Laser Additive ManufacturingTe ch n olog ica l Ch a l le n ge s & Op p ortu n i t ie s

HBNI Webinar

C P PaulHead, Laser Additive Manufacturing Lab

RRCAT, Indorepaulcp@rrcat.gov.in

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Acknowledgment

Current PhD Scholars

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Presentation Plan

• Introduction

• Global & Indian Scenario

• LAM at RRCAT

• Technological Challenges

• New Opportunities

• Conclusions

Introduction to LAM

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Laser Additive Manufacturing A B RI EF I NT RODUC TION

ISO/ASTM 52900 defines

Five criteria for a process to be called“Additive Manufacturing”

Add a footer 5

a) Process of joining of materials.

c) Layer-by-layer build up approach.

b) Starting from 3D model data.

d) Not subtractive manufacturing methodologies.

e) Not formative manufacturing methodologies.

When laser is used as a heat source, it is called LASER ADDITIVE

MANUFACTURING.

AM is not a new concept, it existed since long

Additive manufacturing is nature’s way of growth.

Man also learned it long back, but it is derived recently to manufacturing .

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Comparison of AM with Conventional Processes

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Description Additive Subtractive Formative

Methodology Addition of layer Removal of material Shaping of material

Volume Mass Customized or

Customized

Medium volume High volume

Lead time Less High Medium

Raw material Shapeless materials

(powder, wire, etc.)

Bulk material Molten Material/

Bulk Material

Buy to fly ratio Low High Medium

Surface Finish Low to Medium Medium to High Medium

Dimensional Accuracy Low to Medium High Medium

Material No limitations Limited by material

hardness

Metals and plastics

Size of components Limited to machine size in most

cases

Large components can

be machined

Large Components are

possible

Complex geometry Possible Limited Medium

Logistics Freedom Yes No No

Speed Can be relatively slow Fast Fast

Green Technology Reduced material wastage High material wastage Reduced Material

Wastage

Overall LAM Methodology

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Ready to use

Machining

Post processing

Object + Imaging system

Designer+ 3D CAD S/W

Math data + Analysis

Slicing

Job manipulation

Mat’l deposition

CAD Model Making Laser Processing LAM Component

How does it help ?

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Production

Application

Synthesis Analysis Doc. & dwg.

PlanningTool Proc. Raw Mat’l Proc.

CNC Program & mfg.

Design

QC Packing Usage

Conventional ManufacturingLaser Additive Manufacturing

Advantages of LAM

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1. Complexity for Free

2. Simplification of Part Fixturing

3. Mass Customization

4. Integrated Components

5. Material Design Freedom

6. Logistic Freedom

7. Reduced Wastage

Classification of LAM

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Laser Additive Manufacturing

Powder Bed Fusion

Laser Sintering

Laser Melting

Directed Energy Deposition

Powder Feeding

Wire Feeding

Classification of LAM

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Directed Energy Deposition (LDED) Powder Bed Fusion (LPBF)

Functionally Graded Structures Multi-material Components Near Net Shaped Components Complex Geometry

Unlimited Complexity Refined Microstructure Light Weight Structures Thin Feature Fabrication

Laser energy selectively fuses regions of apowder bed to build 3D components

Focused laser energy is used to fuse materials bymelting as they are being deposited

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Global Scenario

Template Editing Instructions and Feedback

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Indian Scenario

Who is doing what ? • Industries are mainly using Plastic AM

Machines.

• Some leading academic institutions are joining

LAM R&D.

Who has metal LAMmachines ?

RRCAT, CMTI, ARCI, DMRL, GTRE, IITkgp, IITB, IITK,

IITPkd, CECRI, CGCRI, IGTR, CTTC, WIPRO,

Honeywell, 3D Incredible, Dentcare, GE, Objectify.

Who is in LAM Machine development ?

RRCAT, CMTI, CMERI, IITB, IITkgp, PSG

Coimbatore, Intech

LAM at RRCAT

LAM at RRCAT

In all of our research endeavors and collaborations, we strive tointegrate three key elements together to achieve newfundamental scientific insights, to produce groundbreakinghigh-impact results, and to create innovative LAM technologies.

Indigenously developed LAM-DED Machine

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SpecificationLaser : 2 kW Fiber laser

Job manipulation : 5-axis (Siemens 810D controller)

Working volume : 250 x 250 x 250 mm3

Powder feed rate : 2 – 20 g/min

No. of powder feeder : 2

Wire feeding (1 – 2 mm dia.) : 2 – 20 m/min

Purity in Glove box :< 20 ppm O2 & < 30 ppm H20

Advantages

a. High deposition rate

b. Dense and strong parts

c. Multi-material range

d. Larger parts

e. Easy material change

f. Reduced material waste

Limitations

a. Low dimensional accuracy

b. No self-supported structures

c. High thermal distortion

Indigenously developed LAM-PBF Machine

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SpecificationLaser : 500 W

Beam manipulation : Scanlab Galvanoscanner

Beam Diameter : 500 microns

Scan Speed : 0.02 – 10 m/s

Working volume : 250 x 250 x 250 mm3

Layer thickness : 25 – 250 microns

Advantages

a. Shape complexity

b. Thin features

c. Higher mechanical strength

d. Dimensional accuracy &

Surface Roughness

a. Powder Reusability

Limitations

a. Limited multi-material capability

b. Porosity

c. Low build rate

d. Build Volume

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Comparison of LAM Technologies

Feature DED PBF

Feedstock Powder/ Wire Powder

Part Repair Yes No

Laser Power >1kW 200W - 1kW

New Parts Yes Yes

Multi-Material Yes No

Surface Finish Medium-Poor Medium-Rough

Complexity Limited Maximum

LAM at RRCATProcess Development

Our Collaborators

23Many More…… List is appending fast…

Academic Institutes

National Laboratories

Deloro-50 Bushes

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Fabrication Time: 45 days Fabrication Time: 72 Hours

Collaborators : Dr. C Sudha & Team, PMD, IGCAR

Mesh Type Spacers

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Collaborators : Mr. S K Sinha & Team, RED, BARC

Mesh Type Spacers for Fuel Cluster Simulator of 540 MWe PHWR FuelBundle were successfully developed. These spacers are used to maintain thespacing among the fuel rods in Fuel Rod Cluster Simulator (FRCS) - a testfacility at BARC for experimental investigation of thermal hydraulicbehaviour of reactor fuel elements.

Mesh Type Spacers

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LAM built Honeycomb Shaped Orifice

Honeycomb geometry orifices, made of SS304LN/SS304L, are installed at inlet of

Prototype Fast Breeder Reactor (PFBR) sub-assemblies as pressure drop devices

facilitating uniform temperature distribution and flow of liquid sodium.

A number of techniques, including

GTAW, conventional casting, investment

casting, etc. have been attempted. A

limited success is achieved in

investment casting. However, further

improvement is required

It is proposed to develop LAM process for

the fabrication of these orifices for better

dimensional control and surface finish.

Collaborators : CWD, IGCAR

Compact Heat Exchanger

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Collaborators : I V Dulera, HTRS, BARC

Compact Heatexchangers are robust heatexchangers that combine

Compactness,

Low pressure drop,

High effectiveness, and

Ability to operate with a large pressuredifferential between hot and cold sides.

Fabrication feasibility of CHE by LAM is initiated.

It has potential applications in Supercritical CO2 Brayton cycles forSolar-thermal energy generation and Gen-IV nuclear reactors.

CHE by LAMSize: 200 mm x 200 mm x 150 mm

As per the inputs received from BARC, LAM of Compact Heat Exchanger (CHE) is initiated.

SiC Clad Layers on Zircaloy Tubes

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Collaborators : Mr. S K Sinha, RED, BARC

Under accidental conditions, the local environment changes from normal operatingconditions and it yields in degradation of clad material (Zircaloy-4 (Zr-4) tubes) due tohigh-temperature oxidation and hydrogenation. It was targeted to develop LAM processfor deposition of 0.2 mm thick SiC clad layers on Φ10 mm x 0.6 mm thick x 100 mm lengthZircaloy-4 tube.

Deposition of SiC layers issuccessfully demonstrated.

Six such tubes are delivered toBARC for further examination.

With Ar gas at ID

Effect of Ar flow

EDS-Elemental Mapping SiC Deposited Zircaloy Tubes

Zircaloy-4 tube & its cross-section (typical)

Processing and Characterization of Materials using LDED

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OUTPUT AS PUBLICATIONS

K Benarji, Y Ravi Kumar, A N Jinoop, C P Paul, K S Bindra (2020) Metals and Materials International. DOI: 10.1007/s12540-020-00838-y

K Benarji, Y Ravi Kumar, C P Paul, A N Jinoop, K S Bindra (2020Proceedings of the Institution of Mechanical Engineers,

Part L: Journal of Materials: Design and Applications 234, pp. 452-466.

Copper (In-house Requirement)

OUTPUT AS PUBLICATIONS

S Yadav, C P Paul, A N Jinoop, A K Rai, K S Bindra (2020)

Journal of Manufacturing Processes 58, 984-997.

Stainless Steel 316 and its composites (Collaborator: NIT Warangal)

Functionally Graded Materials using LDEDCollaborator: IIT Kanpur & Institute of Plasma Research

OUTPUT AS PUBLICATIONS

S Yadav, A N Jinoop, N Sinha, C P Paul, K S Bindra (2020) Int. J. Adv. Manuf. Technol. 108, 3779–3791.

Delero-50 and Stainless Steel FGMCollaborator: IGCAR

Graded Porous Structures

Specially Designed Components

Gear with Honeycomb Core Spacers

Prototype Hip Implant Impeller

Technological Challenges

Limitations of LAM

1. High Production Costs

2. Mechanical Properties

3. Requires Post-processing

4. Limited Build Volume

5. Stair Stepping Effect

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Opportunities in LAM

Machine/ Software Development

Process Development &

Control

Material/ Feedstock

Development

Design for LAMModeling & Simulation

Characterization & Testing

Quality Controls & Assurance

Application Development

Education & Training

All themes are important and we all need to work together to exploit its full potential

Summary

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Summary

• LAM is a novel methodology capable of providingnew manufacturing solutions

• There is decent lead at international level, India isgearing for the adaptation.

• RRCAT has taken a lead role from machinedevelopment to process modeling.

• Collaboration with other national labs & academicinstitutes are playing key role.

• Innovation required is not limited to processdevelopment & material characterization.

• There is a need to tackle all 9 domains forsuccessful deployment of technology.

Thank You

paulcp@rrcat.gov.in,

drcppaul@gmail.com

+91-731-248 8396

+91-94256-66596

https://www.rrcat.gov.in/technology/laser/lmpd/laml/index.html

https://sites.google.com/site/drcppaul03/