Management with a comprehensive IN625 Powder … - Claus.pdf · Management with a comprehensive ......

1 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

AM Capabilities for Thermal Management with a comprehensive study of IN625 Powder Reuse* and the effect on tensile properties

Frederick Claus

Business Development Manager – Aerospace and Defense

Stratasys Direct Manufacturing

* STUDIED ACROSS SEVEN (7) EOS M280 MACHINES OVER THE

COURSE OF EIGHT MONTHS WITH MORE THAN 800 BUILDS

High Efficiency High Temperature Modular Power Utilizing

Innovative Designs, Materials, and Manufacturing Techniques


AGENDA

• Stratasys Direct Manufacturing – Technologies and Services

• Validating Additive Metals Process for Production Parts

• Additive Capabilities for Thermal Management

• Applications

• Challenges and Future Work


Stratasys Direct Manufacturing is

one of the largest providers of

additive and conventional

manufacturing solutions:

• 7 U.S. manufacturing facilities

• 12 manufacturing technologies

• 600+ employees

• Certifications: ISO 9001, AS9100

• ITAR registered

• Over 25 years experience

About Stratasys Direct Manufacturing


Our experienced team of project engineers is committed to your success with:

• Design support for additive manufacturing

• Technical direction and recommendations

• Material, technology and build optimization for quality,

speed and reduced cost

• Material and Manufacturing Process development

Your Team

5

Stratasys Direct Manufacturing Technologies and Services


Technologies

ADDITIVE

CONVENTIONAL

PolyJet & Stereolithography

Photo-curable ResinsFused Deposition Modeling

Plastic extrusion

Laser Sintering

Laser Based Plastic Powder Bed FusionDirect Metal Laser Sinter

Laser Based Metal Powder Bed Fusion


Product Development Cycle

Concepts

Design &

Engineering

Prototype

Low Volume

Production

Full Scale

Production

CONVENTIONAL

ADDITIVE

8

Stratasys Direct Manufacturing Additive Metals Capacity and Capabilities


Additive Metals Capacity and Capabilities

Two (2) Facilities located in: Austin and Belton, TX

Seventeen (17) Laser Powder Bed Fusion Machines

8 M280’s, 1 M270, 1 M400 in Austin, TX

4 M280’s and 3 M290 in Belton, TX

Ten (10) Metal Alloys

Staff: Programmers, Machine Technicians, Finishers,

Machinists, Design Engineers, Application Engineers

and Manufacturing Process Engineers

Post AMM Support

Five (5) CNC Mills; 3, 4, and 5-axis

Two (2) CNC Lathes

Two (2) Wire EDM and Drill EDM

Surface grinder, Stress-relief kiln, Down

draft tables, shot peen blast cabinets,

multiple tumbling machines

Outsource: Abrasive flow machining,

Mechanical-Chemical PolishingAMM Inspection

Metallographic Mount and Polisher, hardness tester, Zeiss CMM, Flow bench, High resolution scale,

Profilometer

10 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY10

ADDITIVE METALS PRODUCTION FACILITIES

Austin, TX

Belton, TX

Austin and Belton, TX - Similar Capacity,

Redundant Capability

1111 S T R A T A S Y S D I R E C T M A U F A C T U R I N G / C O N F I D E N T I A L

Current Alloy Offerings1. SS 17-4 PH*2. SS316L3. IN 625* 4. IN 718* 5. IN718 API-std6. CoCrMo7. Monel K-5008. Invar-369. AlSi10Mg10. Ti 6-4 Gd5*

* Powder chemistry ordered to meet respective AMS standards.*

Standard Text = Performance Super Alloys

Bold Text = Quick Turn Alloys

Alloys sourced directly from multiple established atomizers.

IN625: -45um +10um, Unused

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

Additive Manufacturing Metal AlloysFeedstock = Argon gas atomized powder.

All materials are kept in airtight,

color-coded containers

Materials are batched and blended to ensure full

traceability


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

DMLS is only an incremental step in Additive Manufacturing. SDM offers the total solution.

Additive Manufacturing includes the Conventional

13

ANSWERING PROCESS QUESTIONS

Industry claims powder degrades with time and exposure.

• Companies are forming around the fear.

• Customer’s specs call for no part to be built with any powder

older than 90 days.

The mechanical and material properties trended against Blend

Composition will answer industry’s question of powder degradation.

Addressing the Industry-Wide Question; Does AM Feedstock degrade with time and exposure?

IN625: -45um +10um, Unused

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

14

IN625 Powder Recycle and

Reuse Study* ANALYSIS ACROSS SEVEN (7) EOS M280 MACHINES OVER THE COURSE OF EIGHT MONTHS WITH MORE

THAN 800 BUILDS


Powder Reuse StudyAddressing the industry wide question.

Material Property Study - Insight into Powder Life Cycle

Tensile and Microstructure

Industry claims powder degrades with time and exposure.

Companies are forming around the fear

Customer’s specs call for no part to be built with any powder older than 90 days.

SDM’s answer:

- 7 machines building the same material

- 2 tensile bars and 1 metallographic coupon positioned per plate

- over 60 builds/machine

Material properties trended against Blend Composition will answer industry’s

question of powder degradation.

IN625 – As Built Microstructure


Build Configuration

Back Left

Front Left Front RightFront Left

Front Right

Back Left

3 Sacrificial Cylindrical Blanks, >800 Builds


Processing

Additive

Manufacturing (94hour build, >2800

Layers)

Stress Relief(1925F for 120min)

Plate Part Separation(Saw)

HIP(1950F @ 14.5ksi for 4hrs)

Solution Heat

Treatment(2175F for 60min)

Machining (Per ASTM E8 cylindrical

bars)Testing

(Per ASTM E8 cylindrical

bars)

Tensile Blanks were process alongside

component

Coupons represent relieved component.


7 Machines, 2 Material Providers, 8 Material Lots, >55 Builds per

Machine

210 tensile bars, 14 Chemical, 20 Metallography

Comparisons:

Material Provider

Build Location

Machine to Machine Consistency

Powder Composition

What was Involved

19

Implemented a digital system providing a resolution in powder composition unmatched by industry.

Logging and minding powder composition over time.

Fundamentals

Workbench - BuildIt / Powder ReportDigital means to log and mine powder composition


Material Recycle and ReusePowder Composition is in a constant state of f lux.

• SDM Recycles 100%

material

• The majority of powder

has been recycled.

• No test method is

identified to qualify

recycled powder

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Axi

s Ti

tle

Times Recycled

Theoretical IN625 Batch Composition Over 30 Recycles

90 Day Limit Build 31

Build 26 Build 21

Build 12 Build 11

Build 6 Build 1

% of Original Batch


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

UTS (ksi) Yield (ksi) Modulus (Msi) Elongation (%) Reduction of Area (%)

Perc

enta

ge

Str

ength

(ksi, M

si)

Build Plate Location - Tensile Property Comparison

BL FL FR

n = 66 , 74, 70

Build Location – Machine to Machine – Powder Composition – Material Provider

Build Location Comparison


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

UTS Yield Mod Elogation RA

Perc

ent

Str

ength

(ksi, M

Si)

Tensile Property

Machine Comparison - Tensile Property Comparison

SI1849 SI1476 SI2001 SI2006 SI1848 SI1989 SI1991 - Sup. 1

Machine To Machine ComparisonBuild Location – Machine to Machine – Powder Composition - Material Provider


Powder Evolution / Life Cycle Build Location – Machine to Machine – Powder Composition – Material Provider

0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Str

ength

(ksi)

Age of Oldest Powder (days)

SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)

Elongation (%) RA (%)

% Virgin % Original Blend


Tensile Properties Overlaid Onto Powder CompositionBuild Location – Machine to Machine – Powder Composition – Material Provider

0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Str

ength

(ksi)






0 10 20 30 40 50

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250

Times Recycled

Str

ength

(ksi)





Introduction of Separate Powder LotsBuild Location – Machine to Machine – Powder Composition – Material Provider

Lot 30 Lot 32 Lot 33 Lot 34 Lot 35


Microstructure Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider

0 10 20 30 40 50 60

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Str

ength

(ksi)


SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)



A B C

A (xy)

8e-3inB (xy)

8e-3inC (xy)

8e-3in


Microstructure Different OrientationsBuild Location – Machine to Machine – Powder Composition – Material Provider

A (xy)

8e-3inB (xy)

8e-3inC (xy)

8e-3in

A (xz)

8e-3in

B (xz)

8e-3in

C (xz)

8e-3in


0 10 20 30 40 50 60

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Str

ength

(ksi)


SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)



Material Chemistry Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider


Material Chemistry Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider

0.0

0.5

0 50 100 150 200 250 300

Weig

ht (%

)

Powder Age (days)

IN625 Chemisrty SI1991 Sup. 1 SI1849 Sup 1 Limit

Times Recycled

20.021.022.023.0

0 50 100 150 200 250 300

8.0

9.0

10.0

0 50 100 150 200 250 300

3.0

4.0

5.0

0 50 100 150 200 250 300

3.0

4.0

0 50 100 150 200 250 300

Cr

Mo

Nb+Ta

Al

Fe

10 20 30 40 50 60


Material Provider Comparison

0%

5%

10%

15%

20%

25%

Ultimate Tensile Strength (ksi)

Ultimate Strength Material Provider Comparison, Uts

0%

7%

14%

21%

28%

35%

Yield Strength (ksi)

Yield Strength Material Provider Comparison, Yts

Material Provider 1, n = 180

Material Provider 2, n = 30



0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0


Perc

ent

Str

eng

th (

ksi, M

si)

Tensile Property

Material Provider - Mechanical Property Comparison

Provider A Provider B



n = 180 n = 30




0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0


Perc

ent

Str

enth

(ksi, M

Si)

Tensile Property

Machine Comparison - Tensile Property Comparison

SI1849 SI1476 SI2001 SI2006

SI1848 SI1989 SI1991 - Sup. 1 SI1991 - Sup. 2




0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Str

ength

(ksI)

Times Recycled

Material Strength vs. Times Recycled, 2 machines




0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Str

ength

(ksI)

Times Recycled





0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 10 20 30 40 50 60 70

Str

ength

(ksI)

Times Recycled

Material Strength vs. Times Recycled, 6 machines , 2 atomizers


The different chemistries produced by different suppliers produced statistically different ultimate

tensile strength.

SupplierSupplier 1

(% by Weight)

Supplier 2 (% by Weight)

Al 0.32 0.14

Cr 21.02 21.54

Mo 9.2 9.1

Nb+Ta 3.66 3.73

Fe 0.04 3.90



Material Chemistry




0.0

0.5

0 50 100 150 200 250 300

Weig

ht (%

)

Powder Age (days)

IN625 Chemisrty SI1991 Sup. 1 SI1849 Sup 1 SI1991 Sup. 2 Limit

20.0

22.5

0 50 100 150 200 250 300

8.0

9.0

10.0

0 50 100 150 200 250 300

0.0

2.5

5.0

0 50 100 150 200 250 300

3.0

4.0

0 50 100 150 200 250 300

Cr

Mo

Nb+Ta

Al

Fe


Out of the 220 Bars, 2 Appeared “Different”

0 10 20 30 40 50 60 70

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

0 50 100 150 200 250 300

Times Recycled

Str

ength

(ksi)





Build 51334

Build 50814

BL

FL

FL

FR


Tensile Results Build 50814

0

10

20

30

40

50

60

70

80

0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70%

Str

ess (

ksI)

Strain (%)

50814-FR

50814-BL

50814-FL


Tensile Comparison, Build 51334 & 54747

0

10

20

30

40

50

60

70

80

90

0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70%

Str

ess (

ksi)

Strain (%)

51334-FR

51334-FL

51334-BL

54747-FL

54747-BL


Solution Heat Treated, HIP’ed, Stress Relieved, Additive IN625 (100x)

z

x

y

z

x

y

Stress Relieved, Additive IN625 (100x)

Metallographic Comparison, Build 51334 & 54747


SDM’s mission to control, track, and develop the AM production process has

lead to vertical integration of multiple post process operations and

inspection techniques providing the industry with

• The most efficient and economic powder management process.

• Decreased response time to process drift and potential defect parts.

• Increased confidence in DMLS material/part quality

• Separation from SDM’s competition.

• Increased customer confidence.

• Insight into powder lifecycle

Conclusion


AM Capabilities for Thermal Management


Next-generation thermal management demands:

• Increased performance with minimum pressure loss

• Reduced size and weight

• Affordable, modular, scalable

Part Consolidation

• Eliminate thermal resistance between components

• Reduce assembly time and weight

Tool-less, Digital Inventory

• Easily iterate through the design/build/test cycle

• Reduced lead times

• Simplified supply chain

WHY CHOOSE AM FOR THERMAL MANAGEMENT?


Design freedom enables increased performance

• Few tooling constraints

• Cost does not scale with complexity

• Nonlinear, tapered, optimized variable geometries

• Extended surfaces: fins, vanes, blades

• Heat pipe capillary wicking structures

• Conformal internal passages

• Thermal topology optimization

WHY CHOOSE AM FOR THERMAL MANAGEMENT?


Additive Applications


Known thermal management applications include:

• 3D modeling for concept validation

• Integral regenerative cooling of rocket engines

• Optimized wicking structures for passive heat pipes

• Microchannel and jet impingement strategies for

microelectronic device cooling

• Lattice structures for integral thermal shielding

• Conformal cooling for injection molds

• Thin-film cooling

• Pin-fin heat exchangers

ADDITIVE THERMAL MANAGEMENT APPLICATIONS


3D printing provides vibrant, informative models to:

• Serve as a “proof of concept”

• Conduct flow analysis

• Communicate business value

• Illustrate product enhancements

PROOF OF CONCEPT MODELS


• Phase II SBIR

• Manufacture advanced combustion liners with shaped film cooling holes for gas turbine engines

• Take advantage of complex internal passages and inlet/outlet geometry without post-machining

THIN-FILM COOLING


• An optimal process was developed with CTS to apply TBC to the effusion hole surfaces

• Successful adhesion and acceptable porosity in TBC layer

• Experimental testing at research institution

THERMAL BARRIER COATING


CHALLENGES AND FUTURE WORK


• Process capabilities

• Wall thickness and feature detail

• Surface finish

• Support design and removal

• Powder removal

• Limited material selection

• Metals: Various copper and aluminum alloys

• Plastics: Still under development

LIMITATIONS OF AM FOR HEAT EXCHANGERS


DESIGN CONSIDERATIONS: HORIZONTAL HOLES

1-

5mm0.05in - 0.19in

6-

9mm0.20in - 0.35inOver

9mm

0.36in

1-5 mm 6-9 mm Over 9 mm

0.05-0.19

in 0.20-0.35

in


DESIGN CONSIDERATIONS: TRAPPED SUPPORTS


• Lower limit bounded by laser spot size, ~100 μm or 0.004”

• Practical lower limits are defined by thermal stress

• Geometry and material dependent

• Warpage mitigated by support structure design

WALL THICKNESS


• Current materials: AlSi10Mg and C18150

• Thermal conductivity, specific heat, and mechanical properties similar to wrought

• Material availability driven by industry demand, gas atomizer capacity

• We are actively evaluating further Al and Cu alloy blend

• Further characterization of geometry capabilities on a per-material basis

MATERIALS


• Additive metal manufacturing empowers designers to

create the next generation of thermal management systems

for improved functionality

• Unparalleled geometric freedom without traditional tooling

constraints

• Reduce cost, lead-time, and assembly time

• Integration of multiple components into efficient,

modular, scalable systems

• Maintain digital inventories and iterate quickly

SUMMARY


THANK YOU

Andrew Carter

Process and Manufacturing Engineer

Stratasys Direct Manufacturing

Austin, TX

[email protected] | 512-655-5019

Management with a comprehensive IN625 Powder … - Claus.pdf · Management with a comprehensive ......

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