SANDVIK - SIEMENS ADDITIVE EVENT4-5 JUNE 2019 IN SANDVIKEN

DIFFERENT PRINTING TECHNOLOGIES FOR METALS

MIKAEL SCHUISKYVP R&D AND OPERATIONSSANDVIK ADDITIVE MANUFACTURING

THE 7 FAMILIES OF AMMETAL PROCESSES ARE UNDER DEVELOPMENT FOR ALL

2

1994EOS

EOSINT M160

1998 OPTOMEC

LENS

2016 (2007)XJET

CARMEL AM

1996EXTRUDE

HONE(EXONE) MIT 3DP

2011FABRISONIC

UAM

2018MARKFORGED

DESKTOP METALMETAL X/STUDIO

2018LITHOZ

HAMMER

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5/10/2019 5:30 PM

16,2%

4,1% 1,4% 0,0% 0,0%

52,7%

8,1%

0,0%

17,6%

0%

10%

20%

30%

40%

50%

60%

70%

Perc

ent

WHAT AM PROCESS TECHNOLOGIES DO YOU CONSIDER BEING RELEVANT FOR YOU?ACCODRING ADDITIVE NEXT PARTICIPANTS

TOP 3 AM PROCESSES:

1. PBF LASER2. BINDER JETTING3. PBF EBEAM

18/06/20194

Powder bed fusion maturity and challenges for future industrialisation

• Fibre laser source(s) focussed to a small spot on the top surface of the powder bed

• Galvanometer mirrors move the laser across the powder bed in a series of scan vectors

• Multiple lasers possible• Most widely used metal AM

technology: > 1,000 systems sold per year

5

POWDER BED FUSIONOVERVIEW

• High-value manufacturing−Heat exchangers & thermal

management−Difficult-to-process, expensive materials−Fluid transfer−Structural parts where weight is critical−Where extensive quality assurance is

acceptable−Customised or low / medium volumes

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POWDER BED FUSIONAPPLICATION MATURITY

• Mature applications−Aerospace−Turbo machinery−Healthcare−Tooling

STRENGTHS

• Full melting and solidification in one step− Density > 99.5% and often > 99.95%

• High strength and ductility possible –exceeding wrought properties

• No shrinkage

• No contamination from binders

• Heat treatment used to tailor properties− HIP commonly used to enhance ductility

and homogenise micro-structure7

POWDER BED FUSIONPROCESS CHARACTERISTICS

LIMITATIONS

• Residual stress can lead to distortion

• Surface roughness typically > 5 um Ra− Rougher surface on down-skins

• Limited range of materials

• Supports required to remove heat from overhang regions and resist residual stress

• Spatter formation and vaporisationleads to some process waste

• Care needed in powder handling to minimise oxidation

• Improve ratio of capital cost to output− Increase throughput – more kg/day

− Reduce technology costs – lower cost per W

• Reduced powder costs− Increased atomisation capacity and

yield

− Optimised re-cycling to minimisewaste

8

POWDER BED FUSIONINDUSTRIALISATION – LOWER PART COSTS

• Reduced running costs− Efficient use of factory floor

space

− Low power and gas consumption

• More automation− Faster, automated build

changeover

− Avoid excessive costs and machine footprint

• Increased process yield− Parameters tailored to suit local part geometry

− Multi-laser techniques to tailor micro-structure

• Reduced post-process QA− In-process monitoring to verify conformance and direct efficient NDT

• Better materials− New alloys designed to suit the process

− Tailored properties for the application combined with good ‘buildability’9

POWDER BED FUSIONINDUSTRIALISATION – HIGHER QUALITY

KRISTIAN EGEBERGADDITIVE BY SANDVIKPLAN IT – PRINT IT – PERFECT IT

MAGNUS BOSTRÖM, PhDSr R&D ENGINEERSANDVIK ADDITIVE MANUFACTURING

BINDER JETTING

THE BINDER JET PROCESS

IR

Powderfeed

Print head

Roller

T

GLUING PARTICLES TOGETHER

1

2

3

4

CURRENT STATUSIMMATURE COMPARED TO LASER

• Fundamentally faster printing speed than laser• No support structures necessary during printing• Two companies have printers on the market

• ExOne• Höganäs Digital Metal

• Three companies have announced upcoming releases• Desktop Metal• GE• HP• Other related technologies: Stratasys & 3DEO

• Very much MIM grade materials available• Few well characterized binder jetted materials

CHALLENGES

• Sinterability to high relative density• Grain size• Alloy dependent

• Sintering deformation – size limiting• Green body ~60% relative density

• Machine development• Need for new technology in the printers to keep speed with the

printheads – printheads get ~20% faster every year• Green body handling

• Automation – printing only the first step in a production line

TRENDS

• Binder development• Green body strength comparable to

Portland cement (~6 MPa three point bend test) a good goal

• Key to automation

• Higher printing speeds• Fundamentally much faster than

laser • However, at the end of the day,

what matters is cost per produced part after post processing with appropriate quality.

• Standard quality parts• Pores accepted – part of design• Tolerances on par with cast material• Low print and material cost per

component essential

• High quality parts – Niche products• Pore free• Tight tolerances• Closely controlled chemistry• Higher print cost per component

acceptable• E.g.

• Cemented carbide inserts• Aerospace

Manufacturer of DED Systems

DED is an AM process in whichfocused thermal energy is used tofuse materials by melting themas they are deposited. (ASTM F3187-16)BeAM’s deposition nozzle is mountedon the Z-Axis of a CNC machine. The nozzle is moved in 3 linear axis while the build platform has 2 rotational axis.15

DIRECTED ENERGY DEPOSITION

16

DIRECTED ENERGY DEPOSITION

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DIRECTED ENERGY DEPOSITION

Hybrid Technology

LBM

DED

LBM – Maraging steel – 22 total hoursDED – Inconel 625 - 3 total hoursBase of duct was built using LBMTop rings were added to base using DEDLBM Lattice structure reduces weightDED Increased wear resistance

Multi-material Hybrid High Performance Piston Head

SANDVIK - SIEMENS ADDITIVE EVENT4-5 JUNE 2019 IN SANDVIKEN

THANK YOU!