webinar - adding to additive manufacturing with particle ... · pdf filewebinar - adding to...
TRANSCRIPT
1
Webinar - Adding to Additive Manufacturing with Particle Size and Shape Analysis
Many Additive Manufacturing (3D printing) techniques such as selective laser sintering (SLS) and selective laser melting (SLM) use particle powders as a raw material. The particle size and shape have a strong effect on the manufacturing result. Therefore it is important for manufacturers and suppliers to control the particle size and shape of their powders used in this process. In order to control particle size and shape these parameters must be measured. We discuss how to use the CAMSIZER technology to improve additive manufacturing results by monitoring the incoming particles. Value of Dynamic Image Analysis in 3D additive manufacturing How does Dynamic Image Analysis work? Why two cameras can control and monitor dust and oversize? Check the production of 3D printing powders Check the incoming raw material and the recycled powder for reuse
CAMSIZER XT 3D Printing
Additive Manufacturing
June 23 of 2016
Jeff Bodycomb HORIBA Scientific
Gert Beckmann
Retsch Technology GmbH
4
Classification Technology Description Materials Developers (Country)
Binder Jetting 3D Printing Ink-Jetting
S-Print M-Print
Creates objects by depositing a binding agent to join powdered
material.
Metal, Polymer, Ceramic
ExOne (USA) VoxelJet (Germany) 3D Systems (USA)
Direct Energy Deposition
Direct Metal Deposition Laser Deposition
Laser Consolidation Electron Beam Direct Melting
Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate.
Metal powder, Metal wire
DV3D (USA) NRC-IMI (Canada)
Irepa Laser (France) Trumpf (Germany)
Sciaky (USA) Material Extrusion
Fused Deposition Modelling Creates objects by dispensing material through a nozzle to build
layers.
Polymer Stratasys (USA) Delta Micro Factory (China)
3D Systems (USA) Material Jetting Polyjet
Ink-Jetting Thermojet
Builds parts by depositing small droplets of build material, which
are then cured by exposure to light.
Photo-polymer, Wax
Stratasys (USA) LUXeXcel (Netherlands)
3D Systems (USA) Powder Bed
Fusion Direct Metal Laser Sintering
Selective Laser Melting Electron Beam Melting
Selective Laser Sintering
Creates objects by using thermal energy to fuse regions of a powder
bed.
Metal, Polymer, Ceramic
EOS (Germany), Renishaw (UK) Phenix Systems (France)
Matsuna Machinery (Japan) ARCAM (Sweden) 3D Systems (USA)
Sheet Lamination
Ultrasonic Consolidation Laminated Object Manufacture
Builds parts by trimming sheets of material and binding them together
in layers.
Hybrids, Metallic, Ceramic
Fabrisonic (USA) CAM-LEM (USA)
VAT Photopoly-merisation
Stereolithography Digital Light Processing
Builds parts by using light to selectively cure layers of material in
a vat of photopolymer.
Photo-polymer, Ceramic
3D Systems (USA) EnvisionTEC (Germany)
DWS Srl (Italy) Lithoz (Austria)
Processes
5
Type Technologies Materials
Extrusion Fused deposition modeling (FDM) or Fused Filament Fabrication (FFF)
Thermoplastics, Eutectic metals, Edible materials, Rubbers, Modeling clay, Plasticine, Metal clay (including Precious Metal Clay)
Robocasting or Direct Ink Writing (DIW)
Ceramic materials, Metal alloy, Cermet, Metal matrix composite, Ceramic matrix composite
Light polymerized Stereolithography (SLA) Photopolymer Digital Light Processing (DLP) Photopolymer
Powder Bed Powder bed and inkjet head 3D Printing (3DP)
Almost any metal alloy, Powdered polymers, Plaster
Electron-Beam Melting (EBM) Almost any metal alloy including Titanium alloys
Selective Laser Melting (SLM) Titanium alloys, Cobalt Chrome alloys, Stainless Steel, Aluminium
Selective Heat Sintering (SHS) Thermoplastic powder
Selective Laser Sintering (SLS) Thermoplastics, Metal powders, Ceramic powders
Direct metal laser sintering (DMLS)
Almost any metal alloy
Laminated Laminated Object Manufacturing (LOM)
Paper, Metal foil, Plastic film
Powder Fed Directed Energy Deposition Almost any metal alloy
Wire Electron Beam Freeform Fabrication (EBF3)
Almost any metal alloy
Processes
3D Printing (Plastic and Metal Powder) Applications Plastic, Ceramic & Metal Powder
8 © Retsch Technology GmbH
Automotive, Airospace Industry, Fast Prototyping => small numbers => individual modifications Paper => Plastics => Metal Laser Melting (3D Metal Printing)
Vacuum or Nylon Casting
Product Examples (3D Printing Powders)
9 © Retsch Technology GmbH
The world’s first 3D printed metal gun is a beautiful .45 caliber M1911 pistol
The world’s first 3D printed dress
3D Printing of Metal Construstions
10 © Retsch Technology GmbH
3D printing with metal: The final frontier of additive manufacturing
Content
Instrument
1.Measurement principle
2.Results
Applications
3. Markets and applications
4. Alternative analysis methods
14 © Retsch Technology GmbH
CCD - Basic CCD - Zoom Detection of particles
One pixel is element of a projection when at least half of the pixel is covered.
Measurement principle
Resolution
Measurement principle (CAMSIZER XT)
16 © Retsch Technology GmbH
Advanced, patented optics design
Sample flow
Light source 2
Light source 1
Basic Camera
Zoom Camera
17 © Retsch Technology GmbH
Advanced, patented optics design
Sample flow
Light source 2
Light source 1
Basic Camera
Zoom Camera
Measurement principle (CAMSIZER XT)
18 © Retsch Technology GmbH
Advanced, patented optics design
Sample flow
Light source 2
Light source 1
Basic Camera
Zoom Camera
Measurement principle (CAMSIZER XT)
19 © Retsch Technology GmbH
Advanced, patented optics design
Sample flow
Light source 2
Light source 1
Basic Camera
Zoom Camera
Measurement principle (CAMSIZER XT)
Particle Size
21 © Retsch Technology GmbH
xc min
xc min
“width”
A
A‘ = A x a
rea
“diameter over projection surface”
xarea
“length”
xFe max
xFe max
CAMSIZER results are
compatible with
sieve analysis
Results X-Jet
22 © Retsch Technology GmbH
Better Size Analysis due to Understanding of Particle Shape: Length, Width, Average Diameter
23 © Retsch Technology GmbH
• Breadth-/ Length-Ratio
• Roundness
• Symmetry
• Convexity
xFe max
xc min
A
r1
r2
C
A convex
A real
Particle Shape (CAMSIZER and CAMSIZER XT)
P
© Retsch Technology GmbH
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Correlation RDNS_C - Roundness 1
2
3
4
5
1
2
3
4
5
Rou
ndne
ss (R
DN
S_C
CA
MS
IZE
R)
Roundness (visual ISO procedure)
R² = 0.9694
Dispersion Modules (CAMSIZER XT)
30 © Retsch Technology GmbH
Particle Size Range from 1 µm to 3 mm
Three modes in 2 modules (dry and wet):
X-Fall: for dry and free flowing particles X-Jet: air pressure dispersion for fine and agglomerated powders X-Flow: wet module for emulsions and suspensions, with ultrasonic probe, optional for organic solvents
Modular "X-Change" Concept
31 © Retsch Technology GmbH
Flexible configuration for a wide application range
simple • safe • fast
Dispersion Modules (CAMSIZER XT)
32 © Retsch Technology GmbH
Dry Dispersion Inserts (2 Plug-In Options)
X- Fall (Gravity dispersion)
X-Jet (Air pressure dispersion)
Advantages
fast repeatable and reproducible
maintenance free and robust
precise
33 © Retsch Technology GmbH
Dispersion Modules (CAMSIZER XT)
34 © Retsch Technology GmbH
Dry Dispersion with X-Jet
Measurement range from 1 µm to 3 mm
For fine powders and agglomerating materials
Dry Dispersion by pressurized air
Results
36 © Retsch Technology GmbH
For agglomerating powders
- Metal powder - Coal dust - Wheat flour
Particle size
38 © Retsch Technology GmbH
Reproducibility of Metal Powder Results
Customer had sent 30 different samples to Retsch Technology but some of these samples were the same (red, blue and green). We found out the groups and showed to the customer the good reproducibility of CAMSIZER XT (and proofed his sample splitting as well)
xc_min [µm] 10 15 20 25 30 35 40 45 50 0
10
20
30
40
50
60
70
80
90
Q3 [%]
0
1
2
3
4
5
6
7
8
9
q3 [%/µm]
Powder-#8-X-Jet-30kPa_vvv_xc_min_Mv.rdf Powder-#8-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#8-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#13-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#13-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#13-X-Jet-30kPa_vvv_xc_min_Mv.rdf Powder-#27-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#27-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#27-X-Jet-30kPa_vvv_xc_min_Mv.rdf
CAMSIZER XT for Metal Powders
40 © Retsch Technology GmbH
Metal Powder
Reproducibility and Instrument-to-Instrument agreement Δ = 0.1µm – 0.3µm
Features of the CAMSIZER®
41 © Retsch Technology GmbH
Calibration Reticule
- Traceble to an International Standard - Covering the Whole Measurement Range - Instrument to Instrument Agreement
Static Calibration
Physical Dynamic Partical Standards
44 © Retsch Technology GmbH
Whitehouse Glass Bead Standard XX030 for X-Dry and X-Fall
Dynamic Calibration
47 © Retsch Technology GmbH
Particle size
Results X-Flow
Particle Size Distribution 2.5 µm + 5 µm, Wet Dispersion
xc_min [µm]4 6 8 10 120
5
10
15
20
25
30
35
40
45
50
q3 [%/µm]
Duke10um12um_gl0_xc_min_009.rdfDuke10um12um_gl0_xc_min_010.rdfDuke10um12um_gl0_xc_min_011.rdfDuke10um_xc_min_002.rdfDuke10um_xc_min_003.rdfDuke10um_xc_min_004.rdf
48 © Retsch Technology GmbH
Particle size
Results X-Flow (Calibration)
Particle Size Distribution 10 µm + 12 µm, Wet Dispersion
Content
49 © Retsch Technology GmbH
Instrument
1.Measurement principle
2.Results
Applications
3. Markets and applications
4. Alternative analysis methods
• Digital image processing with patented 2-camera system (ISO 13322-2)
• Wide dynamic range from 1 µm to > 3 mm
• Newly developed optical system with ultra bright LEDs for sharp contrasts and large depth of focus
• Short analysis time 1 – 3 minutes for few million particles
• Safe detection of oversized and undersized
• Modules for dry and wet dispersion
• Analysis results compatible to sieve analysis
Advantages
50 © Retsch Technology GmbH
Content
51 © Retsch Technology GmbH
Instrument
1.Measurement principle
2.Results
Applications
3. Markets and applications
4. Alternative analysis methods
• Industrial labs
• Research institutes
• Production control
• Quality control for final products
• Quality control of incoming raw materials
• Immediate control and optimisation of
production processes
Application areas
52 © Retsch Technology GmbH
Application areas
53 © Retsch Technology GmbH
Typical sample materials
• Pharmaceutical powders, granules or
small pellets
• Pulverized and granulated food, spices
• Detergents, enzymes, fillers for washing powders
• Metal or ore powders
• Abrasives (medium and small grit)
• Sand and cement, building materials, limestone
• Fibres
Content
54 © Retsch Technology GmbH
Instrument
1.Measurement principle
2.Results
Applications
3. Markets and applications
4. Alternative analysis methods
Sieving CAMSIZER XT Size range 10 µm - 63 mm 1 µm – 3 mm Shape analysis no yes Detection of oversized particles each particle few big particles
from < 0.1% Vol. Resolution poor high resolution
Multi-modal distributions poor size resolution better resolution
Repeatability and lab-to-lab comparison „difficult“ superior
Comparison with sieving identical results possible
Handling simple, but time consuming easy and fast
Sieving CAMSIZER XT
56 © Retsch Technology GmbH
Results X-Jet
57 © Retsch Technology GmbH
Identical results to sieve analysis
xc_min [mm] 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0
10
20
30
40
50
60
70
80
90
Q3 [%]
Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_005.rdf Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_003.rdf Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_004.rdf T38567-Sieve-Analysis-Customer-Site.ref
58 © Retsch Technology GmbH
Sieving CAMSIZER XT
Spheroidal Particles
x [µm] 200 400 600 800 1000 1200 0
10
20
30
40
50
60
70
80
90 Passing [%]
Sample-1__xc_min_002.rdf Sample-1__xc_min_001.rdf Sieving-Nominal-S1.ref
xc min = ∅ = d = Xc min
particle-width
59 © Retsch Technology GmbH
Sieving CAMSIZER XT
Influence of Mesh Width
1400µm 1400µm 1429.5µm
Mesh sizes warp Mesh sizes weft
Nominal Sieve Mesh = 1400µm Real Sieve Mesh >1400 = 1455
only beads < 1400µm
will pass the sieve mesh
beads > 1400µm will not pass the sieve mesh
Upper mesh size range ~1455µm sieve No. 03033531 (nominal 1400µm)
Theory: Reality:
60 © Retsch Technology GmbH
Sieving CAMSIZER XT
Real Mesh Width
x [µm] 200 400 600 800 1000 1200 0
10
20
30
40
50
60
70
80
90 Passing [%]
Sample-1__xc_min_002.rdf Sieving-upper-range-S1.ref
61 © Retsch Technology GmbH
Sample Reproducibility of CAMSIZER XT measurements of xc min (red, and blue) with Basic + Zoom or Zoom only, Retsch sieve result (real mesh sizes from optical inspection) AS 200 TAB (*black), Customer nominal sieve results (*blue)
Results of Metal Powder
xc_min [µm] 10 20 30 40 50 0
10
20
30
40
50
60
70
80
90
Q3 [%] Solder_Sample_G_xc_min_001.rdf Solder_Sample_G_xc_min_002.rdf Solder_Sample_G_xc_min_003.rdf Tin-Solder_Sample_G__xc_min_001.rdf Tin-Solder_Sample_G__xc_min_002.rdf Tin-Solder_Sample_G__xc_min_003.rdf RT1763 Sieve-Analysis G customer-site-nominal.ref RT1763 Sieve-Analysis_G_AS200tap_real-sizes.ref
Applications: Metal powders Material: Cu
62 © Retsch Technology GmbH
Identical results to the sieve analysis
xc_min [mm]0.04 0.1 0.2 0.4 1 20
10
20
30
40
50
60
70
80
90
Q3 [%]
Automatic reports, many languages
available
Comparison of Methods: Sieving • robust and industrial-suited • easy handling • references available from user
Advantages
Disadvantages
• high amount of time and work • low resolution, small number
of investigatable classes • limited sample amount
(overloading is critical) • Difference between
nominal and real sizes
Competing Measuring Methods
Worn out sieves
64 © Retsch Technology GmbH
F2
F1
1. Move
2. Sliding friction
3. Static friction
xc_min [mm]0.5 0.6 0.7 0.8 0.9 1.00
10
20
30
40
50
60
70
80
90
Q3 [%]
0
50
100
150
200
250
300
350
400
450
q3 [%/m m]5454_PT100_xc_min_008.rdf5454_random_xc_m in_009.rdf5454_Huntsman-sieve.ref
Round particles with low density
are captured without
rerelease
Sieving Problems (here Blinding and Overloading)
Test Sieves that comply with standards
If sieve analysis is used for quality control within the context of DIN EN ISO 9000:2000
then both the sieve shaker and the test sieves must be subjected to
test agent monitoring.
w = mesh width d = wire diameter
Tolerance for mean value (Y): The mean value of the mesh width must not differ from the nominal value w by more than the tolerance ± Y. w
w
Ø d
Ø d
Technical requirements & testing according to ISO 3310
CAMSIZER XT Laser sizer
68 © Retsch Technology GmbH
Laser sizer CAMSIZER XT Size range down to 20 nm > 1 µm Shape analysis no yes Detection of oversized particles percent range few big particles
< 0.1% Vol.
Resolution good for fines better resolution for large particles
Multi-modal distributions more difficult better volume model, better size resolution
Comparison with sieving not possible identical results
Information content black box + mathematics pictures
CAMSIZER XT Optical Microscope
69 © Retsch Technology GmbH
Microscope CAMSIZER XT Size range 0.5 – 500 µm 1 µm -3 mm
Shape analysis yes superior image quality yes
Detection of oversized particles no few big particles
< 0.1% Vol. Resolution better good
Statistics Low, few 1,000 particles million particles/minute
Comparison with sieving not possible identical results possible
Handling time consuming fast Representative Sample Amounts
difficult, only narrow distributions
yes, small and large amounts
71 © Retsch Technology GmbH
xc_min [µm]200 400 600 800 10000
10
20
30
40
50
60
70
80
90
Q3 [%]
PPO-646_xc_min_001.rdfRT1766_ppo646_sieve.ref
CAMSIZER XT Optical Microscope
72 © Retsch Technology GmbH
CAMSIZER XT CAMSIZER
CAMSIZER CAMSIZER XT Size range 30 µm – 30mm 1 µm -3 mm Shape analysis yes yes Detection of oversized particles yes yes
Images / second 60 277 Resolution CCD-Cameras 790,000 1,300,000
Comparison with sieving identical results possible
identical results possible
Handling fast fast Representative Sample Amounts
yes, small and large amounts
yes, small and large amounts
73 © Retsch Technology GmbH
Comparison of CAMSIZER and CAMSIZER XT
Results of CAMSIZER (black) and CAMSIZER-XT (red) of sample #30 CAMSIZER distribution is wider, the results are not that accurate and
repeatable as results from CAMSIZER XT.
Results of Metal Powder
xc_min [µm] 15 20 25 30 35 40 45 50 0
10
20
30
40
50
60
70
80
90
Q3 [%]
XT-with-X-Jet-#30-Einzel-250kPa_xc_min_005.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_006.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_007.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_008.rdf #30-classic-CAMSIZER-Repeatability-xc_min_013.rdf #30-classic-CAMSIZER-Repeatability-xc_min_014.rdf #30-classic-CAMSIZER-Repeatability-xc_min_015.rdf #30-classic-CAMSIZER-Repeatability-xc_min_Mv.rdf
CAMSIZER XT for 3D Printing Powders
74 © Retsch Technology GmbH
• Unique, almost 100% agreement with sieve results (particle width = xc min) • Reliable detection of oversized and undersized particles down to 0.01% • Fast: typically 1-3 minutes per measurement • Flexible dispersion options (air pressure, liquid, free fall) • Shape analysis (roundness, aspect ratio, circularity, etc.) • Surface area calculation • Independent measurement of particle length and width provides more details • CAMSIZER’s “equivalent circle area” (xarea) to compare with laser particle sizers • Very repeatable and reproducible results, with excellent instrument-to-instrument agreement • Very high resolution (excellent capability to detect multimodal distributions!) • Easy to operate, results independent from operators
Applications Plastic, Ceramic & Metal Powder