Metal Additive Manufacturing Myths: The Truth About Powder ... · Metal Additive Manufacturing Myths: The Truth About Powder Reuse and its Effect on Mechanical Properties additivemanufacturingseries.com

Metal Additive Manufacturing Myths: The Truth About Powder Reuse and its Effect on Mechanical Properties

additivemanufacturingseries.com

Andrew Carter, Processing and Manufacturing Engineer, Stratasys Direct Manufacturing

2 STRATASYS DIRECT MANUFACTURING

Over 1,200 Granted

or Pending Additive

Manufacturing

Patents Globally

$668 Million

Revenue (2017)

Publicly Traded On

Nasdaq (SSYS)

Over 30

Technology and

Leadership Awards

Headquarters:

Eden Prairie, MN

and Rehovot, Israel

30 Years of Additive Applied.


Stratasys Direct Manufacturing is one of the largest providers of 3D printing and advanced manufacturing services.

7 U.S. manufacturing facilities

9 Manufacturing technologies

500+ employees

Certifications: ISO 9001, AS9100

ITAR registered

ABOUT STRATASYS DIRECT MANUFACTURING


Valencia, CA

Poway, CA

Tucson, AZ

Phoenix, AZ

MANUFACTURING FACILITIES

Eden Prairie, MN

Austin, TX

Belton, TX


Our experienced team of project and applications engineers are committed to your success with:

Design support for advanced manufacturing

Technical direction and recommendations

Material, technology and build optimization

for quality, speed and affordability

OUR TEAM


TECHNOLOGIES

ADDITIVE

CONVENTIONAL


Additive Metal Production

SECTION TWO


ADDITIVE METAL CAPACITY

2 Facilities (Austin, TX & Belton, TX)

17 DMLS MACHINES

1 EOS M400

1 EOS M400-4

2 Fully supported Machine Shops

Dedicated Quality Lab

Cutup Metallography

Flow Bench, Hydrostatic Tester

CMM


ADDITIVE ALLOYS

Current OfferingSS 17-4 PH*SS316LAlSi10Mg

Ti 6-4 Gd5*

CoCr

-Std avail.)

*Powder chemistry ordered to meet respective AMS standards.*

Standard Text = Performance Super Alloys

BoldText = Quick Turn Alloys

Sourced directly from multiple established atomizers.

IN625: -45um +10um, Unused

SS17-4: -45um +10um, Recycled

All materials are kept in airtight, color-coded containers

Materials are batched and blended to ensure full traceability


ADDITIVE MANUFACTURING IS MOSTLY CONVENTIONAL

Stress Relief

Plate-Part Separation

Part Serialization

In-process Inspection

HIP

SHT, PHT

Dimensional Inspection

RadiographicInspection

Performance Inspection

Stratasys Direct, In-house

Powder Removal

This is the only Additive Step

Dimensional InspectionCMM, Faro, Surface Roughness

Radiographic InspectionX-ray, CT scan

Performance InspectionHydrostatic Pressure, Air Effective Area

Heat Treating Vendor Radiographic Testing Vendor

Post Machining

Outsourced operations are executed by strategic partners where SDM programs take priority.

Cutup Metallography

DMLS


The truth of powder recycling

SECTION TWO


EOS Recommended method M280-M290

(BY THE MACHINE MANUFACTURERS)

+ =

EOS M280 Build Chamber EOS Supplied Sieve Sieve Directly in machine


Machine Manufacturer

Powder HandlingMethod

Additive Industries Internal

AddUp Mixed

GE (Concept Laser) External

3D Systems Internal& External

EOS External

Rennishaw Internal

SLM Solutions Mixed

Trumphf External

Velo3D Internal

No equipment

manufacturer is

concerned with

material traceability.


Internal Powder Recycling is managed in side the additive equipment.

External Powder Recycling is performed by additional hardware.

Mixed Solution offers both internal and external recycling methods.


MANUFACTURING SCENARIO


POWDER DOES NOT ALWAYS STAY IN THE SAME MACHINE

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

Start Production –

1

2

3

4

Machine

PowderID #

PowderComposition


SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

Start Production –execute 4 builds and refresh with virgin each time

1

2

3

4



Unplanned Maintenance & Increase customer demand 6 machines producing product, swapped material between two machines, 6 powder evolution ID numbers.

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

2

3

4

5

6

3

2




Unplanned Maintenance & Increase customer demand execute 3 builds on all machines

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

2

3

4

5

6

3

2



Full Production All machine capacity dedicated to producing product, 8 powder evolution ID numbers

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

8

7

4

3

2

5

6



Full Production execute 5 more builds across all machines

SI1476 SI1991 SI2001 SI1160

SI1848SI2006SI1989SI1849

1

8

7

4

3

2

5

6


Sometimes simplicity is best.

MATERIAL RECYCLING STATION


MATERIAL TRACEABLITY


Additive CoCr

Powder chemistry was sourced for a land based gas turbine application

Powder was transferred between additive systems to meet production demands.

Additive API IN718

Powder chemistry and material heat treatment was sourced per American Petroleum Institute specification (API 6A718).

Virgin and recycled material was processed on 3 different machine models.

MECHANICAL DATA STRATASYS DIRECT MFG HAS IT


ADDITIVE COBALT-CHROME PROPERTY STUDY

CoCr IN718

Study: 6 EOS M280 Machines, 2 Material Providers, 6 different powder blends, 56

builds per machine, 51 samples (17 Builds) from before a CA, and 39 samples (from 39

builds) from after the CA, data represents >336builds over a 9 month period.

Testing Included: 90 tensile bars, 12 chemistry and 12 metallography

Mechanical Testing

Nadcap & A2LA Accredited Test House

Comparisons:

Machine to Machine

Powder Composition (times recycled)

Material Provider (chemistry)


INITIAL RUN CHART ALL DATA AT A GLANCE

0

50

100

150

200

250

0 50 100 150 200 250 300

Str

en

gth

(ksi)

Time (days)

Additive CoCr Room Tensile Results

UTS YTS

CoCr IN718


INITIAL RUN CHART FIRST OBSERVATION

0

50

100

150

200

250

0 50 100 150 200 250 300

Str

en

gth

(ksi)

Time (days)

Additive CoCr Room Tensile Results

UTS YTS

CoCr IN718


TENSILE RESULTS SEGMENTED THREMAL TEREATMENT

0

50

100

150

200

250

0 50 100 150 200 250 300

Str

en

gth

(ksi

)

Time (days)

Additive CoCr Tensile Results

8

9

10

12

14

15

SCRAPPED AFTER STRESS RELIEF

SCRAPPED AFTER SR + HIP

CoCr IN718


MECHANICAL PROPERTES VS. THERMAL CONDITION

7.7

6%

13.5

7%

3.9

1%

7.0

0%

6.7

8%

4.0

2%

44.6

9%

13.7

8%

CoCr IN718

0%

10%

20%

30%

40%

50%

0

50

100

150

200

250

UTS YS Mod Elong.

Pe

rcen

t E

lon

ga

tio

n &

Re

du

ctio

n o

f A

rea

Str

en

gth

, M

od

ulu

s (k

si,

Msi

)

Tensile Property

Mechanical Properties

SR SR, HIP, SHTImproper Heat Treatments


TENSILE RESULTS ONLY REPRESENTING FULLY HEAT TREATED MATERIAL.

0

50

100

150

200

250

0 50 100 150 200 250 300

Str

en

gth

(ksi

)

Time (days)

Additive CoCr Tensile Results

8

9

10

12

14

15

CoCr IN718


NON-CONFORMANCE

0.125IN

0.050IN

Issue: Lack of fusion

Location: The interface between

contour and hatch.

Change in process parameters:

~60% increase in deposition speed

~50% increase in laser power

9 part build to a 10 part buildNon Conformance:Lack of Fusion

CoCr IN718


BEFORE CORRECTIVE ACTION VS. AFTER CORRECTIVE ACTION

0%

5%

10%

15%

20%

25%

Ultimate Tensile Strength

0%

5%

10%

15%

20%

25%

30%

Yield Strength Distributions

n=31n=29

Post Corrective ActionPre Corrective Action

n=31n=29

Post Corrective ActionPre Corrective Action

CoCr IN718


TIMES RECYCLED

0

20

40

60

80

100

120

140

160

180

200

0 10 20 30 40 50 60

Str

en

gth

(ksi

)

Times Recycled

Ulitmate and Yield Strength vs. Times Recycled

9

10

12

14

15

CoCr IN718

PowderEvolution


CONCLUSIONS

CoCr IN718

Additive CoCrHeat treatment is a key factor in additive CoCr mechanical and material properties.

A major process change in laser parameters (~60% increase in deposition speed

through a reduction of 0.27 W/m2) had negligible affect on mechanical properties.

Additive CoCr mechanical properties do not depend on material recycling.


WHAT IS ADDITIVE API IN718?

API American Petroleum Industry

API Standard 6A718 Nickel Base Alloy 718 (UNS N07718) for Oil and Gas Drilling and Production Equipment.

Chemistry

Metallography

Tensile

Impact

Hardness

ADDITIVE API IN718 STUDY

CoCr IN718


MANUFACTURING STUDY PARAMETERS

Machine Systems: M280, M290, M400

Builds Per Machine: 3 (1 with 100% Virgin Material, 2 with highly recycled material)

Locations on Build Plate: 5

Samples at each location: 2 tensile, 4 (2 z, 2 y ) impact, 2 microstructure

Total Tested Sample Size: 90 per mechanical property, 11 metallurgical samples

CoCr IN718


BUILD LAYOUT

CoCr IN718


BUILD LAYOUT

BLBR

C

FL

FR

CoCr IN718


PROCESSING

Additive Manufacturing

Stress Relief

Plate Part Separation

(Saw)

HIP

Solution Heat Treatment

(1825F for 60min)

Machining (Per ASTM E8 cylindrical barsPer ASTM E23 notched izod)

Testing(Per ASTM E8 cylindrical bars,

per at NADACAP facility)

Precipitate Heat Treatment

(1425F for 8hrs)

CoCr IN718


Mechanical Properties:

Tensile, ASTM E8 (gage length 4x gage diameter)

Impact, ASTM E23

Testing Standards and Study Comparisons

Microstructure Comparisons:

XY and YZ grainsize

Mechanical Property Comparisons:

Machine Systems (M280, M290, M400)

Build Locations

Material Recyclability

Orientation Dependent Izod Impact

CoCr IN718


MACHINE SYSTEM COMPARISON TENSILE RESULTS

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS YS Mod Elong. RA

Pe

rcen

tag

e

Str

en

gth

, M

od

ulu

s (k

si,

MS

I)

M280 M290 M4000

.45

%

0.4

2%

0.4

0 %

0.6

5 %

0.6

9 %

0.8

4 %

3.7

5%

7.1

0%

3.8

8% 3.6

6%

3.4

6%

2.2

8%

7.8

7%

6.0

6%

4.3

5%

n=30 n=30 n=30

CoCr IN718


BUILD LOCATION COMPARISON TENSILE PROPERTIES

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS (ksi) YS (ksi) Modulus (Msi) Elong. (%) RA (%)

Pe

rcen

tag

e

Str

en

gth

, M

od

ulu

s (k

si,

Msi

)

Build Location Comparison, Tensile Properties

BL BR C FL FR

n=18 n=18 n=18n=18 n=180.4

9%

0.4

9%

0.4

2%

0.3

5%

0.4

7%

0.5

8%

0.7

9%

0.7

4%

0.8

3%

0.7

2%

3.7

7%

3.8

3%

4.6

7%

4.0

9%

8.0

9%

4.0

5%

1.7

9%

4.1

9%

2.3

9%

2.1

6%

6.6

7%

4.1

2%

8.3

8%

5.5

8%

4.5

4%

CoCr IN718


TENSILE PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

UTS YS Modulus Elongation Reduction of Area

Pe

rcen

tag

e

Str

en

gth

, M

od

ulu

s (k

si,

Msi

)

Virgin vs. Highly Recycled Material - Tensile Properties

100% Virgin Powder Highly recycled Powder (>15X)

n=30 n=60

0.3

8%

0.4

7%

0.7

2%

0.6

4%

4.7

6%

5.5

4%

2.8

8%

3.3

2%

7.4

2%

5.4

9%

CoCr IN718


TENSILE PROPERTIES AS A FUNCTION OF TIMES RECYCLED

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

50.0

100.0

150.0

200.0

250.0

0 5 10 15 20 25

Elo

ng

atio

n, R

ed

uct

ion

of A

rea

(%

)

Str

en

gth

, M

od

ulu

s (k

si,

Msi

)

Times Recycled

Additive API IN718 Tensile Properties as a Function of Powder Recycling.

UTS YS Mod. Elong. RA

CoCr IN718


Reported Measurements:

Absorbed Energy (ft-lbs): difference in energy of the striking unit at the instant of impact.

Lateral Expansion Measurement (mils):the sum of material expansion on both sides of the sample perpendicular to the striking direction.

Percentage of shear fracture (%): difference between total fractured area and the area of unstable fracture region.

NOTCHED BAR IMPACT

Lateral Expansion:Larger of A2 or A4 plus

the larger of A1 and A3.

Percent of Shear Fracture:A*B/total fracture region

All impact testing was performed at -75F per API specification.

CoCr IN718


MACHINE SYSTEM COMPARISON IMPACT

21.10 21.53 20.90

0

5

10

15

20

25

30

M280 M290 M400

En

erg

y (

ft-lb

s)

Machine System

Absorbed Energy Fracture Plane XY

3.3

2%

4.6

0%

4.8

4%

Vertical-sampleFracture Plane XY

CoCr IN718


BUILD LOCATION COMPARISON IMPACT

21.2820.89

21.28 21.33 21.11

0

5

10

15

20

25

30

BL BR C FL FR

En

erg

y (

ft-lb

s)

Build Location

Absorbed Energy Fracture plane XY

4.3

8%

5.0

2%

4.3

8%

4.4

2%

3.8

3%


CoCr IN718


IMPACT PROPERTIES PRODUCED WITH VIRGIN VS. HIGHLY RECYCLED POWDER

21.6 20.8

20.8

20.621.2

21.6

0

5

10

15

20

25

30

0 5 10 15 20 25

En

erg

y (

ft-lb

s)

Times Recycled

Absorbed Energy as a Function of Material Recycling Fracture Plane XY


CoCr IN718


VERTICAL VS HORIZONTAL IMPACT PROPERTIES

Vertical

Horizontal

Vertical-sampleFracture Plane XYHorizontal-Sample

Fracture Plane XZ

17.60

21.18

0

5

10

15

20

25

Horizontal Sample (Fracture plane xz) Vertical Sample (fracture plane XY)

En

erg

y (

ft-lb

s)

3.6

7% 4

.48

%

CoCr IN718


HORIZONTAL DIRECTIONAL IMPACT PROPERTIES

AB

C

D17.86 17.71 17.95 17.00

0

5

10

15

20

25

A B C D

En

erg

y (

ft-lb

s),

La

t. E

xp. (m

ils),

% s

he

ar

Fra

ctu

re (

%)

A

B

C

D

5.93% 5.41% 6.64% 4.48%

Notch Location

Fracture Direction

A X+

B Z-

C X-

D Z+ CoCr IN718


XY vs. ZY

XY has a higher frequency of equiaxed grains than ZY

Wider range of duplex grain structure in the ZY plane.

ADDITIVE API718 METALLOGRAPHY

XY ZY

CoCr IN718



A major process change in laser parameters (~60% increase in deposition speed

through a reduction of 0.27 W/m2) had negligible affect on mechanical properties.


Additive API IN718Consistent mechanical and material properties are achievable across multiple

platforms and across the build plate.

Conventional heat treatments applied to additive material may not achieve the

specifications minimums of wrought material. Mechanical and material properties are

independent of the amount of material recycling.

CONCLUSIONS - ADDITIVE API IN718

CoCr IN718


CONCLUSIONS


A major process change in laser parameters (~60% increase in deposition speed through a

reduction of 0.27 W/m2) had negligible affect on mechanical properties.


Additive API IN718Consistent mechanical and material properties are achievable across multiple platforms and

across the build plate.

Conventional heat treatments applied to additive material may not achieve the

specifications minimums of wrought material. Mechanical and material properties are

independent of the amount of material recycling.

CoCr IN718


CONCLUSION

Stratasys Direct Manufacturing, committed to promoting the wide spread adoption of Additive Manufacturing as a viable means of producing end-use critical components and makes these manufacturing studies available to industry.

Thank You

Andrew CarterSenior Manufacturing EngineerStratasys Direct ManufacturingAustin, [email protected]/ 512-655-5019
mailto:[email protected]/

Documents

Metal Additive Manufacturing Myths: The Truth About Powder ... · Metal Additive Manufacturing Myths: The Truth About Powder Reuse and its Effect on Mechanical Properties additivemanufacturingseries.com