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ZEISS 3D ManuFACTLeverage Holistic Quality Assurance and Correlations to improve yield

Challenges:

Ensuring reliability of 3D printed process and parts.

3D printing – additive Manufacturing – is increasingly becoming part of

industrial production chains.

Medical, aerospace and automotive are among the leading industries in

developing applications for additive manufacturing and implementing the

technology.

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• Lead time for part and material development takes very long. Range are years rather than days.

• Once having a developed part in the serial production the quality is not stable because of many unrecognized instabilities in the process chain.

AM todayAt the process development starting point

SPOILER, TODAY:

Donisi, Sven; Rosswag; Efficient and holistic qualification process for new materials in AMThe gap between the number of materials used for conventional manufacturing methods compared to AM is in

the range of thousands when looking at steel for example.

Munk, Alexander; KSB SE & Co. KGaA; Quality assurance in serial AM with focus on SLMOnly by having a stable process chain it is possible to assure the quality of LPBF parts in serial AM.

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Outer and Inner

Structure

Build Defects, Porosity,

Inclusions

Process Characterization

Surface

Characterization

Powder

Characterization

Microstructural Characterization

ZEISS 3D ManuFACTAdditive Manufacturing is a Multiscale Quality Challenge with unique information at each length scale.

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Digital

MIC

Sub-micron

XRM

Widefield

MICConfocal

MICC-SEM FE-SEM

1 μm 700 nm 250 nm 200 nm < 2 nm < 1 nm < 1 nm

•Outer dimensions

•Inner dimensions

•Surface Roughness

Geometry

• Cracks

• Pores

• Inclusions

• Grains

Microstructure

• Defect Characterization

• Powder Quality

Material

CT

3,5 μm20 μm

3D

Sensor

CMM

ZEISS Solution Portfolio for AMIndustry Leading Quality Control Portfolio from µm to nm

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ZEISS 3D ManuFACTThe Holistic Quality Solution for Additive Manufacturing coveringthe whole process chain

Powder and Material Characterization

SEM, CT, LM

In-Process Metrology & Data Analysis

Post Prints Heat Treatmentand Part Removal

CMM, 3D-Scanning

Defect and Inner Structure Inspection

CT, LM

Post Print Material Quality Inspection

SEM, CT, LM

Dimensional and Surface Quality Inspection

CMM, CT, LM, 3D-Scanning

Process Data Statistics and AnalyticsPiWeb, Analysis, correlation tools

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AM ChallengeEnable fast recipe development and Process Control

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ZEISS AM application centre in ORNLLongterm Investment at Zeiss AM application centre to develop AM know-how

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ZEISS AM application centre in ORNLDuramax HTG, Comet L3D 2, EVO LS15, XB550, Metrotom 800 HR, Versa 620, SmartProof 5, LM Imager.M2M, LM SmartZoom 5, 2x Stereo Stemi305

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From Powder to PerformanceZEISS 3D ManuFACT

Powder and Material Characterization

Light Microscope (LM) Scanning Electron Microscope (SEM)X-Ray Computed Tomography (CT X-Ray)

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Imaging of AM PowderParticle Size DistributionLight Microscope

Light Microscopy image of metal powder Automated segmentation Particle size distribution

▪ Light microscopy offers quick way to assess powder particle size distribution▪ Enables assurance of essential powder quality characteristics

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Imaging of AM PowderHow round and solid is the powder?Scanning Electron Microscope

Fresh powder with open pores Recycled powder with satellites Cross-cut powder with porosities

▪ Scanning electron microscopy offer nanometer level resolution ▪ Evaluation of batches or single particles possible ▪ Focused ion beam (FIB) offers possibility for sample preparation in nanometer scale

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Imaging of AM PowderAl – defect volume fractionXRM

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Imaging of AM PowderA205 – Recycled powder X-Ray Microscope

0

200

400

600

800

1.000

1.200

1.400

1.600

Aspect Ratio

Particle diameter

0

200

400

600

800

1.000

1.200

1.400

1.600

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From Powder to PerformanceZEISS 3D ManuFACT

Post Print Heat Treatmentand Part Removal

Coordinate Measuring Machine (CMM)3D Scanning

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Post print heat treatment and part removalBuild → heat → remove

As build

After heat treatment (650°C for 1h in Ar atmosphere)

After removal from build plate

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From Powder to PerformanceZEISS 3D ManuFACT

Defect and Inner Structure Inspection

X-Ray Computed Tomography (CT X-Ray)Light Microscope (LM)

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Defect and Inner Structure InspectionSurface defects, defects in microstructure and inspectionLight Microscope

DelaminationMicro cracks

Fatigue cracks

Part inspectionDefect inspection

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Inner DefectsAL ArtefactCT

20 mm voxel resolution

3 mm voxel resolution

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Inner DefectsAL Artefact X-Ray Microscope

Versa scan of gear wheel Analysis of scan Detail scan of ROI

Detail scan of ROI

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Correlative workflow for the determination and analysis of inner defects inadditively manufactured parts

▪ Additively manufactured

gear part

▪ XRM-Scan for non-destructive

determination of inner defects

▪ Correlation of XRM and

FIB/SEM for further investigation

▪ Detailed investigation

of inner defect

▪ Reconstruction of XRM-

volume and localization of

defects

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EDS-element-mapping of abnormality shows Fe, Mn, Cr and Co whereasmatrix consists of Al and Si

EDS-element-map, dispersion of

Al-signal on FIB-crossection

EDS-element-map, dispersion of

Fe-signal on FIB-crossection

EDS-element-map, dispersion of

Mn-signal on FIB-crossection

EDS-element-map, dispersion of

Si-signal on FIB-crossection

EDS-element-map, dispersion of

Cr-signal on FIB-crossection

EDS-element-map, dispersion of

Co-signal on FIB-crossection

Matrix Abnormality

Chemical composition point to H13 tool steel which was used in a previous build job on the manufacturing device

Inclusion in AlSi10Mg most likely due to insufficient cleaning of device prior to build of gear part

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From Powder to PerformanceZEISS 3D ManuFACT

X-Ray Computed Tomography (CT X-Ray)Scanning Electron Microscope (SEM)Light Microscope (LM)

Post Print Material Quality

Inspection

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Analysis of Grain StructureMicrostructure FormationLight Microscope

Microstructure vertical to the build direction

Microstructure along the build direction

Bau

rich

tun

g

Hatch distanceHatch width

Laye

r th

ickn

ess

Build

dir

ecti

on

Image courtesy of University Aalen

Laser beam

2mm

500µm

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Analysis of Grain StructureAdditive Manufactured Parts

Fig. 2: AlSi10Mg, crossection transverse to build direction a) Light microscopic, brightfield contrast, lattice-like

laser structure is visible; b) EBSD-Mapping, individual grains colored, laser structure not visible.

a) b)

Fig. 1: View inside the SEM chamber with

inserted EBSD-camera and 70° tilted

specimen.

Grain distribution

and orientation in

EBSD (b)

independend from

laser track and

cellular structure (a)

LM, Laser tracks Same area EM, EBSD

Fig. 3: AlSi10Mg, crossection transverse to build direction, a) Light microscopic, brightfield contrast, cellular

structure, fine Si-eutectic in Al-rich matrix; b) EBSD-Mapping, individual grains colored, crystal formation does not follow cellular microstructure.

a) b) Same area EBSDLM, Zoomed in

cellular structures

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In a typical DCT experiment, the source, sample, and detector are placed in a

symmetric Laue geometry; then, during sample rotation, the polycrystallinity of

the sample will give rise to diffraction spots on the detector plane as and when

different grains satisfy the Bragg condition. By tracking the motion of these

diffraction spots during sample rotation, the grain structure can be reconstructed

in 3D.

Learn more: S.A. McDonald et al., Scientific Reports (2015) 5:14655

C. Holzner, et al., Microsc. Microanal. 22, 1970-1971 (2016).

https://www.zeiss.com/microscopy/int/local-content/labdct.html

LabDCTDifraction Computer Tomography in the lab: understanding 3D crystallography

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3D grain analysis together with defect detectionCorrosion propagation along grain boundariesCT

Several inclusions fall on grain boundaries as identified by the

Lab DCT and absorption data.

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From Powder to PerformanceZEISS 3D ManuFACT

Light Microscope (LM)X-Ray Computed Tomography (CT X-Ray)Coordinate Measuring Machine (CMM)3D Scanning

Dimensional and Surface

Quality Inspection

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Surface Metrology Ti-6AI-4V – As built X-Ray Microscope, Light Microscope

Confocal

µm

-50

0

50

100

150

XRM

µm

-50

0

50

100

150

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Surface Metrology Ti-6AI-4V – After sand blastingX-Ray Microscope, Light Microscope

µm

-10

-5

0

5

10

15

20

Confocal

µm

-10

-5

0

5

10

15

20

XRM

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Comparison of roughness measured with Light Microscope and X-Ray Microscope delivers very similar results

µm

-10

-5

0

5

10

15

20

µm

-50

0

50

100

150

After sand blastingAs built

µm

-50

0

50

100

150µm

-10

-5

0

5

10

15

20

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MeasurementNominal

ValueRun 1 Run 2 Run 3 Average Delta

Diameter -Outside

Cover2.0000 2.0010 2.0010 2.0010 2.0010 0.0010

Radius of the

handle0.4300 0.4344 0.4344 0.4343 0.4344 0.0044

Width of the part 4.3550 4.3550 4.3540 4.3550 4.3547 -0.0003

Radius of the

internal hole10.5690 0.5690 0.5690 0.5680 0.5687 -0.0003

Radius of the

internal hole20.5690 0.5680 0.5680 0.5680 0.5680 -0.0010

Measurement results of several features with dimensional significance

ORNL test partRepeatability Test

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From Powder to PerformanceZEISS 3D ManuFACT

Process Data Statistics and Analytics

PiWeb + Analytics and Correlation

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Process data statistics and analytics

ZEISS PiWeb