Build 31 Build 26

Build 21 Build 12

Build 11 Build 6

Build 1 % of Original Batch


POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

Start Production – 4 machines producing product, 4 powder evolution ID #’s

1

2

3

4

Machine

PowderID #

PowderComposition


SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

Start Production – execute 4 builds and refresh with virgin each time

1

2

3

4



Unplanned Maintenance & Increase customer demand – 6 machines producing product, swapped material between two machines, 6 powder evolution ID numbers.

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

2

3

4

5

6

3

2




Unplanned Maintenance & Increase customer demand – execute 3 builds on all machines

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

2

3

4

5

6

3

2



Full Production – All machine capacity dedicated to producing product, 8 powder evolution ID numbers

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

8

7

4

3

2

5

6



Full Production – execute 5 more builds across all machines

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

8

7

4

3

2

5

6


Sometimes simplicity is best.

MATERIAL RECYCLING STATION


MATERIAL TRACEABLITY


IN625Blends were kept to a single system.

CoCrBlends were transferred between systems to meet production demands.

IN718Virgin material compared material from different lots and different machines.

Elevated Temperature Tensile Results IN718 & IN625Sampled from multiple machines at varying levels of reuse.

MECHANICAL DATA – STRATASYS DIRECT MFG HAS IT


Study: 7 EOS M280 Machines, 2 Material Providers, 8 Material Lots, >55 Builds per Data represents 385 production builds over an 8 month period.Testing Included: 210 tensile bars (tests performed approx. every 4 builds), 14 Chemical, 20 MetallographyData Analysis: All data submitted to Battelle

Additive IN625 Property Study

Comparisons:Build LocationMachine to MachinePowder CompositionMaterial Provider

AMS 7000:Process Control Document (PCD)Class B - Material Chemistry and PSD

Mechanical Testing:Nadcap & A2LA Accredited Test House

IN625 CoCr IN718 High Temp


POWDER EVOLUTION / LIFE CYCLE

0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Stre

ngth

(ksi)

Age of Oldest Powder (days)

SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend



TENSILE PROPERTIES OVERLAID ONTO POWDER COMPOSITION

0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Stre

ngth

(ksi)





INTRODUCTION OF SEPARATE POWDER LOTS

0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Stre

ngth

(ksi)



Lot 30 Lot 32 Lot 33 Lot 34 Lot 35



MICROSTRUCTURE OVER TIME

0 10 20 30 40 50 60

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Stre

ngth

(ksi)


SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend

A B C



MICROSTRUCTURE OVER TIME

0 10 20 30 40 50 60

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Stre

ngth

(ksi)



A B C

A (xy)8e-3in

B (xy)8e-3in

C (xy)8e-3in



MICROSTRUCTURE – DIFFERENT ORIENTATIONS

A (xy)8e-3in

B (xy)8e-3in

C (xy)8e-3in

A (xz)8e-3in

B (xz)8e-3in

C (xz)8e-3in



MATERIAL CHEMISTRY OVER TIME

0 10 20 30 40 50 60

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Perc

ent

Stre

ngth

(ksi)





MATERIAL CHEMISTRY OVER TIME

0.0

0.5

0 50 100 150 200 250 300

Wei

ght (

%)

Powder Age (days)

SI1849 & SI1991 - Chemistry SI1991 Sup. 1 SI1849 Sup 1 Limit

Times Recycled

20.021.022.023.0

0 50 100 150 200 250 300

8.09.0

10.0

0 50 100 150 200 250 300

3.04.05.0

0 50 100 150 200 250 300

3.0

4.0

0 50 100 150 200 250 300

Cr

Mo

Nb+Ta

Al

Fe

10 20 30 40 50 60



MATERIAL PROVIDER COMPARISON

0%

5%

10%

15%

20%

25%

Ultimate Tensile Strength (ksi)

Ultimate Strength Material Provider Comparison, Uts

0%

7%

14%

21%

28%

35%

Yield Strength (ksi)

Yield Strength Material Provider Comparison, Yts

Material Provider 1, n = 180Material Provider 2, n = 30

Provider 1 YTS, Avg = 53.3ksi σ = 0.769ksi Provider 2 YTS, Avg = 53.0ksi σ = 0.756ksi

Provider 1 UTS, Avg = 124.0ksi σ = 0.731ksi Provider 2 UTS, Avg = 127.2ksi σ = 0.577ksi




0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

UTS Yield Mod Elongation RA

Perc

ent

Stre

ngth

(ksi,

Msi)

Tensile Property

Material Provider - Mechanical Property Comparison

Supplier 1 Supplier 2

n = 180, 30

0.61

%

0.59

%

1.37

%

1.09

%

11.4

1%

4.72

%

6.47

%

1.71

%

5.51

%

4.73

%



Machine to Machine Consistency

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Stre

ngth

(ksI

)

Times Recycled

Material Strength vs. Times Recycled, 1 machine



0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Stre

ngth

(ksI

)

Times Recycled

Material Strength vs. Times Recycled, 2 machines




0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Stre

ngth

(ksI

)

Times Recycled






0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Stre

ngth

(ksI

)

Times Recycled

Material Strength vs. Times Recycled, 6 machines , 2 atomizers




The different chemistries produced by different suppliers produced statistically different ultimate tensile strength.

Supplier Supplier 1 (% by Weight)

Supplier 2 (% by Weight)

Al 0.32 0.14

Cr 21.02 21.54

Mo 9.2 9.1

Nb+Ta 3.66 3.73

Fe 0.04 3.90

Material Chemistry




0.0

0.5

0 50 100 150 200 250 300

Wei

ght (

%)

Powder Age (days)

IN625 Chemistry SI1991 Sup. 1 SI1849 Sup 1 SI1991 Sup. 2 Limit

20.0

22.5

0 50 100 150 200 250 300

8.09.0

10.0

0 50 100 150 200 250 300

0.0

2.5

5.0

0 50 100 150 200 250 300

3.0

4.0

0 50 100 150 200 250 300

Cr

Mo

Nb+Ta

Al

Fe



OUT OF THE 220 BARS, 2 APPEARED “DIFFERENT”

0 10 20 30 40 50 60 70

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Stre

ngth

(ksi)



Build 50814

FL

FR

Build 51334

BLFL



Solution Heat Treated, HIP’ed, Stress Relieved, Additive IN625 (100x)

z

xy

z

xy

Stress Relieved, Additive IN625 (100x)

METALLOGRAPIC COMPARISON, BUILDS 51334 & 54747



CONCLUSION – ADDITIVE IN625

Stratasys Direct Manufacturing’s mission to control, track, and develop the AM production process has lead to vertical integration of multiple post process operations and inspection techniques providing the industry with:

• An efficient and economic powder management process

• Increased confidence in DMLS material/part quality

• Increased customer confidence

• Insight into powder lifecycle

• Evidence process variation at the additive system level is reduced via certified heat treatments



Additive CoCr Property Study


90 room temperature tensile blanks from:• 2 material provides• 6 different machines • 51 bars sampled before corrective action (17 builds)• 39 bars sampled after the corrective action (39 builds)• >50 times recycled


90 room temperature tensile blanks from:• 2 material provides• 6 different machines • 51 bars sampled before

corrective action (17 builds)• 39 bars sampled after the

corrective action (39 builds)• 6 different powder evolutions

MANUFACTURING STUDY SAMPLING

Powder EvolutionNum. Machine Before or After

Corrective Action

8 SI1476 Before

9 SI1991 Before

10SI1849 Before

SI1476 After

12SI1849 Before

SI2006 After

14 SI1848 After

15 SI1991 After








Corrective Action

8 SI1476 Before

9 SI1991 Before

10SI1849 Before

SI1476 After

12SI1849 Before

SI2006 After

14 SI1848 After

15 SI1991 After








Corrective Action

8 SI1476 Before

9 SI1991 Before

10SI2001 Before

SI1476 After

12SI1849 Before

SI2006 After

14 SI1848 After

15 SI1991 After



COMPARISONS:

• Before and after the corrective action

• Machine to Machine

• Material Provider

• Material Blend Composition (times recycled)

PROVOCATIVE THEORIES:

• Heat treating is a key factor to reducing process variation

• Laser based powder bed deposition process window is larger than previously believed.

STUDY OUTCOMES



INITIAL RUN CHART – ALL DATA AT A GLANCE

0

50

100

150

200

250

0 50 100 150 200 250 300

Stre

ngth

(ksi)

Time (days)

Additive CoCr Room Tensile Results

UTS YTS


INITIAL RUN CHART – FIRST OBSERVATION

0

50

100

150

200

250

0 50 100 150 200 250 300

Stre

ngth

(ksi)

Time (days)

Additive CoCr Room Tensile Results

UTS YTS


MECHANICAL PROPERTIES

0%

5%

10%

15%

20%

25%

30%

113.

011

9.0

125.

013

1.0

137.

014

3.0

149.

015

5.0

161.

016

7.0

173.

017

9.0

185.

019

1.0

197.

020

3.0

209.

0

Ultimate Tensile Strength

0%

5%

10%

15%

20%

25%

30%

35%

40%

Yield Strength Distributions

n=31n=59Post Corrective ActionPre Corrective Action



TENSILE RESULTS SEGMENTED BY POWDER EVO. NUMBER

0

50

100

150

200

250

0 50 100 150 200 250 300

Stre

ngth

(ksi)

Time (days)

Additive CoCr Tensile Results

8910121415


TENSILE RESULTS SEGMENTED THREMAL TEREATMENT

0

50

100

150

200

250

0 50 100 150 200 250 300

Stre

ngth

(ksi)

Time (days)


8910121415

SCRAPPED AFTER STRESS RELIEF

SCRAPPED AFTER SR + HIP


TENSILE RESULTS ONLY REPRESENTING FULLY HEAT TREATED MATERIAL.

0

50

100

150

200

250

0 50 100 150 200 250 300

Stre

ngth

(ksi)

Time (days)


8910121415


0%

10%

20%

30%

40%

50%

0

50

100

150

200

250

UTS YS Mod Elong.

Perc

ent E

long

atio

n &

Red

uctio

n of

Are

a

Stre

ngth

, Mod

ulus

(ksi,

Msi)

Tensile Property

Mechanical Properties

SR SR, HIP, SHT

MECHANICAL PROPERTES VS. THERMAL CONDITION

7.76

%

13.5

7%

3.91

%

7.00

%

6.78

%

4.02

%

44.6

9%

13.7

8%


CHEMICAL RESULTS

27%

30%

0 50 100 150 200 250 300

Cobalt Chrome Chemistry

5%

7%

0 50 100 150 200 250 300

0.08%

0.23%

0 50 100 150 200 250 300

0.00%

0.50%

0 50 100 150 200 250 300

0.00%

0.20%

0 50 100 150 200 250 300

Com

posit

ion

(% b

y w

eigh

t)

Time (days)

Cr

Mo

Ni

C

Ni


CHEMICAL RESULTS

27%

30%

0 50 100 150 200 250 300

Cobalt Chrome Chemistry

5%

7%

0 50 100 150 200 250 300

0.08%

0.23%

0 50 100 150 200 250 300

0.00%

0.50%

0 50 100 150 200 250 300

0.00%

0.20%

0 50 100 150 200 250 300

Com

posit

ion

(% b

y w

eigh

t)

Time (days)

Cr

Mo

Ni

C

Ni

PRO

DUCT

ION

HAL

T –

LOST

O

PPO

RUN

TIY

TIM

E


NON-CONFORMANCE - REVISITED

0.125IN

0.050IN

Issue: Lack of fusion

Location: The interface between contour and hatch.

Change in process parameters:• ~60% increase in deposition speed• ~50% increase in laser power• 0.27 W/m2 energy density (or flux)• 9 part build to a 10 part build

Non Conformance:Lack of Fusion


BEFORE CORRECTIVE ACTION VS. AFTER CORRECTIVE ACTION

0%

5%

10%

15%

20%

25%

138.

014

1.0

144.

014

7.0

150.

015

3.0

156.

015

9.0

162.

016

5.0

168.

017

1.0

174.

017

7.0

180.

018

3.0

186.

018

9.0

192.

019

5.0

Ultimate Tensile Strength

0%

5%

10%

15%

20%

25%

30%

68.0

70.0

72.0

74.0

76.0

78.0

80.0

82.0

84.0

86.0

88.0

90.0

92.0

94.0

96.0

98.0

100.

010

2.0

104.

0

Yield Strength Distributions




MATERIAL MANAGEMENT REVISITED

• SDM Recycles 100% material

• The majority of powder has been recycled.

• No test method is identified to qualifyrecycled powder

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Pow

der C

ompo

sitio

n

Times Recycled

Theoretical Batch Composition Over 30 Recycles

Build 31 Build 26

Build 21 Build 12

Build 11 Build 6

Build 1 % of Original Batch


TIMES RECYCLED

0

20

40

60

80

100

120

140

160

180

200

0 10 20 30 40 50 60

Stre

ngth

(ksi)

Times Recycled

Ulitmate and Yield Strength vs. Times Recycled

9

10

12

14

15


Heat treatment is the larger factor in additive metal mechanical properties than previously beleived.

An ~60% increase in deposition speed through a reduction of 0.27 W/m2 along with an 11% increase of deposited material had negligible affect on mechanical properties.

Stratasys Direct recognizes a corrective as an opportunity to increase manufacturing efficiency to provide the customer product faster at a reduced priced.

Stratasys Direct now provides industry with internal tensile specification minimums for CoCr.

CONCLUSIONS – ADDITIVE COBALT CHROME


WHAT IS ADDITIVE API IN718?

API – American Petroleum Industry

API Standard 6A718 – Nickel Base Alloy 718 (UNS N07718) for Oil and Gas Drilling and Production Equipment.

• Chemistry• Metallography• Tensile• Impact• Hardness

ADDITIVE API IN718 STUDY


MANUFACTURING STUDY PARAMETERS

Machine Systems: M280, M290, M400Builds Per Machine: 3 (1 with 100% Virgin Material, 2 with highly recycled material)

Locations on Build Plate: 5Samples at each location: 2 tensile, 4 (2 – z, 2 –y ) impact, 2 microstructure

Total Tested Sample Size: 90 per mechanical property, 11 metallurgical samples


BUILD LAYOUT


BUILD LAYOUT

BLBR

C

FLFR


PROCESSING – API SPEC’ED HEAT TREATMENTS

Additive Manufacturing

Stress Relief

Plate Part Separation

(Saw)

HIP

Solution Heat Treatment

(1825F for 60min)Machining

(Per ASTM E8 cylindrical barsPer ASTM E23 notched izod)

Testing(Per ASTM E8 cylindrical bars,

per at NADACAP facility)

Precipitate Heat Treatment

(1425F for 8hrs)


Mechanical Properties: Tensile, ASTM E8 (gage length 4x gage diameter)Impact, ASTM E23

Testing Standards and Study Comparisons

Microstructure Comparisons:XY and YZ grainsize

Additive API IN718 vs. Wrought API IN718

Mechanical Property Comparisons:Machine SystemsBuild LocationsMaterial RecyclabilityOrientation Dependent Izod Impact


MACHINE SYSTEM COMPARISON – TENSILE RESULTS

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS YS Mod Elong. RA

Perc

enta

ge

Stre

ngth

, Mod

ulus

(ksi,

MSI

)

Machine Comparison, Tensile Properties produce on EOS M280's, M290‘s, & M400's

M280 M290 M4000.

45%

0.42

%

0.40

%

0.65

%

0.69

%

0.84

%

3.75

%

7.10

%

3.88

% 3.66

%

3.46

%

2.28

%

7.87

%

6.06

%

4.35

%

n=30 n=30 n=30


BUILD LOCATION COMPARISON – TENSILE PROPERTIES

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS (ksi) YS (ksi) Modulus (Msi) Elong. (%) RA (%)

Perc

enta

ge

Stre

ngth

, Mod

ulus

(ksi,

Msi)

Build Location Comparison, Tensile Properties

BL BR C FL FRn=18 n=18 n=18n=18 n=180.

49%

0.49

%0.

42%

0.35

%0.

47%

0.58

%0.

79%

0.74

%0.

83%

0.72

%

3.77

%3.

83%

4.67

%4.

09%

8.09

%

4.05

%1.

79%

4.19

%2.

39%

2.16

%

6.67

%4.

12%

8.38

%5.

58%

4.54

%


TENSILE PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS YS Modulus Elongation Reduction of Area

Perc

enta

ge

Stre

ngth

, Mod

ulus

(ksi,

Msi)

Virgin vs. Highly Recycled Material - Tensile Properties

100% Virgin Powder Highly recycled Powder (>15X)n=30 n=60

0.38

%

0.47

%

0.72

%

0.64

%

4.76

%

5.54

%

2.88

%

3.32

%

7.42

%

5.49

%


TENSILE PROPERTIES AS A FUNCTION OF TIMES RECYCLED

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

50.0

100.0

150.0

200.0

250.0

0 5 10 15 20 25

Elon

gatio

n, R

educ

tion

of A

rea

(%)

Stre

ngth

, Mod

ulus

(ksi,

Msi)

Times Recycled

Additive API IN718 Tensile Properties as a Function of Powder Recycling.UTS YS Mod. Elong. RA


Reported Measurements:

Absorbed Energy (ft-lbs): difference in energy of the striking unit at the instant of impact.Lateral Expansion Measurement (mils):the sum of material expansion on both sides of the sample perpendicular to the striking direction.Percentage of shear fracture (%): difference between total fractured area and the area of unstable fracture region.

NOTCHED BAR IMPACTLateral Expansion:

Larger of A2 or A4 plus the larger of A1 and A3.

*Figures from ASTM E23, “Standard Test Methods for Notched Bar Impact Testing of Metallic Materials.”

Percent of Shear Fracture:A*B/total fracture region

All impact testing was performed at -75F per API specification.


MACHINE SYSTEM COMPARISON – IMPACT

21.10 21.53 20.90

0

5

10

15

20

25

30

M280 M290 M400

Ener

gy (f

t-lb

s)

Machine System

Absorbed Energy – Fracture Plane XY

3.32

%

4.60

%

4.84

%

Vertical-sampleFracture Plane XY


BUILD LOCATION COMPARISON – IMPACT

21.28 20.89 21.28 21.33 21.11

0

5

10

15

20

25

30

BL BR C FL FR

Ener

gy (f

t-lb

s)

Build Location

Absorbed Energy – Fracture plane XY

4.38

%

5.02

%

4.38

%

4.42

%

3.83

%



IMPACT PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER

21.6 20.8

20.8

20.621.2

21.6

0

5

10

15

20

25

30

0 5 10 15 20 25

Ener

gy (f

t-lb

s)

Times Recycled

Absorbed Energy as a Function of Material Recycling – Fracture Plane XY



VERTICAL VS HORIZONTAL IMPACT PROPERTIES

Vertical

Horizontal

Vertical-sampleFracture Plane XYHorizontal-Sample

Fracture Plane XZ

17.60

21.18

0

5

10

15

20

25

Horizontal Sample (Fracture plane xz) Vertical Sample (fracture plane XY)

Ener

gy (f

t-lb

s)

3.67

% 4.48

%


HORIZONTAL DIRECTIONAL IMPACT PROPERTIES

AB

CD

17.86 17.71 17.95 17.00

0

5

10

15

20

25

A B C D

Ener

gy (f

t-lb

s), L

at. E

xp. (

mils

), %

shea

r Fra

ctur

e (%

)

A

B

C

D

5.93% 5.41% 6.64% 4.48%

Notch Location Fracture Direction

A X+

B Z-

C X-

D Z+


XY vs. ZYXY has a higher frequency of equiaxed grains than ZYWider range of duplex grain structure in the ZY plane.

ADDITIVE API718 METALLOGRAPHY

XY ZY


CONCLUSTIONS – ADDITIVE API IN718


Elevated Temperature Tensile Results – IN718 and IN625

SECTION Three


Metallic Materials Properties Development and Standardization (MMPDS) Handbook • A source of accepted A, B, and S basis allowables for metallic material and

fasteners.• It is recognized by the FAA, DoD, and NASA

Properties at Elevated Temperature:• At temperatures above room temperature generally result in a decrease in

strength and an increase in ductility.• Data is plotted as percentages of room temperature allowable property against

temperature.

FRAMING THE SCOPE OF THE STUDY


0%

20%

40%

60%

80%

100%

120%

-200 0 200 400 600 800 1000 1200 1400

Perc

enta

ge o

f Roo

m T

empe

ratu

re P

rope

rty

Temperature (deg F)

Expected Behavior of Solution-treated and Aged IN718 % of Room Temp. UTS and YTS, AMS5662 A Basis (0.250-0.99in) Bar

% of Room Temp. Modulus, AMS 5662 & 5663 A Basis (0.250-0.999in) Bar

IN718 EXPECTED BEHAVIOR

Room

Tem

p.


IN718 – FIRST GLANCE

70

90

110

130

150

170

190

210

-200 0 200 400 600 800 1000 1200 1400

Stre

ngth

(ksi)

Temperature (deg F)

Temperature Effect on the Tensile Strength of Additive solution-treated and aged IN718

% of Room Temp. UTS and YS, AMS 5662 (0.25-0.99 in) Bar UTS, Additive Solution Treated and Aged IN718

YS, AMS 5662 & 5663 A Basis (0.250-0.999in) Bar YS, Additive Solution Treated and Aged IN718


EXPECTED BEHAVIOR OR ADDITIVE IN718

70

90

110

130

150

170

190

210

230

-200 0 200 400 600 800 1000 1200 1400

Stre

ngth

(ksi)

Temperature (deg F)

Temperature Effect on the Tensile Strength of Additive solution-treated and aged IN718

UTS & YS, AMS 5662 & 5663 A Basis (0.250-0.999in) Bar UTS, Additive Solution Treated and Aged IN718

YS, AMS 5662 & 5663 A Basis (0.250-0.999in) Bar YS, Additive Solution Treated and Aged IN718

Expected Behavior of Additive IN718 UTS Expected Behavior of Additive IN718 YS


EXPECTED BEHAVIOR OR ADDITIVE IN718

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

-200 0 200 400 600 800 1000 1200 1400

Mod

ulus

(Msi)

Temperature (deg F)

Temperature Effect on the Elongation of Additive solution-treated and aged IN718Modulus, AMS 5662 & 5663 A Basis (0.250-0.999in) Bar Modulus, Additive Solution Treated and Aged IN718

Expected Behavior of Additive IN718 Modulus


SMALL (0.16”) VS. LARGE (0.25”) DIAMETER BARS

ASTM E8, Round Bars, gage length 4X gage diameter

0

50

100

150

200

250

Ultimate Tensile Strength Yield Strength Modulus

Stre

ngth

, Mod

ulus

(ksi,

Msi)

0.25" diameter bars room temp 0.16" diameter bars room temp 0.25" diameter bars 1000F 0.16"diameter bars 1000F


ADDITIVE IN718 TENSILE PROPERTIES AS A FUNCTION OF RECYCLING

0

50

100

150

200

250

0 1 2 3 4 5 6

Stre

ngth

(ksi)

Times Recycled

@ Room Temp.

UTS

YS

0

50

100

150

200

250

0 1 2 3 4 5 6

Stre

ngth

(ksi)

Times Recycled

@ 1000F

UTS

YS


z

xy

ADDITIVE IN718 METALLOGRAPHY

Tested 6 Samples for Grain Size in the XY and XZ planes.

Every sample (regardless of orientation) has an average grainsize ASTM No. 3.5 to 4.5.

Precipitation Hardened, Solution Heat Treated,

HIP’ed, Stress Relieved, Additive IN718(100x)


A COMPARISON OF DIFFERENT THERMAL PROCESSING

0

50

100

150

200

250

-200 0 200 400 600 800 1000 1200 1400 1600

Stre

ngth

(ksi)

Temperature (deg F)

Temperature Effect of UTS and YS of additive IN718 processed with two different heat treatments

Heat Treat 1 UTS

Heat Treat 2 UTS

Heat Treat 1 UTS Expected Behavior

Heat Treat 2 UTS Expected Behavior

Heat Treat 1 YS

Heat Treat 2 YS

Heat Treat 1 YS Expected Behavior

Heat Treat 2 YS Expected Behavior


IN625 EXPECTED BEHAVIOR

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 200 400 600 800 1000 1200 1400 1600

Perc

enta

ge o

f Roo

m T

empe

ratu

re P

rope

rtie

s

Temperature (deg F)

Temperature Effect on Ultimate and Yield Strength of IN625

% of Room Temperature UTS % of Room Temperature YSRo

om Te

mp


ADDITIVE IN625 AT FIRST GLANCE

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400 1600

Stre

ngth

(ksi)

Temperature (deg F)

Temperature Effect on Ultimate and Yield Strength of IN625

UTS, AMS 5666 Bar S Basis Allowables YS, AMS 5666 Bar S Basis Allowables

UTS, Additive IN625 YS, Additive IN625

YS, Balloted AMS7000 IN625


ADDITIVE IN625 TENSILE PROPERTIES AS A FUNCTION OF RECYCLING

0

20

40

60

80

100

120

0 10 20 30 40 50

Stre

ngth

(ksi)

Times Recycled

@ 800F

0

20

40

60

80

100

120

0 10 20 30 40 50

Stre

ngth

(ksi)

Times Recycled

@ 1200F

Si1849 SI1991

0

20

40

60

80

100

120

0 10 20 30 40 50

Stre

ngth

(ksi)

Times Recycled

@ 1400F

Ultimate Tensile and Yield Strength of Additive IN615

Material Properties are consistent regardless of the time recycled.


CONCLUSIONS – ELEVATED TEMPERATURE TENSILE

The elevated temperature tensile response of additively produced nickel base super alloys is similar to the expected behavior or wrought materials. Recycling of feedstock material has little to no influence on room or elevated temperature properties of IN718 and IN625. The appropriate heat treating is required to achieving expected behavior in tensile response at elevated temperatures.

Stratasys Direct Manufacturing, committed to promoting the wide spread adoption of Additive Manufacturing as a viable means of producing end-use critical components makes these manufacturing studies available to industry.


CONCLUSIONS


CONCLUSION


THANK YOU

Andrew CarterSenior Manufacturing EngineerStratasys Direct ManufacturingAustin, [email protected]/ 512-655-5019

mailto:[email protected]/

metal additive manufacturing myths - map your show · 2018-10-02 · metal additive manufacturing...

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