Additive Manufacturing (AM) Seminar Blown powder activities

Copyright © TWI Ltd 2015

By Carl Hauser

Additive Manufacturing (AM) Seminar

Blown powder activities


OUTLINE

• Overview of Laser Metal Deposition

• Industrial Applications

• Fundamental Research

• Integrating technology and capability

• Summary

• Outlook


Overview of Laser Metal Deposition

• Filler Material: Powder and wire

• Melt pool dimensions: 0.2mm to 3mm

• Heat input into part: low to moderate

(minimal distortion/ small HAZ)

• Dilution with substrate: <5%

• Adhesion: Metallurgical bonding

• Structure: Fully dense (similar to a cast

structure)


Overview of Laser Metal Deposition

• Resource efficient: High % powder

usage

• Work Envelope: Governed by robotic

manipulator / gantry.

• 2D TO 3D: Using multiple layering

techniques

• Base Materials: carbon steel, alloyed

steel, titanium alloys, aluminium alloys,

nickel super alloys……

• Coating alloys: Fe-, Co-, Ni-alloys, Ti-

alloys, Cermets……….


TWI Hardware Capability

• Build Envelope: Maximum component

length 2.5m.

• Number of Axis: 5 + 2 (Trumpf) and

6+2 (Robot) (integrated rotary/tilt

manipulator2)

• Lasers: 1.8kW HQ (High Quality) CO2

and Trumpf TruDisk 8002 (5.3KW)

laser.

• Spot size: Variable and programmable

but with a 0.25mm (minimum) spot size

at focus position.

• Powder Feed: Sulzer Metco Twin-10-C

double hopper powder feeder.

Trumpf DMD 505 Gantry Cell

REIS RV60-40 Robot Cell


Variable and programmable Optics

Image Courtesy of Trumpf

Variable laser spot size

2mm

Diffractive Optics for thin section deposition


Cladding Nozzle

• Powder Spot ≥ 0.3 mm

• Laser Power ≤ 2KW

•Oxygen Contamination ≤ 20ppm

• Powder Spot ≥ 1,5 mm

• Laser Power ≤ 6KW

• Oxygen Contamination ≤ 50 ppm

• Geometries with limited access

• Laser Power > 2KW

• Unidirectional scanning

Images Courtesy of Fraunhofer ILT

Working Plane

Coaxial Multi-Jet Off-Axis

Deposition rate

Geometric Complexity


Some Industrial Applications

Industrial Sectors

•Oil and gas

•Power generation

•Mining

•Transport

•Medical

Activity Type

•OEM part manufacture

•Surfacing (wear /corrosion resistance)

•Repair

•Customised parts

•Salvage/legacy parts

•Small batch production


Turbine Shaft Cladding

• 5 years development with an industrial gas turbine manufacturer for the cladding of bearing journals onto a range of gas turbine shafts to combat wear and corrosion.

• The shaft materials includes Ni alloy and martensitic stainless steel.

• Cladding material is a NiCrMo high tensile steel.

• There are strict limits for defects (porosity, cracks) and min hardness levels and max Cr levels to achieve.

• Heat input is restricted to reduce dilution and hence Cr content in the deposit.

• TWI has produced Weld Procedure Specifications for the different materials and developed process control systems to ensure deposition quality and consistency.

• The work is being carried out using our Trumpf laser cell >100 shafts per year


Tungsten Carbide edge to Knife Blade

• Automated laser deposition system designed to continuously deposit WC onto the edge of cutting knife blades (0.8mm thick) at a rate of hundreds of thousands per month.

• Cladding material is a NiCrMo high tensile steel.

• 10 fold increase in life expectancy

WC Deposited Edge

Finished Blade

LMD technology is not only suitable for high value, low volume applications!


Turbine Blade Cladding (Repair)

Turbine Blade Cladding (Repair) – Inconel/stainless steel/stellite


Integrated Manufacture


Fundamental Research Projects

MERLIN project: Development of additive manufacturing technologies

for component manufacture in civil aero engines.

• A focus was to develop complex geometric geometries using LMD

• LMD is generally limited to coatings and freestanding 3D structures


Helicopter Combustion Casing


Dimensional Tolerance

• Wall thickness 0.8 ±0.1mm

• Average tolerance 0.244mm from CAD (not including top flange)

• Corrosion resistance to agreed limits

• Manufacturing lead time reduced from several months to several hours


AMCOR Project

AMCOR: EC collaborative project

looking at hard facing and corrosion

resistant coatings.

• Automotive FGM gears

• Cladding of large hydraulic cylinder

piston rods – to replace PTA process

• Repair of broach machine tools

• Cladding of valves used to introduce

steam into power station turbines

• Hybrid manufacture of cutting rollers

used for cutting rocks


AMCOR Project


Integrating technology and capability

SNIFFLES Project: Development of a portable mass

spectrometer for border and urban environment

security.

• Current unit size is 400x 300 x 180mm

• Unit is currently to heavy (16kg)

ChemSniff Project: To Move a step closer to

commercialisation

• Targets: 8Kg and 100mm in thickness.

• Approach: Design for manufacture (AM), light

weighting and conformal fit.

• Use of several AM technologies:

6

1.Battery

2.NEG pump and vacuum chamber

(SLM/LMD)

3.Ion Pump

4.LIT-MS (DLP)

5.ECU3

6.Casing (SLA)


OXIGEN Project

OXIGEN: EC collaborative project

looking at Oxide Dispersion

Strengthened Materials for the Additive

Manufacture of High Temperature

Components in Power Generation

.

• Base alloys with ODS particles (e.g.

yttria)

• Nickel based alloys

• Titanium aluminide alloys


Conclusions

• LMD is not a universal solution to all repair problems

• However, be careful not to look at deposition cost in isolation – look also at other potential benefits and improvements inherent with the process

• If an LMD solution is targeted and developed intelligently, it can produce:

Full fusion/high bond strength to substrate Low heat input, low dilution, low distortion, small HAZ Least effect on substrate material properties High accuracy with good surface finish High repeatability with good traceability

• These can produce cost benefits which outweigh any extra costs which accrue from the deposition process in isolation


Increased range of materials: aluminium alloys, graded layers, CERMET

Large scale 3D structures

Micro LMD (high resolution and net shape)

Portable cladding systems (on side repair)

Repair of turbine blades

OUTLOOK


Contact

Eur Ing Carl Hauser PhD CEng

Principal Project Leader

TWI Ltd

Tel: +44 (0)114 269 9046 E-mail: [email protected]

Web: www.twi-global.com

mailto:[email protected]

http://www.twi-global.com/



Additive Manufacturing (AM) Seminar Blown powder activities

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