Consorzio per la ricerca e lo sviluppo delle Applicazioni industriali del Laser E del Fascio elettronico e dell'ingegneria

di processo, materiali, metodi e tecnologie di produzione

Consortium for R&D of laser and electron beam industrial application and process engineering, materials, methods

and technologies of production

C. Testani (CALEF), G.Barbieri (CALEF); S. Frosini (EL.EN)

Introduction: - CALEF Consortium - Ti-Metallurgy competences - Additive Manufacturing - Laser for Medical Application (EL.EN.)

Introduction: - CALEF Consortium

- Ti-Metallurgy competences - Additive Manufacturing - Laser for Medical Application (EL.EN.)

Introduction: - CALEF Consortium - Ti-Metallurgy competences

- Additive Manufacturing - Laser for Medical Application (EL.EN.)

Introduction: - CALEF Consortium - Ti-Metallurgy competences - Additive Manufacturing

- Laser for Medical Application (EL.EN.)

o CALEF Consortium is a non-profit organization, established in 1998 to develop research projects of national interest, mainly co-financed by public funds

o The Consortium CALEF was established to use and manage the Laser Lab resulting from the PIT LASER project (financed by national and European funds), for research on welding processes and surface treatment of metal materials.

o The Consortium is composed of several partners which have knowledge and experience in many specific fields, ranging from basic research, training, high specialization (ENEA, Bari Polytechnic, University of Calabria, University of Salerno and Italian Institute of Welding), to the development of advanced systems (El.En SpA, APR srl, Lasit SpA and TTM Laser), for industrial applications (Aeronautic Alenia Aermacchi), Automotive (Fiat Research Centre SCpA, FCA Italy SpA) and laser for medical applications (EL.EN).

o CALEF Consortium is a non-profit organization, established in 1998 to develop research projects of national interest, mainly co-financed by public funds

o The Consortium CALEF was established to use and manage the Laser Lab resulting from the PIT LASER project (financed by national and European funds), for research on welding processes and surface treatment of metal materials.

o The Consortium is composed of several partners which have knowledge and experience in many specific fields, ranging from basic research, training, high specialization (ENEA, Bari Polytechnic, University of Calabria, University of Salerno and Italian Institute of Welding), to the development of advanced systems (El.En SpA, APR srl, Lasit SpA and TTM Laser), for industrial applications (Aeronautic Alenia Aermacchi), Automotive (Fiat Research Centre SCpA, FCA Italy SpA) and laser for medical applications (EL.EN).

o CALEF Consortium is a non-profit organization, established in 1998 to develop research projects of national interest, mainly co-financed by public funds

o The Consortium CALEF was established to use and manage the Laser Lab resulting from the PIT LASER project (financed by national and European funds), for research on welding processes and surface treatment of metal materials.

o The Consortium is composed of several partners which have knowledge and experience in many specific fields, ranging from basic research, training, high specialization (ENEA, Bari Polytechnic, University of Calabria, University of Salerno and Italian Institute of Welding), to the development of advanced systems (El.En SpA, APR srl, Lasit SpA and TTM Laser), for industrial applications (Aeronautic Alenia Aermacchi-Leonardo), Automotive (Fiat Research Centre SCpA, FCA Italy SpA) and ai advanced energy systems (Servizi di Ricerche e Sviluppo-SRS S.r.l.)

Brindisi

Cosenza

Trisaia

Orbassano

60,72 39,27

Pubblic

Private

APR – Areas of Interest

1. New welding technologies

2. Additive manufacturing

Seite 12

LABORATORY: MATERIALS AND CHEMICAL-PHYSICAL PROCESSES - MATPRO

Reference Giuseppe Barbieri The laboratory is focused on research and development for structural and functional materials for application in manufacturing technologies . In particolar: •Chemical and physical methodologies, meccano-chemical synthesis of micro and nanostructured materials

•Bulk and C-coatings by mean of PVD. •Development of laser, electron beam, and hybrid material for additive manufacturing. «Materials by Design» approach for advanced metallurgy, numeric simulation from bulk to atomic scale. • Laboratory characterisation with STEM analises, and advaced dignostic for nano-materials and thermodinamic Phase assessments.

Laser Beam Welding

Ytterbium Fiber Laser: λ=1 μm, Power 2300 W (upgradable to 4 kW), fiber (Ø100 μm) delivery

Wobble Module: fmax=300 Hz, adjustable diameter up to a certain limit same advantages of

laser/TIG hybrid technique

CNC machine & optics

Laser source

Laboratory Characterisation

Non Destructive testing/control

Optical Metallography

Scanning and Transmission Electron Microscopy

XPS and Auger Electronic Spectroscopy

RX diffraction

Thermal analyses (DTA, DSC, etc.)

Raman Spectroscopy

Positronic Spectroscopy

Atomic emission Spectroscopy

Microwaves Spectroscopy

Lab. UNISA

Wo

rk s

tati

on

LASER SOURCES

IPG Fiber Laser 10 kW Trumpf TruDisk 4002 Yb:YAG up to 4 kW

Robot ABB GANTRY System Remote and rotating focusing heads

Additive laser Manufacturing

Laser additive manufacturing with EOSINT M270 IM Xtended dual-mode.

Metal alloys for mechanical, aerospace and biomedical field, such as 17-4 Stainless Steel, Ti-6Al-4V and Co-Cr alloys, are investigated.

Moreover, special interest is given to lattice structures, casting moulds and turbine airfoils.

Building volume 250mm x 250mm x 215mm

Building speed 2-20 mm3/s

Layer thickness 20-100 mm

Laser type Yb – fibra, 200 W

Precision optics F-theta lens, high speed scanner

Variable focus diameter 100-500 μm

Lab. UNISA

• DM20 (base nichel-bronzo, per prototipi funzionali, stampi)

• CoCrSP2 (base cobalto-cromo, per impianti dentari)

• GP1 (acciaio inox, per prototipi funzionali, stampi)

• Ti-6Al-4V (base titanio, per applicazioni aerospaziali e biomedicali)

• IN718 (base nichel-cromo, per componenti aerospaziali)

Powder bed EOSINT M270 IM Xtended SI 598 Dual Mode

Powder Laser Cladding

Coating, local damage repair, revising and fixing of new parts

Additive Manufacturing Laser

Additive Manufacturing Laser

EOS FORMIGA P110

Plastiche

EOSINT M280

Acciai

<<The Royal Brompton Hospital, London, UK, have adopted Additive Manufacturing for applications in cardiology by using the technology to develop both a tool which can be used to perform semi-automatic sutures in the operating theatre and a cardiac stabiliser for endoscopic heart operations. The suturing device features metal additively manufactured gears produced using the LaserCUSING process on an Mlab machine by Concept Laser.>>

June 16, 2017

Endoscopic suturing head showing

additively manufactured gears

(Courtesy Coherent)

Additive Manufacturing

AM facility at UNISA and UNICAL

El.En.

http://www.elengroup.com/en/

http://www.lasit.it/en/

Funded Research efforts: strong POINT for

H2020 and FP9

ONE ITALIAN PARTNER: 14 members with specific knowledge sectorial and multidisciplinary

CALEF: choose the right members for each your project

22

CCB Beta T

885°C

HC Alfa

Titanium:

• density 4.51 g/cm3 (Fe 7.9, Al 2.7, Mg 1.74)

• Melting point 1668°C (Fe 1530°C, Al 660°C, Mg 649°C)

• Ti is fourth more abundant metal: Al, Fe, Mg, Ti.

• Ti is an allotropic metal: two cristals: alpha and beta

• The alpha-beta transus is at 885°C , “b-transus” temperature

Alfa (Compact Hexagonal) Beta (Cubic Centred Body) 885°C

•The “beta transus” temperature depends upon alligants percentage:

• Alfa stabilizers: Al, O, N, C, Ga e Ge (increase beta transus)

• Beta stabilizers are V, Mo, Ta e W , Mn Fe Cr Co Cu Ni Si lower transus).

Introduzione

23

All the thermomechanical transformation and

operations are based on the Beta-transus

temperature

Al e

q

Mo eq Allig. Eq

IMI 685

b-metastabili

LCB

IMI 685

Ti6242

Ti6Al4V

IMI 550

TiAl3V

SP 700

10-2-3 Ti15-3

b21S

Ti-17

Ti 6246

38644

Da: Donachie, Titanium a Technical Guide, ASM

The Beta-Transus temperature represents a

reference starting point for all thermomechanical

processes for titanium alloys.

24

Titanium Microstructures Ti6Al4V alloy

Heat treatment at 1000°C x 20 min and water

quench (1000x) Heat treatment at 600°C x 20 min and water

quench (1000x)

25

Ti-Fatigue behaviour

*

Alloy YS

(MPa) YS/Density

(106 Nm/kg) UTS

(MPa) UTS/density (106 Nm/kg)

fatigue 107 cicles

Fatigue life at 107

ciclesdensity (106Nm/kg)

Ti-Cp 351 78 482 107 243 54

Ti6Al4V 927 206 1017 226 607 135

Ti6Al2Sn4Zr2Mo 909 202 1004 223 553 123

Ti4Al4Mo2Sn0,5Si 1080 225 1186 247 652 136

Ti10V2Fe3Al 1294 264 1382 282 759 155

Maraging Steel 1343 170 1596 202 544 121

FV520 B Steel 1193 153 1287 165 819 105

13%Cr-SS 751 95 830 105 537 68

18/8 SS 544 68 600 75 320 40

Aerospace Strutural Handbook M.T. McLellan, Ed.2000.

26

Requirements for medical devices

Ti Properties

Reduce pain High specific strength

Increase mobility High thoughness

Correct abnormality or deformity

Low elasticity Modulus (E)

No adverse biological reaction

Low weigth

Reliable performance High corrosion resistance

Strength and long life service

Bio-compatible and Non magnetic

• Bones are constantly remodelled by osteoblasts and osteoclasts.

• Implants much stiffer than bone will bear more of the load reducing stress in the bone.

• The body will respond by increasing osteoclast activity , causing bone resorption • (Keith Jackson TD, JRI. European Titanium Conf. 23° June, Birmingham, 2009)

Titanium biomedical application – 1000 Ton/year

27

Titanium biomedical application – 2/2

Ti-prostheses have to sustain: corrosion and fatigue loads

The titanium alloy without hydroxy-apatite coating

is not well suited for prostheses….

Allergic reaction

28

Prostheses fatigue fractures

• Hip-prosthesis fracture for fatigue cracking due to initial notch detected in a zone with an hydroxy-apatite coating defect.

• Fatigue damage with coatings thicker than 100 microns,

• Hydroxy-apatite dissolution with coating below 30 microns

• Best compromise: 50 microns.

CALEF is willing to collaborate in the field of:

• ADDITIVE Manufacturing

• LASER MEDICAL

Laser For Biomedical Application

Contact Person: C. Testani (CALEF) +39 345 62 18 500

President: G. Barbieri (ENEA): +39 345 764 4874

Administration:Tel. +39 (0) 835 974 754

Fax +39 (0) 835 974 739

E-mail:calef@trisaia.enea.it PEC: consorziocalef@pec.it

WEB: www.consorziocalef.it