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Metal Additive Manufacturingprincipes en toepassingen

Henk Buining [email protected] T 0888 66 55 83

Afdeling: Equipment for Additive Manufacturing

15 medewerkers op AM

45 medewerkers op supporting technology e.a.

High-tech Systems & Materials

Inleiding AM TechniekenEfAM

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Equipment for Additive Manufacturing.

1600+ References 1990 – 2015

For example: Workshops, technology transfers, research projects


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Projectvorm: Technologie Cluster

Minstens vijf bedrijven en een Innovatief onderwerp

Overdracht TNO kennis

Uitwerken praktijkcases

Ontwerpmethoden voor AM:

• unit cells

• topologie optimalisatie

• Graded structures

Start: begin 2016


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EU Reseach Projects - TNO

CassaMobile

Finished projects Current projects Funding programs

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Outline

• Additive manufacturing definition

• Direct metal additive manufacturing

• Applications

• Indirect metal AM technologies


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Additive Manufacturing: Definition

The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

Synonyms• Additive Manufacturing (AM)• Additive Fabrication (AF)• Rapid Manufacturing (RM)• Digital Manufacturing• Direct Digital Fabrication• Free Form Fabrication (FFF)• 3D-Printing• Layer Manufacturing

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Hits on synonyms

Bron: Google


nov 2010 dec 2011 april 2013Rapid Prototyping 8.000.000 7.930.000 7.320.000 hitsDigital Manufacturing 481.000 515.000 679.000 hits3D-Printing (3DP) 392.000 3.220.000 13.600.00 hitsAdditive Manufacturing 303.000 417.000 870.000 hitsFree Form Fabrication 180.000 370.000 377.000 hitsRapid Manufacturing (RM) 107.000 410.000 373.000 hitsAdditive Fabrication (AF) 56.000 31.000 36.000 hitsLayer Manufacturing 38.000 43.000 48.500 hitsDirect Digital Fabrication 3.000 13.500 112.000 hits

Hits on google “3D Printing”


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10

Cou

rtes

y to

: gar

tner

s.co

m


Gartners’ hype cycle July 2015

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Cou

rtes

y to

: gar

tner

s.co

mVan CAD naar slice-file

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Additive Manufacturing

Slice file

3D CAD file

STL file


Additive Manufacturing = Laagsgewijs produceren

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CAD Slice file Onderdeel


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Afkorting Techniek Fabrikanten

SLA Stereo Lithography 3D-Systems

SLSDMLSSLM

Selective Laser Sintering Direct Metal Laser SinteringSelective Laser Melting Laser SinteringLaser Cusion

3D-SystemsEOS SLM Solutions,RealizerPhenix (3D-systems)Concept Laser

FDM Fused Deposition Modelling Stratasys

DLP Digital Light Processing EnvisionTec

3DP 3D-Printing Z-corp, Voxeljet, ExOneFcubic

3D material jetting

3D material jetting 3D-systems (Projet), Stratasys (Objet)

AM TECHNOLOGIES DEFINED BY MACHINE TOOL BUILDERS


ASTM F42

Powder bed fusion SLM, SLS, DMLS of EBM

Vat Photopolymerization Stereo Lithography, DLP

Material jetting Stratasys ObJet , ProJet, Solidscape

Binder Jetting Digital metal, VoxelJet, XOne

Material extrusion FDM

Sheet lamination LOM

Direct energy deposition Cladding: LENS, Skiarc

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Metal Additive Manufacturing

SLM: Selective Laser Melting

DMLS: Direct Metal Laser Sintering

Laser Cusing

SLS: Selective LaserSintering

Electronbeammelting

Cladding

IrepaLaser

TrumpfPOM

OPTOMECLENS

DMG MORI

Direct Indirect

EOSConcept Laser3D-Systems

RealizerRennishaw

SLM SolutionsPhenixSisma

ARCAM

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SLM: Selective Laser Melting

DMLS: Direct Metal Laser Sintering

Laser Cusing

(SLS: Selective LaserSintering)

Electronbeammelting

Cladding

DMG MORI Easyclad / Irepa ; Optomec; Sciaky; Trumpf; POM; LENS (Optomec); Deloro Stellite;

InnsTek; Laser Consolidation; Electron Beam Free Form Fabrication; Plasma Transferred Arc; Deloro

Stellite; Precision Optical Manufacturing; Reis Lasertec; Huffman Corporation; Trumpf; Sulzer

Metco; Laser Line;

Direct Indirect

EOSConcept Laser3D-Systems

RealizerRennishaw

SLM SolutionsPhenixSisma

ARCAM

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Powder Bed Fusion – Laser BasedSLM, DMLS, Laser Cusion


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http://www.youtube.com/watch?v=1YgEOsZ8iJg


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Important process limits

• Bottom layer ‘bonus’ material & rough surface

• Support structure needed

• Accuracy and roughness: Mostly post machining needed (included

thermal treatments)

• Limited number of materials applicable

Powder

Bottom layer different!Support or building plate needed!!

Layers Melting depth


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Powder Bed Fusion – work flow

Example - Custom Lugs

Cha

rge

bike

s


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Design for metal AM

Pre processing & Building

Cha

rge

bike

s


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Powder removal

Cha

rge

bike

s


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Support Structures

Fixing the part

Heat drain to build plate


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Near netshape technology: Post treatments needed

Digital model Near Net Shape Part Net Shape Part

Lens

-O

ptom

ec


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Arcam - Electron Beam Melting

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Direct Energy Deposition:Laser cladding

Traditional application:

surface layer and repair

Also used in critical

applications (e.g. turbine

tip repair)

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PBF MetalUnique possibilities

Function IntegrationInternal geometries

Light weightSpecial surfaces

Innovative materials

Complex parts inadvanced equipment

Thermal stabilizedparts (of super alloys)Human related parts


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General Electric Aviation

Additive Manufacturing of functional parts for Aircraft Engines

Acquired in 2012:

• Morris Technology (20 DMLS & 2 Arcam EBM systems)

• Avio spa (12 Arcam EBM systems)


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General Electric

Additive Manufacturing of functional parts

Made with Selective Laser Melting

Patented design


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General Electric Aviation

Additive Manufacturing of functional parts for Aircraft Engines

19 Additive fuel nozzles to be installed on every CFM LEAP engine

(over 4500 sold)

100.000 Additive parts will be manufactured by GE Aviation by 2020

300+ 3D printing machines currently in use across GE


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Optimisation Helicopter Frame

Main mechanic structure


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Aluminium frame Manufactured with Selective Laser Melting


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Volume and Constraints

Modelling and Optimization Smoothing

Topology Optimization


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Specifications:

Dimensions: 128 x 160 x 147 mm

Material: AlSi12

Process: Selective Laser Melting (MTT)

Production Time: 68 hr.

Cost:

Material € 65

Production € 2500


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Hydraulic Manifolds(Im)possible Crossing


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Hydraulic Manifolds

Flow channel optimization to reduce pressure drop

Conventional production method Optimized flow channel


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Hydraulic Manifolds

Flow test to validate advantage in pressure loss

Conditions:

Temperature: 80 °C

Oil speed 10 m/s = 170 l/min.

Kin. viscosity: 32 cSt.

Density: 0,88 kg/dm3

Burst pressure: 1400 Bar

� Lower weight 20kg =) 1 kg !!

� Smaler volume 23x23x5 =) 8x8x5cm !!

� 4x less presure loss !!


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Binder jetting

Digital MetalExOne

Metal sheet lamination

(LOM)

Direct Indirect

Lost Model casting

Sand moldsand cores

VoxeljetPrometalZ-Corp

PrimeCast (SLS)Quick cast (SLA)

Rapid Shape (SLA)Solidscape

Projet / Polyjet(Stratasys /3DS)

Fabrisonic

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Metal parts Lost models

Voxeljet PMMA

Other technologies for lost model

production

Sintered in separate oven

Sand casting

Binder jetting: Principle

40Inleiding AM TechniekenEfAM

41 Printing binder on stainless steel

Binder jetting of metal powderExOne (v.h. Prometal)

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42 Courtesy ProMetal

Prometal – process steps

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Debinding Sintering Infiltrating

Prometal – post process steps

Binder jetting of metal powder:Högenäs Digital Metal

Similar technology with higher resolution and improved density


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Binder jetting for sand mold and sand core printing

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Binder Jetting for lost model productionVoxeljet: PMMA + lost model casting

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Other technologies for lost model casting

SLS: Selective Laser Sintering (e.g. EOS Polysyrene (Prime Cast))

SLA: Quick Cast, Envisointec, Rapid Shape

Material Jetting: Solidscape, 3D-systems, Stratasys (Objet),


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Powder Bed FusionLaser Sintering / melting / cusing



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Vat PhotopolymerizationStereo Lithography (SLA)


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Stereo Lithography (SLA)Vat Photopolymerization


Vat Photo polymerizationSLA: Quick Cast


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Vat Photo PolymerizationEnvisiontec (PIC 100) and casting


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Material Jetting


Binder Jetting for lost model casting


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