Isak Elfström, VP R&D · • EBM® is the ultimate Additive Manufacturing solution for the aerospace industry with its • High productivity • Excellent material properties •

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Additive Manufacturing with EBM®

Isak Elfström, VP R&D

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• Overview • Applications

• Medical Implants • Aerospace

• Products • Materials

Overview

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Arcam briefly

- Arcam AB incorporated 1997 - Listed on NASDAQ OMX Stockholm - First EBM system delivered in 2003 - More than 100 systems installed worldwide - 55 people, in Sweden, the US, UK, Italy and China - Sales partners in Europe and Asia

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Arcam in the world

Arcam center Arcam client

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• Freedom in Design • Design for function • Integrated trabecular structures

for improved bone ingrowth • Light-weight structures

• Excellent Material Properties

• Controlled microstructure • Better than cast • Compliant with applicable

standards

• Cost-Efficient Production • High productivity • Material recycling

Core Benefits with EBM®

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EBM® - Electron Beam Melting

• The electron beam gun generates a high energy beam (up to 3.000 W)

• The beam melts each layer of powder metal to the desired geometry

• Extremely fast beam translation with no moving parts

• High beam power -> high melt rate (up to 80 cm3/h) and productivity

• Vacuum process -> eliminates impurities and yields excellent material properties

• High process temperature (650 ºC for titanium) -> low residual stress and no need for heat treatment

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The EBM® Machine

Heat Shield

Powder Rake

Powder Container

Build Platform

EB Gun

Control Unit

Build Chamber

Build Tank

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9

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Arcam LayerQam™

• Camera-based quality verification system

• Additive Manufacturing provides a new melted surface for each layer

• The melting depth is thicker than the layer of powder

• Camera-based monitoring of each melted layer provides porosity control of the entire produced part

• Monitoring each layer hence provides a unique capability to verify 100% density of EBM-produced components

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Arcam EBM® LayerQam™ - demo, sample with deliberately generated defects

Micro tomography

Filtered camera images

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• Arcam Products • Materials

Medical Implants

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• Design your unique trademark trabecular structure • With CAD or with a Structure generator software

• Optimize for osseointegration • Pore geometry (no limitation) • Pore size (down to ~400 μm) • Porosity (up to ~85%)

• Competitive manufacturing costs • EBM® production cost, typical: < 2 €/cm3 trabecular structure

Trabecular Structures™

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Bio-Compatibility

Pictures of bone growing into EBM®-manufactured titanium implants with Trabecular Structures™ Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg.

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Implant Categories

• Acetabular cups • Revision cups • Augments • Femoral stems • CMF • Spine • Tibial trays • Shoulders • Triflanges • Femoral knees

In production with EBM®

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• Single-step production of solid and porous sections, with structural continuity between them

• All-porous implants possible (augments, wedges, …)

• High process temperature gives low residual stress, and no need for heat treatment after the build

• No secondary high temperature process to apply the porous structure that could cause grain growth

Production Benefits

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Post-Build Processing

• Remove and recycle excess powder

• Machine inside with conventional CNC

• Clean parts with ultrasonic and solvents

• Quality Control with EBM® LogStudio™

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• CE-certified acetabular cups with integrated Trabecular Structures™ since 2007

• Implants with FDA clearance since 2010 • > 30,000 cups implanted • 2% of the global production of acetabular cups

is now manufactured with EBM®

Adler Ortho, IT 2007 -

Lima, IT 2007 -

Exactech, US 2010 -

CE-certified & FDA-cleared Implants

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Courtesy of Adler Ortho s.r.l.

CE-certified since 2007

Fixa Ti-Por™ Acetabular Cup

Material: Ti6Al4V Build time: 16 cups in 8 hours

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Material: Ti6Al4V Build time: 16 cups in 8 hours

DELTA TT™ Acetabular Cup

Courtesy of Limacorporate S.p.a.


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FUSE™ Lumbar PLIF Cage

Material: Ti Grade 2

Courtesy of Medtronic Inc.


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Summary

• EBM® lets you design and produce unique trademark Trabecular Structures™ with minimum investment

• EBM® offers a unique single-step production method for solid and porous implants

• EBM® provides structural continuity between solid and porous sections, and requires no heat treatment

• EBM® is a proven and cost-efficient technology, with thousands of implanted CE-certified products

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Aerospace

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AM Benefits in Aerospace

• The Aerospace industry’s fundamental characteristics are • Extreme requirements on product performance • Geometric design complexity • Extensive use of Ti alloys • Use of exotic materials

• EBM® is the ultimate Additive Manufacturing solution

for the aerospace industry with its • High productivity • Excellent material properties • Ability to process new materials

• Several aerospace applications in the pipeline

• All major engine OEM’s have ongoing EBM® initiatives • First application in series production during 2012

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AM Drivers in Aerospace

• Freedom in Design • Optimize geometry for weight savings • Optimize geometry for improved function • Brackets (weight), Vane segments (function), Filters (function)

• Materials Savings • Buy-To-Fly ratios of 15-20 are common in Aerospace • 95% of the material is machined away as scrap • For EBM® the Buy-To-Fly ratio is close to 1

• Materials Flexibility • Many alloys with unique characteristics are difficult to cast and forge • EBM® has demonstrated that it can be used to process such alloys

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Turbine Blades

Courtesy of Avio S.p.A.

Material: γ-TiAl Size: 8 x 12 x 325 mm Weight: 0,5 kg Build time: 7 hours / blade

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Aerospace Prototype

Material: Ti6Al4V Size: Ø 180 x 300 mm Weight: 5,5 kg Build time: 40 hours

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Rocket Engine Impeller

Material: Ti6Al4V ELI Size: Ø 140 x 80 mm Weight: 2,5 kg Build time: 16 hours

Courtesy of CalRAM, Inc.

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Arcam Products

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Arcam Q10

• For implant production, in titanium alloys

• Build envelope • 200 x 200 x 180 mm

• Higher productivity

• Improved resolution

• Arcam LayerQam™

• Arcam MultiBeam™

• Integration with Streamics™

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• For aerospace production, in titanium alloys

• Build envelope • 200 x 200 x 350 mm and • Ø300 x 200 mm

• Interchangeable build tanks (tall and wide)


Arcam A2

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• For aerospace production

• Extended build envelope • 200 x 200 x 380 mm

• Designed for processing high temperature materials


Arcam A2X

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• For aerospace production, in titanium alloys

• Largest build envelope • Ø350 x 380 mm


Arcam A2XX

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Powder Recovery System

• > 95% recovery of unmelted powder

• Minimal dust generation for safe operation

• Closed circuit until powder recovery is completed

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Training & Maintenance

• Support & Maintenance agreements to maximize use of machines, incl.

• Application support • Periodic maintenance • Spare parts • Emergency visits • Support hot-line

• Training packages to

ensure operator skills • Basic training • Advanced training

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Arcam Powder Metals

• Pre-alloyed powder • Powder fractions selected for safe operation and handling • Verified material properties • Chemical composition in accordance with applicable standards • Optimized process parameters

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Materials

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Materials Strategy

• Arcam's customers range from companies in the aerospace and medical implant industries who use their EBM® systems for production, to universities and institutes that focus on research.

• Arcam's materials strategy is to supply our industrial customers with the metals they use in their production.

• We simultaneously make it possible for our research-oriented customers to work with other materials, by providing additional training that enables them to use EBM® with these materials.

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Materials Portfolio

• With the high power available (up to 3.000 W) the EBM® process can melt any powdered metal with a melting point temperature up to 3.400 °C (e.g. W), allowing an extensive range of materials.

• The materials currently supplied by Arcam are: • Titanium alloy Ti6Al4V (Grade 5) • Titanium alloy Ti6Al4V ELI (Grade 23) • Titanium CP (Grade 2) • CoCr alloy ASTM F75

• For these materials Arcam has

• Established a validated powder supply chain • Optimized process themes that match powder quality • Verified material properties of the built material

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Other Materials in EBM®

• Arcam has tested and has customers who use a range of other materials in their EBM® machines, including but not limited to:

• Titanium aluminide (γ-TiAl)

• Superalloys (e.g. Inconel 625 & 718)

• Stainless steel (e.g. 316L)

• Tool steel (e.g. H13)

• Aluminium (e.g. 6061)

• Hard metals (e.g. NiWC)

• Copper (e.g. GRCop-84)

• Beryllium (e.g. AlBeMet)

• Amorphous metals

• Niobium

• Invar

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Contact

Arcam AB Krokslätts Fabriker 27A SE-431 37 Mölndal, Sweden Phone: +46 31 710 32 00 Web site: www.arcam.com E-mail: [email protected]

Thank you for your attention!

Arcam - CAD to Metal®

Documents

Isak Elfström, VP R&D · • EBM® is the ultimate Additive Manufacturing solution for the aerospace industry with its • High productivity • Excellent material properties •