Creative Optimization with Additive Manufacturing Webinar ... · Many Additive Manufacturing (also called 3D printing) techniques such as selective laser sintering (SLS), selective

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Creative Optimization with Additive ManufacturingWebinar - Additive Manufacturing with Particle Size and Shape Analysis

Many Additive Manufacturing (also called 3D printing) techniques such as selective laser sintering (SLS), selective laser melting (SLM) and electro-beam melting (EBM) use metal particle powders as a raw material (Aluminum, Titanium, Steel, Nickel, Tungsten and many Alloys). The particle size, size distribution 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 manufacturing and production of Additive Manufacturing powdersCheck the incoming raw material and the recycled powder for reuse

CAMSIZER XT & CAMSIZER X2 Additive Manufacturing

December 5th of 2017

Julie ChenHORIBA Scientific

Gert BeckmannRetsch Technology GmbH

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Classification Technology Description Materials

Binder Jetting 3D PrintingInk-Jetting

S-PrintM-Print

Creates objects by depositing a binding agent to join powdered

material.

Metal, Polymer, Ceramic

Direct Energy Deposition

Direct Metal DepositionLaser Deposition

Laser ConsolidationElectron Beam Direct Melting

Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate.

Metal powder, Metal wire

Material Extrusion

Fused Deposition Modelling Creates objects by dispensing material through a nozzle to build

layers.

Polymer

Material Jetting PolyjetInk-JettingThermojet

Builds parts by depositing small droplets of build material, which

are then cured by exposure to light.

Photo-polymer, Wax

Powder Bed Fusion

Direct Metal Laser SinteringSelective Laser MeltingElectron Beam Melting

Selective Laser Sintering

Creates objects by using thermal energy to fuse regions of a powder

bed.


Sheet Lamination

Ultrasonic ConsolidationLaminated Object Manufacture

Builds parts by trimming sheets of material and binding them together

in layers.

Hybrids,Metallic,Ceramic

VAT Photopoly-merisation

StereolithographyDigital Light Processing

Builds parts by using light to selectively cure layers of material in

a vat of photopolymer.

Photo-polymer,Ceramic

Processes

4

Classification Technology Description Materials

Binder Jetting 3D PrintingInk-Jetting

S-PrintM-Print

Creates objects by depositing a binding agent to join powdered

material.


Direct Energy Deposition

Direct Metal DepositionLaser Deposition

Laser ConsolidationElectron Beam Direct Melting

Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate.

Metal powder, Metal wire

Material Extrusion

Fused Deposition Modelling Creates objects by dispensing material through a nozzle to build

layers.

PolymerFilament

Material Jetting PolyjetInk-JettingThermojet

Builds parts by depositing small droplets of build material, which

are then cured by exposure to light.

Photo-polymer, Wax

Powder Bed Fusion

Direct Metal Laser SinteringSelective Laser MeltingElectron Beam Melting

Selective Laser Sintering

Creates objects by using thermal energy to fuse regions of a powder

bed.


Sheet Lamination

Ultrasonic ConsolidationLaminated Object Manufacture

Builds parts by trimming sheets of material and binding them together

in layers.

Hybrids,Metallic,Ceramic

VAT Photopoly-merisation

StereolithographyDigital Light Processing

Builds parts by using light to selectively cure layers of material in

a vat of photopolymer.

Photo-polymer,Ceramic

Processes

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Type Technologies Materials

ExtrusionFused 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 matrixcomposite, Ceramic matrix composite

Light polymerized Stereolithography (SLA) PhotopolymerDigital Light Processing (DLP) Photopolymer

Powder BedPowder 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

LaminatedLaminated Object Manufacturing (LOM)

Paper, Metal foil, Plastic film

Powder Fed Directed Energy Deposition Almost any metal alloy

WireElectron Beam Freeform Fabrication (EBF3)


Processes

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Type Technologies Materials

ExtrusionFused 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 matrixcomposite, Ceramic matrix composite

Light polymerized Stereolithography (SLA) PhotopolymerDigital 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)


LaminatedLaminated Object Manufacturing (LOM)

Paper, Metal foil, Plastic film

Powder Fed Directed Energy Deposition Almost any metal alloy

WireElectron Beam Freeform Fabrication (EBF3)


Processes

Manufacturing of Metal Powders

7© Retsch Technology GmbH

Direct iron ore reduction (into iron powder) (+) Fast(-) but irregular particle shape

Atomization (iron and other metals)Gas atomization(+) Smoother rounder shape and narrow size distribution (-) but slower and cost intensive

Liquid atomization(+) Fast(-) but irregular particle shape and wider size distribution

Classification of Metal Powders


Separating Particle Sizes and Shapes(for manufacturing and/or testing)

Size Classification: - Sieving or Air Classification

Shape Classification: - Sieving with special shaped meshes- Sieving (fast and slow)

- Air Classification

Recycling of Metal Powders


Separating Particle sizes bySieving or Air Classification

After Atomization (Sieving or Air Classification )

For Recycling (Sieving off defects, dust, twins, agglomerates)

Example of Additive Manufacturing with Laser Sintering

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Example for 3D printing


AM (Metal, Polymer and Ceramic Powder)Applications Plastic, Ceramic & Metal Powder


Automotive, Airospace Industry,Fast Prototyping => small numbers=> individual modificationsPaper => Plastics => Metal Laser Melting (3D Metal Printing)

Vacuum or Nylon Casting

3D Printing of Metal Construstions


3D printing with metal: The final frontier of additive manufacturing

CAMSIZER XT 3D Printing & Rapid Prototyping


3D Printing


3D Printing


Measuring Principle


Digital Image Analysis

STATIC(ISO 13322-1)

• Particles do not move during measurement• High resolution > 0,5 μm• Few 100 particles are analyzed

(low statistic)• Limited measurement range• Time consuming• Particles detected in stable orientation

(2 Dimensions)

DYNAMIC(ISO 13322-2)

• Particles in motion relative to camera

• Resolution > 1 μm• Few million particles are analyzed

(representative measurement)• Wide measurement range• Fast• Particles measured in random orientations

(3 Dimensions)

Content

Instrument

1.Measurement principle

2.Results

Applications

3.Markets and applications

4. Alternative analysis methods


CAMSIZER P4 (What‘s new)CAMSIZER P4


Measurement Range


Big particles are touching the edge too often reliable quantification not possible.

Accurate measurement of big particles is not possible, even if they fit into the field of view:

Upper measurement limit defined by the field of view

Particle size ~ 1/3 of field of view

Two Camera-System (CAMSIZER P4, XT and X2)


Zoom CameraBasic Camera

Small particles in high resolution

Large amountof big particles

One pixel is element of a projection when at least half of the pixel is covered.

Resolution

ISO 13322-2:Smallest detectable particle:

1 pixel

CCD Basic CCD Zoom



Advanced, patented optics design

Sample flow

Light source 2

Light source 1

Basic Camera

Zoom Camera

Measurement principle (CAMSIZER XT)

New Optical Design of CAMSIZER X2


Advanced, patented optical design

Comparison CAMSIZER XT CAMSIZER X2


Why is perpendicular orientation* better?

* Light Measurement Plane †

Focal plane is always in the measurement plane

Measurement Results


What is the size of this particle?

Particle Size


xcmin

xc min

“width”

A

A‘ = Ax a

rea

“diameter overprojection surface”

xarea

“length”

xFe max

xFemax

CAMSIZER results are

compatible with

sieve analysis

Results X-Jet


Better Size Analysis due to Understanding of Particle Shape:Length, Width, Average Diameter

Particle Shape


• Width/length(aspect ratio)

• Roundness (sphericity)

• Symmetry

• Convexity

xFe max

xc min

A P

r1

r2

S

A convex

A real

= 1

< 1

Particle Shape: Mixture


32.8 %

67.2 %

xFe max

xc min

Q3 (round) =

Better Hardware for New Software Features


CAMSIZER P4 and CAMSIZER X2


KrumbeinsRoundness and SphericityFor proppants, sands, and other non-round, angular particlesCompatible with ISO 13503-2 and API

Krumbein Sphericity SPHT_Kmeasures the elongation of the particles (like w/l = b/l).

Average diameter of all corners dividedby diameter of maximum inscribed circle

Krumbein Roundness RDNS_Cmeasures the „angularity“, or „corner curvature radius“

Optical Process Control


Analysis for size and shape

Particle X-Plorer: New Software Features


New Image database

New Tool for improved understanding and documentation

Typically ~100.000 single particle pictures per measurement

Particle X-Plorer New Software Features


3D - Scatter Plot3D - Point Cloud

3D-Display of data points

Powerful toolfor distinguishing particleswith different sizeand / or different shapes


Powdered Metal

Sorting metals by Roundness (“Willingness” to roll)

Reports and Warnings


Dispersion Modules (CAMSIZER XT)


Particle Size Range from 1µm to 3mm

Three modes in 2 modules (dry and wet): X-Fall: for dry and free flowing particlesX-Jet: air pressure dispersion for fine and agglomerated powdersX-Flow: wet module for emulsions and suspensions,

with ultrasonic probe, optional for organic solvents

The Next Generation


CAMSIZER XT => CAMSIZER X2

Extended size range: 0.8 µm to 8 mm New optics:

Higher resolution: 0.8 µm per pixel

Larger field of view (□Basic)New cameras:

Higher resolution 2 * 4.2 Mpixel310 frames per second/muchhigher data rate (factor 3.6)

Size range: 1.6 µm to 3 mm New optics:

Resolution: 1.6 µm per pixel(with integration => 2.5µm)

Smaller field of view (▫Basic)New cameras:

Camera resolution 1.3 Mpixel270 frames per second

Modular "X-Change" Concept


Flexible configuration for a wide application range

simple • safe • fast



Dry Dispersion Inserts (2 Plug-In Options)

X- Fall (Gravity dispersion)

X-Jet (Air pressure dispersion)

Measurement principle – X-Fall


Measurement range from 10µm to 8mm

For free flowing materials

similar to standard CAMSIZER

Sample recovery after analysis

• Complete sample recovery

• No contamination

Dry Dispersion with X-Fall

CAMSIZER X2 with X-Dry and X-Fall


Measurement principle – X-Flow


Measurement rangefrom 1 µm to 600 µm for emulsions and suspensions

stronger dispersionwith ultrasonicmodule

Optional for organicsolvents

Wet Dispersion with X-Flow

New X-Flow for CAMSIZER X2


Measurement principle


Highlights of the optics setup design:• More than 275 images per second

• Full frame cameras with > 1.3 Megapixel resolution

• Separate light sources for optimised brightness, homogenity, and contrast

• 2 Cameras: High resolution combined with excellent statistic

for a wide dynamic range

• Image processing in real-time: Each particle in each image is analysed

• Hundreds of particles in each image: Excellent statistics in short time

CAMSIZER XT can measure in a wider dynamic rangewith better statistics and reproducibilitythan any other image processing system

Advantages

fast repeatable and reproducible

maintenance free and robust

precise




Dry Dispersion with X-Jet

Measurement range from 1µm to 3mm

For fine powders and agglomeratingmaterials

Dry Dispersion by pressurized air

CAMSIZER X2 with X-Dry and X-Jet


Results


For agglomerating powders

- Metal powder- Coal dust- Wheat flour

Particle size

Lower Measurement Range



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 45 500

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.rdfPowder-#8-X-Jet-30kPa_TP1_vvv_xc_min_001.rdfPowder-#8-X-Jet-30kPa_TP2_vvv_xc_min_002.rdfPowder-#13-X-Jet-30kPa_TP1_vvv_xc_min_001.rdfPowder-#13-X-Jet-30kPa_TP2_vvv_xc_min_002.rdfPowder-#13-X-Jet-30kPa_vvv_xc_min_Mv.rdfPowder-#27-X-Jet-30kPa_TP1_vvv_xc_min_001.rdfPowder-#27-X-Jet-30kPa_TP2_vvv_xc_min_002.rdfPowder-#27-X-Jet-30kPa_vvv_xc_min_Mv.rdf

CAMSIZER XT for Metal Powders


CAMSIZER XT for Metal Powders


Metal Powder

Reproducibility and Instrument-to-Instrument agreementΔ = 0.1µm – 0.3µm

Features of the CAMSIZER®


Calibration Reticule

- Traceble to an International Standard- Covering the Whole Measurement Range- Instrument to Instrument Agreement

StaticCalibration


Features of the CAMSIZER XT

Calibration Reticule

StaticCalibration

Physical Dynamic Partical Standards


Whitehouse Glass Bead Standard XX030for X-Dry and X-Fall

Dynamic Calibration

Size Range and Sieve Correlation


System Comparison DIA, DIA, DIA, Sieving, LD


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


Particle size

Results X-Flow (Calibration)

Particle Size Distribution 10µm + 12µm, Wet Dispersion


Particle size

Results X-Flow

Particle Size Distribution 2.5µm + 5µm, Wet Dispersion


X-Flow Measurement Results CAMSIZER X2

Particle size distribution: 2.5 µm and 5 µm

High resolution for small particles.

Content


Instrument


2.Results

Applications



• Digital image processing with patented 2-camera system (ISO 13322-2)

• Wide dynamic range from 1µm to > 3mm

• 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


Content


Instrument


2.Results

Applications



• 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


Application areas


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


Instrument


2.Results

Applications



Alternative Methods


0.8µm - CAMSIZER X2 - 8mm

Sieving CAMSIZER XTSize range 10µm - 63mm 1µm – 3mmShape analysis no yesDetection of oversizedparticles each particle few big particles

from < 0.1% Vol.Resolution poor high resolution

Multi-modal distributions poor size resolution better resolution

Repeatability andlab-to-lab comparison „difficult“ superior

Comparison with sieving identical results possible

Handling simple,but time consuming easy and fast

Sieving CAMSIZER XT


Results X-Jet


Identical results to sieve analysis

xc_min [mm]0.1 0.2 0.3 0.4 0.5 0.6 0.70

10

20

30

40

50

60

70

80

90

Q3 [%]

Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_005.rdfCa-hydrogenphosphate_100kPa-T38567-vvv_xc_min_003.rdfCa-hydrogenphosphate_100kPa-T38567-vvv_xc_min_004.rdfT38567-Sieve-Analysis-Customer-Site.ref


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


Sieving CAMSIZER XT

Influence of Mesh Width

1400µm 1400µm 1429.5µm

Mesh sizes warpMesh 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:


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


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 40 500

10

20

30

40

50

60

70

80

90

Q3 [%]Solder_Sample_G_xc_min_001.rdfSolder_Sample_G_xc_min_002.rdfSolder_Sample_G_xc_min_003.rdfTin-Solder_Sample_G__xc_min_001.rdfTin-Solder_Sample_G__xc_min_002.rdfTin-Solder_Sample_G__xc_min_003.rdfRT1763 Sieve-Analysis G customer-site-nominal.refRT1763 Sieve-Analysis_G_AS200tap_real-sizes.ref

Applications: Metal powdersMaterial: Cu


Identical results to thesieve 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


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

Roundparticles withlow density

are capturedwithout

rerelease

Sieving Problems (here Blinding and Overloading)

Test Sievesthat comply with standards

If sieve analysis is used for quality controlwithin the context of DIN EN ISO 9000:2000

then both the sieve shaker and thetest sieves must be subjected to

test agent monitoring.

w = mesh widthd = wire diameter

Tolerance for mean value (Y):The mean value of the mesh width must not differ from thenominal value w by more than the tolerance ± Y.

w

w

Ø d

Ø dTechnical requirements & testing

according to ISO 3310

CAMSIZER XT finding Fibers in Beads


Finding the Fibers

CAMSIZER XT Laser sizer


Laser sizer CAMSIZER XTSize range down to 20nm > 1µmShape analysis no yesDetection of oversizedparticles percent range few big particles

< 0.1% Vol.

Resolution good for fines better resolution forlarge 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


Microscope CAMSIZER XTSize range 0.5 – 500 µm 1 µm -3 mm

Shape analysis yessuperior image quality yes

Detection of oversizedparticles no few big particles

< 0.1% Vol.Resolution better good

Statistics Low,few 1,000 particles million particles/minute

Comparison withsieving not possible identical results possible

Handling time consuming fastRepresentative Sample Amounts

difficult, only narrowdistributions

yes, small and large amounts

Static Dynamic Image Analysis


Digital Image Analysis

STATIC(ISO 13322-1)

• Particles do not move during measurement• High resolution > 0,5 μm• Few 100 particles are analyzed

(low statistic)• Limited measurement range• Time consuming• Particles detected in stable orientation

(2 Dimensions)

DYNAMIC(ISO 13322-2)

• Particles in motion relative to camera

• Resolution > 1 μm• Few million particles are analyzed

(representative measurement)• Wide measurement range• Fast• Particles measured in random orientations

(3 Dimensions)




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 CAMSIZER

CAMSIZER CAMSIZER XTSize range 30 µm – 30mm 1 µm -3 mmShape analysis yes yesDetection of oversizedparticles yes yes

Images / second 60 277Resolution CCD-Cameras 790,000 1,300,000

Comparison with sieving identical resultspossible

identical resultspossible

Handling fast fastRepresentative Sample Amounts




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

[email protected]

xc_min [µm]15 20 25 30 35 40 45 500

10

20

30

40

50

60

70

80

90

Q3 [%]

XT-with-X-Jet-#30-Einzel-250kPa_xc_min_005.rdfXT-with-X-Jet-#30-Einzel-250kPa_xc_min_006.rdfXT-with-X-Jet-#30-Einzel-250kPa_xc_min_007.rdfXT-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

Summary


Wide dynamic measurement range (factor of >1500)

High resolution, length and diameter!

Shape analysis

Very Sensitive for over- and undersized particles, 0.001%

Results compatible to sieve analysis

Different dispersion options

Measurement ranges

CAMSIZER P4 20µm – 30mm

CAMSIZER X2 0.8µm – 8mm

32.8 %

67.2 %

xFe max

xc min

Q3 (round) =

Thank you for yourattention!

Documents

Creative Optimization with Additive Manufacturing Webinar ... · Many Additive Manufacturing (also called 3D printing) techniques such as selective laser sintering (SLS), selective