Additive Manufacturing

Constructeursdag

‘Out of the Box ontwerpen’

De Fabrique, Utrecht, 19 november 2013

Philippe Reinders Folmer

General Manager Benelux

3D CAD

Additive Manufacturing – Laser Melting

Materialise Magics .STL AM250 .MTT -Orientation

-Supports

-Nesting

-Machine parameters

• AM opens the box

• Metal powders

• Design considerations

• Applications

• Renishaw’s approach

• Design for process

Slide 3 11/21/2013

AM – the process

De vertoonde video van de AM250 lasermelting

machine is te bekijken op:

www.renishaw.nl/lasermelting

Of bekijk dezelfde video via deze QR-code op uw

mobile telefoon:

• Design driven Manufacturing or Manufacturing driven Design..?

– Limitations by current production methods

• Benefits for ‘Designing out of the box’:

– Reducing the number of components

– Optimising design

– Increasing functionality

– Reducing weight

– Optimising flow

– Increasing reliability

• AM is an additional metalworking method in combination with current

production methods like milling, turning, polishing

Additive Manufacturing opens the box

Slide 4 11/21/2013

The process uses gas atomised metallic powders like:

316L, 17-4 PH and Maraging steel

Cobalt Chrome and dental CoCr

Inconel 718

Titanium Al64V *

Aluminium AlSi10Mg *

No pre-treatments or binders are used

* Reactive materials require ultra low oxygen levels

What metals can be processed?

• Atomisation – a molten metal

stream is disintegrated into fine

particles after colliding with a

high velocity stream of

atomising medium like water, air

or inert gas.

• Mechanical – during milling

forces act on the material to

reduce the particles.

• Chemical – by reduction of

metallic oxides, thermal

decomposition or by means of

electrolytic deposition.

Slide 6 11/21/2013

Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.

Metal powder production methods

Each method results in powders with

different characteristics and appearance:

• Water atomising

irregular shape, but no internal porosity

• Gas atomising

spherical shape and no internal porosity

• Oxide reduction

irregular shape, large surface area and

substantial internal porosity

• Electrolytic

high purity with dentritic morphology

Slide 7 11/21/2013

A Chemical; Sponge Iron-Reduced Ore

B Electrolytic: Copper

C Mechanical: Milled Aluminium Powder

Containing Disperoids (17)

D Water Atomization : Iron

E Gas Atomization: Nickel-Base Hardfacing Alloy.

Source "Atomization - The Production Of Metal

Powders" A. Lawley, MPIF.

The atomisation process allows for the production of

pre-alloyed powders. The chemical composition of the

feed material and alloy additions to the molten bath

allow for the formulation of an almost unlimited

combination of alloy compositions.

Particle characteristics

Slide 8 11/21/2013

Ti6Al4V

Slide 9 11/21/2013

CoCr (ASTM75)

Slide 10 11/21/2013

Design considerations for production

Manage the re-design process

• Layerthickness & detail versus speed

• Orientation & functionality versus nesting & quantity

• Add fixturing items for post-processing

Manage the process

• Maintain file integrity

• Safety (separate powder handling from production)

• Manages production (compare ‘build to master’ and ‘build to build’)

Small bespoke series components

dental crowns & bridges, implants etc

Complex geometries & structures

Thermal management, medical implants, transition to composite structures

Hidden internal features

conformal cooling, valve bodies etc.

Nobel materials & alloys

materials difficult to machine & hazardous to process via other methods

Short series or one off components for test & development

Suitable applications – where does it works best?

Slide 12 11/21/2013

Renishaw’s approach = production process

Use of vacuum chamber, pure Argongas

• Ultra low oxygen level (<0,01%) from start to finish

• Short start-up time (12 minutes from start)

• Low gas consumption (average 30 to 50 ltr/hr)

Glove access, external hopper and off-line preparation

• Operator safety and material integrity

• Re-use and refill during process

• File integrity

Slide 13 11/21/2013

Identify & position

key features

Create a structurally

optimised design

Consider

part/process

orientation demands

Design for process – pump housing redesign

Original DFP3 pump front plate part

• Weight Removal • Part consolidation • Reduction in manufacture and assembly time

Aim

Design for process – assembly front plate

Improved flow path smoothness through CFD simulation of fuel flow velocity a) original flow paths b) redesigned flow paths

Delphi Design for process – assembly front plate

• Pressure test = 2mm wall section • Built on Renishaw AM250 in Ti6Al4V • 54% reduction in volume • 21% reduction in overall packaging area • 5 non-value added assembly operations eliminated

Delphi Design for process – assembly front plate