Fabrication additive par procédé CLAD® : principes ...

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Fabrication additive par procédé CLAD® : principes, performance et exemples d’applications

Additive Manufacturing with CLAD® process: principles, performances and application examples.

Didier BOISSELIER – Jérôme WURSTHORN

– Philippe ACQUIER / IREPA LASER

NOGENT - 29 Novembre 2016

Laser Technological centre in France

Industrial laser applications and developments in the field of material processing

IREPA LASER

More than 30 years of experience. 42 people.

Products : feasibility, technical and economic studies,

training, industrialization, R&D, …

≈ 20 lasers in the lab : YAG, Fiber, diode, Femto, …

•with multiaxis workstations and robot

• analysis means: laser beam analyzer, 3D

profilometer (ALICONA), metallographic, …

Expertise and fine characterization :

Main activities:

Welding and surface treatment

Micro-machining

Training

…. And additive manufacturing

3 CLAD machines

+ future SLM machine

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KEY COMPONENTS OF CLAD® PROCESS

Track width 1 – 2,2mm

Accuracy ±0,2mm

Build up rate 120 cm3/h

Machine

Software

Process

CLAD® Process

Construction by Laser with Additive and Direct Process

MACHINE : MAGIC

5 axis machine :

XYZ + BC

Working space :

3D (CLAD) : 1500x840x800 mm3

Max load : 300 kg

Gas enclosure :

Volume : ≈ 12 m3

O2<40 ppm, H2O<60 ppm

2 lasers :

Fibre 500 W + Diode 2 kW

2 CLAD® heads

FALAFEL FUI Project (Fabrication Additive Laser et Faisceau d’Electrons)

MAGIC = "Machine Aeronautique Gaz Inert CLAD®"

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XY

Z

C

B

MACHINE : BIOCLAD

BioCLAD:• Enceinte gazeuse (1m3)

02 < 40 ppm et H2O < 50 ppm

• 5 axes continus:X400 x Y250 x Z200 + B±110°, Cn360°

• Charge maxi: 50 kg

• CNC : Power Automation 5 axes

• 1 buse

• Laser QCW 600/6000 (mode continu ouimpulsionnel)

• Système de distribution de poudreà plateau vibrant

LASER CLADDING

Layer thickness 0,5 2 mm

Track width 3 5mm

Efficiency > 90%

Dilution < 5%

Layer thickness 0,2 0,7 mm

Track width 0,3 3 mm

Efficiency 20 - 90%

Dilution 5% 20%

CLAD®VS

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APPLICATION POTENTIAL OF THE CLAD® TECHNOLOGY

materials grade State of CLAD® developmentCLAD®

results

Steels

Low carbon steel Parameters ok

Alloy steel (low Ceq) Parameters ok

Tool steel (CPM10V, M2) Cladding ok

Stainless

steels

SS304L, 316L Parameters ok

APX4 Parameters ok

17-4 Ph Parameters ok

SS440, … Setup in progress

Ni base

alloys

Inco 718, 713 Qualified on aero parts

Inco 625, 738 Parameters ok

Nimonic C263, 75 Parameters ok

Rene 77, 142 Parameters ok

Waspalloy Qualified on aero parts

CMSX4 Setup in progress

Ti base

alloys

Ti6Al4V Parameters ok

Ti6Al2Sn4Zr2Mo (6242) Qualified on aero parts

CpTi Parameters ok

Co base Stellite 6, 12, 21, 25 Cladding ok

Al alloys Al alloys (Si, Mn, Mg …) Difficult to process

Cu alloys Cu alloys (Zn, Sn, Al, Ni, …) Difficult to process

Au alloys Au alloys Difficult to process

Others

W Difficult to process

WC Ok with Ni matrix

Mo Setup in progress

MATERIALS …… WELDABILITY

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METALLURGICAL AND MECHANICAL PROPERTIES

• Very low level of pores (<0,01%)

• Fine microstructure (rapid solidification)

• Mainly for weldable materials (Ti and Ni alloys, SS, …)

• Local or global gas shielding for oxidization prevention,

mainly on Ti alloys

• Low dilution of the first layer on substrate

Very few pores detected: Ø 50 – 70 µm

NDT TOMOGRAPHY

1025 November 2016

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115

830900

100111

780

860

50115

9931041

99115

929

1027

100

0

200

400

600

800

1000

1200

E (Gpa) R0,2 (Mpa) Rm (Mpa) A% (x10)

Tensile testing results

forging(AIMS 03-20-002)

casting(IGC 04.40.11)

longitudinal direction Z direction

Ductile failure mode – no significant defect

Mechanical properties: tensile testing of Ti6Al4V

Repairing of worn or damagedparts

Fonctionality adding on existing valued parts

Manufacturing of functionnalparts

Preform manufacturing to bemachined

CLAD®

POTENTIAL OF CLAD® PROCESS

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EXAMPLE : PART REPAIRING

Repairing of the worn knife edges of sealing parts

Collaboration with a company specialized in engine maintenance

Company : Chromalloy France

100 people

Essentially repairing for Pratt & Wittney : PW100/ PT6/ JT15 APU (901)

SEALING RINGROTATION SPEED: 30 000 TR/MIN

6 references of parts repaired and qualified

> 1200 parts repaired and returned to flight

First piece began its second cycle repair in August 2012

REPAIRING

With courtesy

≤400µ

m

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CLAD®


EXAMPLE: FUNCTIONALITIES ADDING

Screw rotor Flange

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CLAD®


TRUMP : PREPARATION

Material : Nickel Based alloy (Nimonic C263)

Manufacturing started on SLM subpart

Part adaptation to the process:

Thickness variation eliminated

Modification of the cones geometry

Corner radius added for the mounting lugs

Subpart built upwith SLM process

by

Subpart built upwith CLAD® process

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TRUMP: PRODUCTION

Material Ni based alloy (Nimonic C263)

Wall thickness 0.8 mm

Construction duration Total : 3h46min(2h46 + 1h)

Deposited mass of Nimonic 520 g

Powder catchment efficiency 21%

Average build up rate 18 cm3/h

Roughness Ra5

Powder to be recycled 1900 g

Industrial demonstrator: airduct Ti64 FUI FALAFEL 2014 – IREPA LASER

Dassault Aviation Courtesy

Hybrid process

SLM + CLAD

Feedback:

Part model evolution

Dialogue: Designer manufacturer

SLM subpartmade by

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BIG PART MANUFACTURING

Technical data:

Material : stainless steel 316L

Weight : 25kg (with 11kg baseplate)

Øext tube : 430mm – wall thickness : 2.5mm

Deposited material : 14kg

Manufacturing time : ≈ 20H

Before machiningAfter machining





CLAD®


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Mounting bracket

EXAMPLE : PREFORM + MACHINING

Material : TA6V

Manufacturing

Start with a plate : 250x60x10 mm3

Wall dimension : 250x55x7 mm3 (460g)

Cycle duration : 49min – PCE = 64% - 120cm3/h

Machining

Minimum machined thickness : 0.3mm !

Overthickness VS distortion

EXAMPLE : PREFORM + MACHINING

Traditional machining14 364 cm3

104.7 Kg

Features added by CLAD4 543 cm3

33.2 Kg

Final part27 Kg

Application example:

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CONCLUSIONSConstruction by laser of parts in true material

additive process : material feeding

direct process : from CAD to part

high quality : no cracks, extra low level of porosities,

high mechanical resistance : fine microstructure

control of the deposited materials:

Multi-material construction

Localized deposition of expensive materials

set up possible for fine repairing, on high value added parts

No size limitation

Able to build up on complex surface (not only flat)

Slicing 3D

Powder to be used = injected powder

Performance of the process:

MesoCLAD : 1 up to 10 cm3/h

MacroCLAD : 10 up to 200 cm3/h

Didier [email protected]

THANK YOU FOR YOUR ATTENTION

Fabrication additive par procédé CLAD® : principes ...

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