selective laser melting versus electron beam melting
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“État actuel des fabrications additives pour les
applications métalliques”
Atelier CNES – 18/19 Novembre 2013, Toulouse, France
Olivier RIGO
Carsten ENGEL
25.11.13 1 © sirris | www.sirris.be | info@sirris.be |
Special thanks …
Le Fonds Européen de Développement Régional et la Région Wallonne investissent dans votre avenir.
25.11.13 2 © sirris | www.sirris.be | info@sirris.be |
Sirris | Metal Additive Manufacturing
25.11.13 3
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
Sirris | Driving industry by technology
130 experts & hight-tech infrastructure
Collective centre of the technology industry • Non profit organization • Industry owned
4,700 industrial interventions (advice, projects, services) •within 1,700 different companies •whose 75% are SME’s •24M EUR turnover
Mission: “Increase the competitiveness of companies of the Agoria sectors through technological innovations”
Sirris | 23 years of Additive Manufacturing
AM centre – Leading position in EU 16 engineers and technicians 17 high-tech additive technologies in house Most complete installed base in EU Driving technology companies in applications
Technologies: • Stereolithography (normal & hi-res) • Paste polymerisation for ceramics and metals (Optoform) • 3D Printing of plaster and metal powder • Laser sintering of polymeric powder (PA,…): P360 – P390 • Objet Connex 500: bi-material • Laser sintering of metal powder (parts and mould inserts) • Electron Beam Melting (Arcam A2) • 3D Printing of wax (Thermojet) • Vacuum Casting of Alu, Bronze, Zamak • Laser Cladding (EasyClad) • Laser Beam Melting (MTT) • Bi-material FDM system • Fab@home system (for students) • MCOR technology (color 3Dprinter)
25.11.13 5 © sirris | www.sirris.be | info@sirris.be |
Sirris | Metal Additive Manufacturing
25.11.13 6
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
Generalities: Metal Additive Manufacturing
25.11.13 7 © sirris | www.sirris.be | info@sirris.be |
Direct
Fabrication
system
Laser
E-Beam
Print head
Nozzle
Post-
processing
Indirect
Binder
Debinding
+ sintering
Post-
processing
Generalities: Metal Additive Manufacturing
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Metallic powder deposited in a powder bed • Electron Beam • Vacuum • Build temperature: 680-720°C
• Metallic powder deposited in a powder bed • Laser Beam • Argon flow along Ox direction • Build temperature: 200°C
25.11.13 8 © sirris | www.sirris.be | info@sirris.be |
Generalities: Metal Additive Manufacturing
25.11.13 9 © sirris | www.sirris.be | info@sirris.be |
Electron Beam Melting
Generalities: Metal Additive Manufacturing
25.11.13 10 © sirris | www.sirris.be | info@sirris.be |
Electron Beam Melting
Benefits and drawbacks - EBM
Benefits Drawbacks
Few developed materials, only conductive materials possible
Tricky to work with fine powder
Powder is sintered -> tricky to remove (e.g. interior channels)
Long dead time between 2 productions (8 hours for cooling – A2, A2X, A2XX systems)
Sintered powder = good for thermal conductivity = less supports
Suitable for very massive parts
Less supports are needed for manufacturing of parts
Possibility to stack parts on top of each other (mass production)
Process under vacuum (no gaz contaminations)
High productivity
No residual internal stress (constant 680-720°C build temperature)
Very fine microstructures (Ti6Al4V), very good mechanical and fatigue results (Ti6Al4V)
Expensive maintenance contract
25.11.13 11 © sirris | www.sirris.be | info@sirris.be |
Generalities: Metal Additive Manufacturing
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Metallic powder deposited in a powder bed • Electron Beam • Vacuum • Build temperature: 680-720°C
• Metallic powder deposited in a powder bed • Laser Beam • Argon flow along Ox direction • Build temperature: 200°C
25.11.13 12 © sirris | www.sirris.be | info@sirris.be |
25/11/2013 © Sirris | www.sirris.be | info@sirris.be |
13
Spread powder
Recoater
Laser beam
Melted zones
Previous layers
Initial plate
Argon
Main tank
The building steps
Generalities: Metal Additive Manufacturing
Laser Beam Melting – SLM Solutions 250HL
25.11.13 14 © sirris | www.sirris.be | info@sirris.be |
Benefits and drawbacks - LBM
Benefits Drawbacks
• Flexibility for new material developments
• Possibility to work with fine powders 10µm (d50)
• Easy powder removing from the parts (the parts are not embedded in pre-sintered cake)
• Short dead time between 2 productions (2 hours for cooling)
• Possibility of restarting an interrupted job
• Easy visual inspection of building process during the manufacturing (either with unaided eye or with optical camera)
• Process is wall thickness dependent. (not suitable for massive parts)
• Process involving internal stresses in the parts need additional annealing
• Process requiring strong supports for parts fasten during the manufacturing (not only for heat transfer)
• Need to use build plates of the same material than the powder used in the machine (e.g.: more expensive for titanium powder)
• Cutting tool necessary (eg: a saw) in order to release the parts from the build plate
25.11.13 15 © sirris | www.sirris.be | info@sirris.be |
Technology comparison – EBM – LBM
LBM EBM
Size (mm) 250 x 250 x 350*¹ 210 x 210 x 350*²
Layer thickness (µm) 30 - 60 50
Min wall thickness (mm) 0.2 0.6
Accuracy (mm) +/- 0.1 +/- 0.3
Build rate (cm³/h) 5 - 20 80
Surface roughness (µm) 5 - 15 20 - 30
Geometry limitations Supports needed everywhere (thermal,
anchorage)
Less supports but powder is sintered
Materials Stainless steel, tool steel, titanium, aluminum,…
Only conductive materials (Ti6Al4V, CrCo,…)
CENG 25/11/2013 © sirris 2013 | www.sirris.be | info@sirris.be | 16
*1 SLM Solutions 250HL *2 Arcam A2
0
2
4
6
8
10
productivity
3D complexity
maximum size
Accuracy Surface finish
mech prop -
density
material range
EBM (Arcam)
LBM (SLM Solutions
Technology comparison – EBM – LBM
CENG 25/11/2013 © sirris 2013 | www.sirris.be | info@sirris.be | 17
*1 SLM Solutions 250HL *2 Arcam A2
Sirris | Metal Additive Manufacturing
25.11.13 18
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
Metallurgical aspects – LBM & EBM
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Metallic powder deposited in a powder bed • Electron Beam • Vacuum • Build temperature: 680-720°C
• Metallic powder deposited in a powder bed • Laser Beam • Argon flow along Ox direction • Build temperature: 200°C
25/11/2013
© sirris 2013 | www.sirris.be | info@sirris.be | 19
Experimental procedures
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Random scanning strategy • Vacuum • Pre-heating of the subtrate: 680-720°C
• Complex lasing strategy: 79° rotation between two successive layers • Argon flow along Ox direction • Pre-heating of the subtrate: 200°C
Characteristics of theTi6Al4V ELI powders
Process Ti (wt%) Al(wt%) V(wt%)
LBM Bal 5,9 4,2
EBM Bal 3,3 4,4
Reference axis for EBM and LBM
25.11.13 20 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Laser Beam Melting
Perpendicular to the building direction
• Equiaxed morphology (around 50μm of diameter) • Width does NOT significantly change along the height
No evolution of the thermal gradient intensity, no evolution of the grain
width
25.11.13 21 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Laser Beam Melting
Parallel to the building direction
• Elongated grains characteristic of an epitaxial growth aligned with the heat flow
• No epitaxial growth apparent
Explanation: Tilt of the primary β grains
Suggestion: combined effect of part geometry and a modification of the direction of the maximum heat flow that had possibly been brought about by the Argon flow
25.11.13 22 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Perpendicular to the building direction
• Equiaxed morphology as for LBM
Electron Beam Melting (EBM)
Parallel to the building direction
Explanation: • Random scanning trategy • Thermal homogeneity due to substrate preheating (680-720°C) • No argon flow
Hoped this would allow a significant reduction of internal stresses and then improve mechanical
properties
• Epitaxial growth: • No Tilt (≠LBM)
25.11.13 23 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Electron Beam Melting (EBM)
• Typical morphology of a Widmanstätten microstructure • Pre-heating of the substrate induces slower cooling rates thus favouring a diffusive transformation to α
Cooling rate is directly influenced by the preheating of the substrate: the lower the preheating, the faster the cooling rates and the finer the resulting microstructure
Characteristics:
• Uniform, Fine Grain
• Columnar
• Lamellar Alpha Phase
• Larger Beta Grains
25.11.13 24 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Electron Beam Melting (EBM)
Two types of porosities (spherical and non- spherical) due to entrapped argon in powder particles (amount porosity in GA is about 0.2-0.1%) or un-melted areas can be observed.
25.11.13 25 © sirris | www.sirris.be | info@sirris.be |
Sirris | Metal Additive Manufacturing
25.11.13 26
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
Mechanichal comparison
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Layer Thickness: 70µm • Job 130503a • As built sample without additional post treatment
• Layer Thickness: 50µm • Job 130423a • Laser Beam • Argon flow along Ox direction
25.11.13 27 © sirris | www.sirris.be | info@sirris.be |
Tensile test:
According to standard ASTM E111-04 and
NF EN 10002 standards
Experimental procedures
25.11.13 28 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Mechanical properties comparison (Tensile testing)
1126
1202
1029
1094
Rp0.2 (Mpa) Rm (Mpa)
Yield strenght/UTS
(Oy samples)
LBM (50µm anealed) EBM (70µm)
3,1
9,9
LBM EBM
A (%)
25.11.13 29 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Mechanical properties comparison (Tensile testing)
1079
1120
974
1032
Rp0.2 (Mpa) Rm (Mpa)
Yield strenght/UTS
(Oz samples)
LBM (50µm anealed) EBM (70µm)
4,1
10,8
LBM EBM
A (%)
25.11.13 30 © sirris | www.sirris.be | info@sirris.be |
Mechanichal comparison
Electron Beam
Melting (EBM)
Laser Beam Melting
(LBM)
• Layer Thickness: 70µm • Job 120124a • As built sample without additional post treatment
• Layer Thickness: 30µm • Job 121214b • Laser Beam • Argon flow along Ox direction
25.11.13 31 © sirris | www.sirris.be | info@sirris.be |
Experimental procedures
Whöler fatigue curve with a stress ratio of 0.1 and 4 different levels tensile test probes (3 each) : 10-50 kcycles (level 1) 100-200 kcycles (level 2) 500-800 kcycles (level 3) 1-2 exp 6 kcycles (level 4)
Mode: strain-strain Control: force Form: sinusoidal R: 0.1 End process criteria: break or 10^7 cycles
25.11.13 32 © sirris | www.sirris.be | info@sirris.be |
Fatigue test:
According to standard ASTM E466-07
Results and discussion
Mechanical properties comparison (Fatigue testing)
EBM Oz Post-machined samples
LBM Oz Post-machined samples
25.11.13 33 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Mechanical properties comparison (Fatigue testing)
EBM Oz Post-machined samples
LBM Oz Post-machined samples
Ref 2 Roll formed TiAl6V4
25.11.13 34 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Hip treatement in order to improve fatigue properties
EBM Oz Post-machined samples
Ref 2 Roll formed TiAl6V4
EBM Oz Post-machined samples + HIP
25.11.13 35 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Orientation impact?
EBM Ox Post-machined samples + HIP
Ref 2 Roll formed TiAl6V4
EBM Oz Post-machined samples + HIP
25.11.13 36 © sirris | www.sirris.be | info@sirris.be |
Results and discussion
Surface roughness impact
EBM Oz Post-machined samples
EBM Oz As-Built sample
Ref 2 Roll formed TiAl6V4
25.11.13 37 © sirris | www.sirris.be | info@sirris.be |
Sirris | Metal Additive Manufacturing
25.11.13 38
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
Case study 01: Massive ESA-CSL part
EBM
Dimensions: 208*175*38mm (L*W*H)
Machining
25.11.13 39 © sirris | www.sirris.be | info@sirris.be |
Case study 02: ESA-CSL-AlmaSpace
LBM Machining
Machining EBW
25.11.13 40 © sirris | www.sirris.be | info@sirris.be |
Case study 03: Design of an “improved”
support geometry for an antenna
Support mass : 223 g 57.5% mass reduction Initial mass ~ 400 g
LBM
25.11.13 41 © sirris | www.sirris.be | info@sirris.be |
Sirris | Metal Additive Manufacturing
25.11.13 42
Index
Sirris – short overview
Generalities:
Metal Additive Manufacturing
Technology comparison: LBM vs EBM
Metallurgical aspects
Mechanical aspects
Case studies
Contact
© sirris | www.sirris.be | info@sirris.be |
+32 498 91 94 71
Olivier.rigo@sirris.be
Olivier RIGO
25.11.13 © sirris | www.sirris.be | info@sirris.be |
Olivier.rigo1
http://www.sirris.be
#sirris
http://www.linkedin.com/company/sirris
25.11.13
http://techniline.sirris.be
© sirris | www.sirris.be | info@sirris.be |
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