metal additive manufacturing myths - map your show · 2018-10-02 · metal additive manufacturing...
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1 STRATASYS DIRECT MANUFACTURING
Metal Additive Manufacturing Myths:
Andrew Carter | Senior Manufacturing Engineer
The truth about powder reuse and its effect on mechanical properties
2 STRATASYS DIRECT MANUFACTURING
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.
3 STRATASYS DIRECT MANUFACTURING
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
4 STRATASYS DIRECT MANUFACTURING
• Valencia, CA
• Poway, CA
• Tucson, AZ
• Phoenix, AZ
MANUFACTURING FACILITIES
• Eden Prairie, MN
• Austin, TX
• Belton, TX
5 STRATASYS DIRECT MANUFACTURING
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
6 STRATASYS DIRECT MANUFACTURING
TECHNOLOGIES
ADDITIVE
CONVENTIONAL
7 STRATASYS DIRECT MANUFACTURING
Additive Metal Production
SECTION TWO
8 STRATASYS DIRECT MANUFACTURING
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
9 STRATASYS DIRECT MANUFACTURING
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
10 STRATASYS DIRECT MANUFACTURING
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
11 STRATASYS DIRECT MANUFACTURING
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
12 STRATASYS DIRECT MANUFACTURING
The truth of powder recycling - “its happening”
SECTION TWO
13 STRATASYS DIRECT MANUFACTURING
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')
+ =
14 STRATASYS DIRECT MANUFACTURING
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)
15 STRATASYS DIRECT MANUFACTURING
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)
16 STRATASYS DIRECT MANUFACTURING
Powder handling is an after thought… (by the OEM’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.
17 STRATASYS DIRECT MANUFACTURING
MANUFACTURING SCENARIO
18 STRATASYS DIRECT MANUFACTURING
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
19 STRATASYS DIRECT MANUFACTURING
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
20 STRATASYS DIRECT MANUFACTURING
SI1476 SI1991 SI2001 SI1160
SI1848SI2006SI1989SI1849
Start Production – execute 4 builds and refresh with virgin each time
1
2
3
4
POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE
21 STRATASYS DIRECT MANUFACTURING
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
POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE
22 STRATASYS DIRECT MANUFACTURING
POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE
Unplanned Maintenance & Increase customer demand – execute 3 builds on all machines
SI1476 SI1991 SI2001 SI1160
SI1848SI2006SI1989SI1849
1
2
3
4
5
6
3
2
23 STRATASYS DIRECT MANUFACTURING
POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE
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
24 STRATASYS DIRECT MANUFACTURING
POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE
Full Production – execute 5 more builds across all machines
SI1476 SI1991 SI2001 SI1160
SI1848SI2006SI1989SI1849
1
8
7
4
3
2
5
6
25 STRATASYS DIRECT MANUFACTURING
Sometimes simplicity is best.
MATERIAL RECYCLING STATION
26 STRATASYS DIRECT MANUFACTURING
MATERIAL TRACEABLITY
27 STRATASYS DIRECT MANUFACTURING
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
28 STRATASYS DIRECT MANUFACTURING
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
29 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
30 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
IN625 CoCr IN718 High Temp
31 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
Lot 30 Lot 32 Lot 33 Lot 34 Lot 35
IN625 CoCr IN718 High Temp
32 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
A B C
IN625 CoCr IN718 High Temp
33 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
A B C
A (xy)8e-3in
B (xy)8e-3in
C (xy)8e-3in
IN625 CoCr IN718 High Temp
34 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
35 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
IN625 CoCr IN718 High Temp
36 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
37 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
38 STRATASYS DIRECT MANUFACTURING
MATERIAL PROVIDER COMPARISON
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
%
IN625 CoCr IN718 High Temp
39 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
40 STRATASYS DIRECT MANUFACTURING
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
Machine to Machine Consistency
IN625 CoCr IN718 High Temp
41 STRATASYS DIRECT MANUFACTURING
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, 3 machines
Machine to Machine Consistency
IN625 CoCr IN718 High Temp
42 STRATASYS DIRECT MANUFACTURING
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, 4 machines
Machine to Machine Consistency
IN625 CoCr IN718 High Temp
43 STRATASYS DIRECT MANUFACTURING
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, 5 machines
Machine to Machine Consistency
IN625 CoCr IN718 High Temp
44 STRATASYS DIRECT MANUFACTURING
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
Machine to Machine Consistency
IN625 CoCr IN718 High Temp
45 STRATASYS DIRECT MANUFACTURING
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, 6 machines , 2 atomizers
IN625 CoCr IN718 High Temp
46 STRATASYS DIRECT MANUFACTURING
MATERIAL PROVIDER COMPARISON
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
IN625 CoCr IN718 High Temp
47 STRATASYS DIRECT MANUFACTURING
MATERIAL PROVIDER COMPARISON
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
IN625 CoCr IN718 High Temp
48 STRATASYS DIRECT MANUFACTURING
MATERIAL PROVIDER COMPARISON
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
IN625 CoCr IN718 High Temp
49 STRATASYS DIRECT MANUFACTURING
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)
Age of Oldest Powder (days)
SI1989 - Vertical Tensile Properties UTS (ksi) Yield (ksi)Elongation (%) RA (%)% Virgin % Original Blend
Build 50814
FL
FR
Build 51334
BLFL
IN625 CoCr IN718 High Temp
50 STRATASYS DIRECT MANUFACTURING
Solution Heat Treated, HIP’ed, Stress Relieved, Additive IN625 (100x)
z
xy
z
xy
Stress Relieved, Additive IN625 (100x)
METALLOGRAPIC COMPARISON, BUILDS 51334 & 54747
IN625 CoCr IN718 High Temp
51 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
52 STRATASYS DIRECT MANUFACTURING
Additive CoCr Property Study
IN625 CoCr IN718 High Temp
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
53 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
54 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
55 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
56 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
57 STRATASYS DIRECT MANUFACTURING
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
10SI2001 Before
SI1476 After
12SI1849 Before
SI2006 After
14 SI1848 After
15 SI1991 After
IN625 CoCr IN718 High Temp
58 STRATASYS DIRECT MANUFACTURING
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
10SI2001 Before
SI1476 After
12SI1849 Before
SI2006 After
14 SI1848 After
15 SI1991 After
IN625 CoCr IN718 High Temp
59 STRATASYS DIRECT MANUFACTURING
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
IN625 CoCr IN718 High Temp
60 STRATASYS DIRECT MANUFACTURING
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
61 STRATASYS DIRECT MANUFACTURING
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
62 STRATASYS DIRECT MANUFACTURING
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
n=31n=59Post Corrective ActionPre Corrective Action
63 STRATASYS DIRECT MANUFACTURING
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
64 STRATASYS DIRECT MANUFACTURING
TENSILE RESULTS SEGMENTED THREMAL TEREATMENT
0
50
100
150
200
250
0 50 100 150 200 250 300
Stre
ngth
(ksi)
Time (days)
Additive CoCr Tensile Results
8910121415
SCRAPPED AFTER STRESS RELIEF
SCRAPPED AFTER SR + HIP
65 STRATASYS DIRECT MANUFACTURING
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)
Additive CoCr Tensile Results
8910121415
66 STRATASYS DIRECT MANUFACTURING
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%
67 STRATASYS DIRECT MANUFACTURING
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
68 STRATASYS DIRECT MANUFACTURING
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
69 STRATASYS DIRECT MANUFACTURING
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
70 STRATASYS DIRECT MANUFACTURING
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
n=31n=29Post Corrective ActionPre Corrective Action
n=31n=29Post Corrective ActionPre Corrective Action
71 STRATASYS DIRECT MANUFACTURING
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
72 STRATASYS DIRECT MANUFACTURING
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
73 STRATASYS DIRECT MANUFACTURING
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
74 STRATASYS DIRECT MANUFACTURING
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
75 STRATASYS DIRECT MANUFACTURING
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
76 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
77 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
BLBR
C
FLFR
78 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
BLBR
C
FLFR
79 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
BLBR
C
FLFR
80 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
BLBR
C
FLFR
81 STRATASYS DIRECT MANUFACTURING
BUILD LAYOUT
BLBR
C
FLFR
82 STRATASYS DIRECT MANUFACTURING
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)
83 STRATASYS DIRECT MANUFACTURING
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
84 STRATASYS DIRECT MANUFACTURING
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
85 STRATASYS DIRECT MANUFACTURING
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
%
86 STRATASYS DIRECT MANUFACTURING
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
%
87 STRATASYS DIRECT MANUFACTURING
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
88 STRATASYS DIRECT MANUFACTURING
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.
89 STRATASYS DIRECT MANUFACTURING
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
90 STRATASYS DIRECT MANUFACTURING
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
%
Vertical-sampleFracture Plane XY
91 STRATASYS DIRECT MANUFACTURING
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-sampleFracture Plane XY
92 STRATASYS DIRECT MANUFACTURING
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
%
93 STRATASYS DIRECT MANUFACTURING
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+
94 STRATASYS DIRECT MANUFACTURING
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
95 STRATASYS DIRECT MANUFACTURING
CONCLUSTIONS – ADDITIVE API IN718
96 STRATASYS DIRECT MANUFACTURING
Elevated Temperature Tensile Results – IN718 and IN625
SECTION Three
97 STRATASYS DIRECT MANUFACTURING
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
98 STRATASYS DIRECT MANUFACTURING
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.
99 STRATASYS DIRECT MANUFACTURING
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
100 STRATASYS DIRECT MANUFACTURING
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
101 STRATASYS DIRECT MANUFACTURING
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
102 STRATASYS DIRECT MANUFACTURING
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
103 STRATASYS DIRECT MANUFACTURING
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
104 STRATASYS DIRECT MANUFACTURING
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)
105 STRATASYS DIRECT MANUFACTURING
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
106 STRATASYS DIRECT MANUFACTURING
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
107 STRATASYS DIRECT MANUFACTURING
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
108 STRATASYS DIRECT MANUFACTURING
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.
109 STRATASYS DIRECT MANUFACTURING
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.
110 STRATASYS DIRECT MANUFACTURING
CONCLUSIONS
111 STRATASYS DIRECT MANUFACTURING
CONCLUSION
112 STRATASYS DIRECT MANUFACTURING
THANK YOU
Andrew CarterSenior Manufacturing EngineerStratasys Direct ManufacturingAustin, TXAndrew.Carter@stratasysdirect.com/ 512-655-5019
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