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Chair of Metal Forming Department Product Engineering
we are forming the FUTURE...
Prospects and Potentials of Metal Additive Manufacturing
Bruno BUCHMAYR
Montanuniversitaet Leoben
2 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Outline
• Motivation und trends in production engineering • AM overview and SLM – method and characteristics • Main influencing parameters • Available materials and powder quality • Pros and Cons – Prospects and Potentials of SLM • The Austrian “addmanu”-Project (FFG-leader) • Potentials for economic business developments • Outlook
3 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Motivation und trends in production engineering
reduction of product development time, increasing variant diversity, individualised products and small batches, component parts with multiple functionality, component parts with complex geometry, rapid development of prototypes by tool-free manufacturing, rapid tool availability and topologically optimised component parts for lightweight
construction
Modern production is characterized by
4 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Classification of laser manufacturing based on different mechanisms of laser–material interaction
Source: Gu et.al. Int. Mats Reviews 57, 2012
+ EBM
5 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Comparison of some AM processes
Laser melting Laser sintering
Source: Gu et.al. Int. Mats Reviews 57, 2012
6 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
EOSINT M280 System at the Chair of Metal Forming
MUL/LUT
7 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Concept of the SLM process (powder bed)
basic body or support structure
overflow shaft
building platform
dosing unit/ metal powder
coater layer thickness 20-50 µm
fibre laser reflector
metal powder metal part
application of a layer of powder
local laser melting lowering of the building platform
8 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
EOSINT M280 Technical Data
Technical Data Building volume incl. building platform 250 x 250 x 325 mm (l/b/h) Heating of the building platform up to 200°C Laser-type: Yb-Fibre laser (λ) 400 W (1064 nm) Precision optics F-theta-lens, high-speed scanner Scan speed during build process up to 7,0 m/s Variable focus diameter 100 - 500 μm Layer thickness 20 – 50 µm Diameter of the powder particles 10 – 45 µm Smallest wall thickness 0,3 mm Power supply 32 A Power consumption max. 8,5 kW / typically 3,2 kW Shielding gases integrated nitrogen generator or argon from gas cylinders
Supp
ort
stru
ctur
e 0,
2mm
9 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Seven steps from CAD to manufactured parts
1 3D-Design 2 Conversion to .stl-files 3 Generation of support structures + slicing (Magics, RP-Tools) 4 Positioning and predefinition of
the process parameters (PSW) 5 SLM Building process 6 Removal of surplus metal powder 7 Finishing steps (shot peening,
heat treatment)
data preparation and slicing
positioning and predefinition of the process parameters
start the building process
building platform with metal parts
10 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Important Processing parameters
Processing parameters
• laser power
• scan speed
• strut width
• hatch distance
• exposure strategy
• temperature of the
building platform
• etc.
density, mech. properties, anisotropy, internal stresses, distortion, ...
11 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
SLM process - surface
Surface roughness: as built 20 – 50 µm
12 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Metallographic microsections
Nickel-based alloy IN718 Maraging steel MS1 – 1.2709
13 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Determination of suitable process parameters
Lase
r po
wer
[W
]
Scan speed [mm/s]
14 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Chain of AM based added-value
Source: RolandBerger
15 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Available materials – metal powder production
Aluminium AlSi10Mg – Motorsports and Aerospace Applications
Titanium Ti6Al4V – Aerospace, Motorsports and Biomedical Industry
Cobalt-Chrome CoCrMo – High-Temperature Engineering, Biomedical and Dental Applications
Stainless Steels 1.4542, 1.4540, 1.4404 – Mechanical Engineering, Medical Technology and Aerospace
Nickel Base Alloys HX, IN625, IN718 – Aerospace, Motorsports and Industry
Maraging Steel MS1 (1.2709) – Tooling and Mechanical Engineering
+ new developments !!!
Vacuum Inert Gas Atomizisation
Ar
16 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Homogeneity of AM products
(100x )
Maraging steel MS1
Vol ~ 3mm³
= multi-pass weldment without porosity
17 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Metal Powder Characterization
EOS GP1
HELOS MS1
18 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Materials related problems
e.g. martensitic Cr-steel having 0,54%C
micro-cracking
Laser weldability ???
19 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Laser weldability of similar materials
Source: LASAG AG, Thun, CH
20 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Advantages and disadvantages of the SLM process
Pros • Freedom of design
• Enhanced complexity of the metal parts
without additional costs
• Direct, tool-free manufacturing
• Lightweight construction potential (topology and shape optimisation, FEA)
• Combination of parts (from 3 1 part)
• Reduction of manufacturing steps
• Increased functionality
• Conformal cooling systems of tools and mould inserts
Cons • Low production speed
• High manufacturing costs (limited
building rate and high metal powder costs)
• Extensively effort for the findings of appropriate designs and suitable process parameters
• Problems regarding anisotropy, surface quality and tolerances
• Economically expedient only for small batch production and individual parts
• Limited part dimensions
• Residual stresses and distortion
For details see: B.Buchmayr, G.Panzl: A SWOT-Analysis …, BHM 160, 2015,15-20
21 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
industry SME R&D institutes
Branches: (1) Materials/Surface coating: Böhler Edelstahl, RHI, Tiger Lacke, Happy Plating (2) Production/Construction/Engineering: Hage Sondermaschinenbau, PKT Bürtlmair, Lithoz, Haratech (3) Electronics: LAM Research (4) Automotive: Magna Steyr Engineering, Mahle Austria Filtersystem (5) Aerospace: Airbus DS, RHP Technology (6) Power engineering: GE Jenbacher (7) R&D and Education: Joanneum Research, FOTEC, Montanuniversität Leoben, Profactor, TU Wien
FFG-leader project - Partners
Start: May 2015, 3Y, 7-8 Mio € Leading institution: MU Leoben
22 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Addmanu – SLM at MUL/LUT
WP1: AM-Tools for polymers - development of new powders - design for intensive cooling - metallic powders for advanced polymers WP2: Light weight design and automotive applications of SLM - Topology and form optimization - cellular structures - multi-material joining - rapid prototyping of first crash cars WP3: Fine structures for aerospace - geometrical limits for channels - heat sink designs - miniature valve systems
Three PhD-students working on
Inspire, CH
NiCrMo-steel, P=250W
Channel diameter of 0,2 mm
MUL/LUT
MUL/LUT
23 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
First prototypes at MUL/LUT
gez. Walzl
Internal cooled drill bits Cooled turbine blade
24 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Production of tool for tooth rings
Rapid prototyping and tooling
punch
tube
die
tool final product
Thread grooving concept
Checking using FE-simulation
25 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Worldwide market for AddManu
see annual Wohlers report
26 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Ready for series production ?
Source: Roland Berger
27 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Application field TOOLING
Conformal cooling channels in tools and mould inserts
source: www.lbc-engineering.de, www.hofmann-innovation.com
28 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Tools for Injection Moulding
dish washer part Cooling very close to the surface
29 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Commercial AM-products for aerospace
GKN-Aerospace GE-aviation
Conventionally designed and produced cast steel nacelle hinge bracket for an Airbus A320 (top) and optimised titanium version of the nacelle hinge bracket made by additive manufacturing technology from EOS
Holder Airbus 380 (source: EOS/EADS) PH-Steel
light weight design
30 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Aerospace applications
Bracket Airbus 380 (source: EOS/EADS) PH-Steel
Flange made of Hastalloy X (Tmax=1200°C)
Source: EOS, Munich
31 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Segment of guiding vane and injection nozzle
Source: EOS Munich
32 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
AddManu for Aerospace parts
AM-User: GE Aviation, AIRBUS DS, MTU, GKN, Boeing, GE Avio Aero, …
Light weight design Injection head for Ariane V jet engine
Testing at NASA, Cleveland
Complex Geometries using high performance materials
GE
GKN
GE
Airbus 320
33 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
AM space components for satellites
source: OHB System AG
1kg weight saving means 15.000.- €
34 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
AM Applications in Automotive Manufacturing
35 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Tools for press hardening of steels (PHS)
Great cycle time dependency on cooling rate advanced tool cooling concepts!
36 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Tools for press hardening of steels (cont.)
Source: Fraunhofer IWU
37 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
AM for automotive industry
Audi-Werkzeugbau Ingolstadt, inner door, Concept Laser
38 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
SLM - Further Potentials
- Medical use,
- Jewellery design,
- Military applications,
- Light weight design in mechan. Eng.,
- Mobile Production,
- Surface technologies,
- Microsystem-technology,
- Sensors,
- Wear protection,
- Copy protection,
- Electronics etc. development of new material systems with better or adjusted properties-profile
To find additional AM applications, we need much more creativity.
39 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
AM Outlook
Quelle: Roland Berger, 2015
40 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Outlook – AM Metal Powder Demand
Source: SmartTech Markets Publishing LLC; Additive Manufacturing Opportunities in the Metal Powder Industry: A 10-Year Market Forecast; Nov.2014
41 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
stay in touch - mamc2016
Abstract Submission till Jan. 15, 2016
42 © 2015, · Bruno Buchmayr 2nd Europ. Sci. Steel Panel, VDEH, 23.Nov.2015
Thank you for your attention
MS 1 powder
and Merry Christmas !
Maraging Steel powder (SEM and microsection)