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Why AM needs a Total Quality Management System

Mike Ford

Sales Director LPW Technology Ltd

Additive World Conference


2007

LPW Technology Ltd established by Dr Philip A Carroll.

ISO 9001 certified.

THE START

AS 9120 certified.

EXPANSION THE FUTURE…

2008 2013 2014 2015

LPW U.S.A.

LPW UK move to bigger facility.

AS9100 & ISO 13485 certified.

2016

Significant investment in capital equipment.

Launch of POWDERSOLVE

POWDERTRACE.

Launch of Total Powder Management.

LPW Germany.

Inhouse Plasma Spheroidisation.

Launch of POWDERFLOW.

AM equipment at Daresbury Campus Technology Hub

Queens award for export

LPW Development

2017

Expansion of production

£20M investment in new facility.

http://issuu.com/lpwtechnology/docs/lpw_additive_manufacturing_solutions?mode=window&backgroundColor=#222222


Our Locations

LPW Technology LPW reseller


Metal Powders

Powder Handling & Testing Equipment

Powder Management Software

Consultancy & Lab Testing Services

Products and Services

• All focused on AM only


•Potential Contamination• Powder Manufacturing Processes

• Powder ProcessingSizing

Blending

• AM Recycling

• Multi Material Machines

• Sampling and Testing of Powders

•Mitigation is paramount!• Segregation and screening

Developing, making, supplying the widest range of metal powders to the highest possible standards

Case Study – The Devil Particle


• Failed aluminium parts

Tuesday 26th August - Problem

Case Study – Aluminium Contamination


• Test

Thursday 28th August - Testing



Validation


Element Weight% Atomic%

Al 81.93 85.51

Si 10.93 10.96

Cr 1.72 0.93

Ni 5.42 2.60

Totals 100.00100.00

Nickel homogeneously spread in the aluminium matrix


• At some points nickel content is relatively high

• Phase diagram would suggest high volume percent ofbrittle intermetallic phases in the Al matrix

• Nickel content could be even higher at some points, butdue to the crack Al noise could be measured fromdifferent planes

Validation


Spectrum Al wt% Si wt% Cr wt% Ni wt% Total

Sum Spectrum 79.55 12.63 1.79 6.03 100.00

Spectrum 2 48.05 5.37 6.30 40.28 100.00

Spectrum 3 58.87 8.61 4.38 28.14 100.00

Spectrum 4 58.30 11.22 3.31 27.16 100.00

Spectrum 5 76.13 16.04 2.27 5.57 100.00

Spectrum 6 81.56 10.24 1.98 6.22 100.00


• Ni solubility in Al is limited to 0.24 wt%• Not contributing to matrix strengthening

• Over solubility limit Ni starts to appear as an insoluble intermetallic (NiAl3) increasing the strength

• Usually up to 4 wt% Ni is used

• NiAl3 volume percent increases with Ni content

• In the hypoeutectic (<5.7 wt%) Ni starts to appear as interdendritic α Al – NiAl3 eutectic

• In the hypereutectic (>5.7 wt%) Ni appears as large NiAl3particles which are detrimental for ductility

• Over ~ 42 % more brittle intermetallic phases are starting to appear in the Al matrix

• The most brittle are the AlNi (61-83 wt%) and NiAl3 (85-87 wt%)• Also known as nickel aluminides – potential for high temperature

structural applications, but with almost 0% ductility

• Solution - Physical Metallurgy: AL – NI Binary Diagram



Mechanical Testing

Standard Additive Manufacturing Process


Mechanical Testing

PowderRange – Metal Powders for AM


Mechanical Testing

PowderLife – Adding Control to the AM Process


Mechanical Testing

Additive Manufacturing from the Perspective of the Powder


• Real time stock control of powder across single or multiple locations

• At any time a report can be generated within the software for all powders

• In stock

• On machines as Work In Progress

• Fool proof audit trail

• Minimising Time required for stock take

• Reduced stock levels

• Automated alerts for powders dropping below the pre-determined minimum stock levels

• Automated alerts for powders dropping out of specification

Stock Control

Impact of In-process Powder Control


• Find location of powder batch and sub-batches

• Any powder at any time can be interrogated for quality and suitability for production

• Powder required for a specific build can be allocated for a specific build

• Powder used for a build is fully traceable, with any testing (mechanical or chemical) relating to the powder batch available with a single mouse click

• A Certificate of Conformance for any powder batch used at any time can be generated reflecting the status of the powder at any time during its life cycle

• Simplified product recall

Traceability



Powder and data flow during manufacture

Key:Powder flowData flow


Powder Recycling Powder Cycle (Laser Bed)


Powder Recycling Powder Cycle (EBM/Top Up)

Batch AS/Batch B

100Kg

Build

Output Batch B 50Kg

50Kg From Batch A

Blend

S/Batch C 100Kg(50% Batch A + 50%

Output Batch B)

Build

Output Batch C 50Kg

Blend

S/Batch D 100Kg(50% Batch A + 50% Output Batch C

(25% Output Batch B + 25% Batch A))

50Kg From Batch A


Powder Recycling Powder Cycle (EBM/Top Up)

Batch AS/Batch B

100Kg

Build

Output Batch B 50Kg

50Kg From Batch A

Blend

S/Batch C 100Kg(50% Batch A + 50%

Output Batch B)

Build

Output Batch C 50Kg

Blend

S/Batch D 100Kg(50% Batch A + 50% Output Batch C

(25% Output B + 25% Batch A))

50Kg From Batch A

Build

Output Batch D 50Kg

Blend

S/Batch E 100Kg(50% Batch A + 50% Output Batch D (25% Batch A + 25% Output Batch C (12.5% Output B + 12.5% Batch A)))

50Kg From Batch A

Build

Output Batch E 50Kg

Blend

S/Batch F 100Kg(50% Batch A + 50% Output Batch E (25% Batch A + 25% Output Batch D (12.5% Batch A + 12.5% Output

Batch C (6.25% Output B + 6.25% Batch A))))

50Kg From Batch A


Powder Management Software PowderSolve

Genealogy



Powder Blending Properties



Powder Test Report


Powder Management Software

Chemical Test Reports


Powder Management Hoppers

• 110 litre will be the standard for all alloys

• Fe 460 Kg

• Titanium 250 Kg

• Ni 470 Kg

• Co 450 Kg

• Al 130Kg

• 250 litre for Aluminium

• Al 300Kg

• Sensors Measuring Weight, Temperature, Humidity, Oxygen.

• All data collected can be uploaded to Software for full powder traceability.


• All hoppers are hermetically sealed to reduce potential for contamination

• Outlet will be a standard LF100 fitting but can be adapted to KF40 to fit SLM, Renishaw and Realizer hoppers.

Powder Management Hoppers


Additive Manufacturing from the Perspective of the Powder

Mechanical Testing


• Requirement for 12,000 components over 10 years

• 20 builds per powder batch

• 10 component per build

• 10 builds per machine per month

Cost Savings (example)


Single powder batch200Kg @ €300/Kg

Total €60,000

20 Builds producing components with a total

weight of 150Kg

50Kg of Powder is out of specification and

unusable powder (Scrap)Total value of Scrap

€15,000


CURRENT COST

• 10 builds per month on one machine Input €30,000 Scrap €7,500

• Annual powder requirements Input €360,000 Scrap €90,000

• Powder required for the complete project life cycle Input €3.6M Scrap €900,000

Manufacture of production components



• Increase powder usage by 1 build per batch from 20 to 21

• Total powder requirements reduce by €171,400

• Scrap powder reduced by €135,000

• Impact on component costs during lifetime of project

• Initial cost per part €300

• Increase powder usage €286 (5% cost reduction)

Manufacture of production components



www.lpwtechnology.com

@LPWTechnology

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