Working with metals in 3D printing

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Metals in Additive Manufacturing

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q  This webinar will be available afterwards at www.designworldonline.com & email

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Before We Start

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Leslie Langnau Managing Editor

Design World

Maximilion Eils Application Development

Consultant Electro Optical Systems

Robert Chiari Regional Sales Manager

Renishaw, Inc.

Metals in Additive Manufacturing Meet your speakers

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Metals Additive Manufacturing

A Renishaw Perspective

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Overview > Benefits of AM > Industries > Materials > Design for Process – Two Case Studies

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Benefits of AM > Freedom of design > Light-weighting of parts; less material, integrated lattice structure > Lower high cost of tooling, and additional re-tooling costs when design changes are required > Significant reduction in tooling lead times

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Benefits of AM (continued) > Faciliates design changes

- more iterations = better products - shorten design cycle = faster to market - less ECO’s and recalls = high quality brand recognition

- all lead to higher profitability

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Benefits of AM (continued) > Supports JITM (Just-In-Time Manufacturing) Methodology

- minimal stocking and handling - reduce warehousing square footage requirements - less capital tied up in inventory > Low to mid-volume production

- 1 off custom design, 100’s, 1000’s, 10,000’s

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Industries > Aerospace – commercial, custom jet, military, MRO > Automotive – Motorsports Racing > Medical – Devices, Implants, Maxillofacial, Dental > Consumer Products – Electronics, Toys, Footwear, Jewelry > Conventional Manufacturing Processes – jigs, fixture, tooling

- Inserts for injection molding tooling, with integrated conformal cooling

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Materials > Renishaw platform is a Fiber Laser based system, commonly referred to as powder bed fusion > LM – Laser Melting process produces full melt of powder layer to layer resulting in fully dense metal parts > Typical properties range between that of a cast part and a forged part > Only Renishaw offers a True Open Architecture platform

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Materials (continued)

For a complete list of available materials and mechanical properties please visit our website www.Renishaw.com

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Materials (continued) > Secondary processes:

- Heat treating - Peening - HIPing

All of the above will further enhance the material properties of AM produced parts

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Thank you!

For more information please visit www.renishaw.com

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Industrial 3D printing EOS North America

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Content •  Introduction into 3D-printing •  Paradigm shift from rapid prototyping to serial production •  Benefits of 3D printing: Freedom of design and freedom of

production •  Example Case Studies •  Metal process characteristics and design constrains •  Metal material properties: Example MS1

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§  Processofmakingathree-dimensionalobjectdirectlyfroma3DCADmodel

§  Partisproducedlayerbylayer

§  Dependingonpartrequirements,differentpost-processescanbeapplied

§ WithinAMtherearedifferenttechnologieswithdifferentprocessmethods,produc=vityandqualitylevels

2.JobPrepara@on(STL/STI/JZData)

1.Design(CADData)

3.Produc@on

FinalPart

4.Finishing

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DirectedEnergyDeposi@on

Process:§  Laserbeamfusesselectedareasofapowderbed

Markets:§  RapidPrototyping,serialproduc=on

Advantages:§  Highmechanicalproper=es§  Highdetailresolu=onDisadvantages:§  Limitedbuildspace§  Highcost

Laserbeam

ScannerLaserSource

PowderRecoater

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Prototyping

§  Plas=candmetalprototypes§  Func=onalandnonfunc=onal§  Onlysmalldesignadjustments

SerialProduc@on

Volumes

Requirements

Applica@onfields

§  Smallvolumesupto100partsperyear

§  Highflexibility(''oneofakind'')§  Fastturnover=me§  Focusonsurfacestructure§  Similar(butnotiden=cal)parts

§  Plas=candmetalcomponents§  DesignOp=miza=onandintegra=onoffeatures(e.g.laVce)

§  Serialproduc=onwithvolumesofupto100.000partsperyear

§  100%Quality,repeatable§  Produc=vityincrease§  Highdegreeofautoma=on§  Integratedintomanufacturingchain

RapidPrototyping Serial

Produc=on

VS

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Tradi@onalManufacturing

Addi@veManufacturing

Addi@veManufacturing1

4

2

3

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Complexityadvantage

AM

Volume

€/Unit


ComplexityofDesign

€/Unit

AM


Volumeadvantage

Strongcostadvantageforsmallvolumeproduc=on

Strongcostadvantageforcomplexcomponents

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Func@onalIntegra@on

Custo-miza@on

ComplexGeometries

Customizedproducts

Integratedandcomplexfunc@ons

Lightweightstructures

Newandcomplexdesigns

Pa@entspecificrestora@ons

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1)Comparedtolastseasonswheelsuspensionsmanufacturedwithinvestmentcas=ngSource:RennteamUniStu^gart,Within,EOS

WheelsuspensionApplica@on§  Extremelightands=ffwheelsuspension§  Topologyop=mized&customizeddesign

§  Incoopera=onwithWithinsoaware

Productdetails§  Weight: Front435g/Rear390g§  Max.forces:ca.100MPa§  Material: Aluminum

Advantages§  Weightsavings22%(front),35%(rear)1)

§  Increaseds=ffnessof20%§  Fastproduc=onandhighaccuracy

Examplelightweight

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CableBracketComponents Assembled&InstalledCableBracket

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CableBracketSitua@on/Challenges§  Secondarystructuredesignwithhigh

weightandsignificantcomplexity§  Unacceptablyhighproduc=onlead=me§  AMre-designandmanufacturingwithin2

weeksSolu@on§  Dedicatedop=miza=ontosaveweight§  Re-designconsideringAMconstraints§  Jus=fica=onaccordingtocustomer’s

standardsBenefits/Results§  Establishmentofanintegralpart.§  Weightsavingsofmorethan30%§  Reduc=onofproduc=onlead=meand

costs

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FlexibleProduc@onVolume

FlexibleProduc@onLoca@on

FlexibleProduc@on

Time

“Fromonetomany”

“Fromlocaltoglobal”

…ondemand”

“Smallandeconomic

produc@onruns”

“Fromjust-in-@meto…

$

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AMDesignConstraints

Thedifferentaspectsofproper=esmustbeconsideredandponderedinordertoimprovethecharacterproper=es.Theresultaremeasuresformeaningfulorienta=on.

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Buildability:Angletorecoater

recoater

x

y

z

Duringrecoa=ng,therecoaterbladeintroducesforcesintotheSupportwhenitaccidentallygetsincontactwith:•  Bulgedareasduetointernalstress•  Clumpsandsplashesofuninten=onally

sinteredpowder

x

z

yx

Plakorm

recoater

x

z

yx

Makesurethatthepartwillnotgrowtowardstherecoaterandthatnosharpedgesareorientatedtowardstherecoater.

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Buildability:Changeofcrosssec@on

The heat buildup when crea=ng parts canaffect the geometry. If not controlled andan=cipateditcancause:§  Stress§  Distor=on§  Cracking§  Delamina=on

Assureaslowgradualchangeinsec=oninz-direc=on

Thermalgradient

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Cost:Build@me

Thelargerthez-heightofthepart,thelongertheen=rebuildprocesslasts.Thisisduetotheincreasednumberofrecoaterpassesneededtoa^ainthedesiredheight.

Minimizethemaximumz-heightofthepartonthebuildplakormtoreducebuild=me

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Cost:Powderamount

Theorienta=onofthepartwillgreatlydeterminetheamountofsuppor=ngmaterialneededforsuccessfulmanufacturing.SupportStructuresarewasterightaaerthebuildprocessandaconsiderablecost-driver

Reducedownward-facingareasforlessaddi=onalSupportStructures

SupportStructures

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Cost:Suitabilityfornes@ng

Tomakeuseofthefullcapacityofthebuildplakormnestpartsasdenseaspossible.ButspacemustbeleaforSupport,wherenecessary

Inthecasethatapartshallbeproducedinhigherquan==es,theimportanceofnes=ngbecomesobvious:§  Buildmorepartsinonego§  Saveset-upcostsBeforenes=ngpartstogether,makesuretheprocessisfullycontrolledtopreventexpensivejobcrashes

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Quality:DimensionalAccuracy

The heat buildup when crea=ng parts canaffect the geometry. If not controlled andan=cipateditcancause:§  Stress§  Distor=on§  Cracking§  Delamina=on

Assureaslowgradualchangeinsec=oninz-direc=on

Thermalgradient

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Quality:SurfaceRoughness

Reducedownward-facingareastoavoidsurfacedegrada=onbySupport

Preferesteepwallstominimizethenega=veeffectsofthestaircaseeffect

Formerlysupportedareaseitherhavepoorsurfacequalityorrequireaddi=onalpost-processing.

SurfaceaaerremovalofBlockSupport

Slicingoccursalongthever=calaxis.Therefore,thevaria=onsofthepartalongthisaxiswilldictatethelevelofaccuracyor“stepping”thatwilloccur.

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Material Group Brand name Material type Typical applications

Maraging Steel EOS MaragingSteel MS1 18 Mar 300 / 1.2709 Injection moulding series tooling; engineering parts

Stainless Steel

EOS StainlessSteel GP1 Stainless steel 17-4 / 1.4542

Functional prototypes and series parts; engineering and medical

EOS StainlessSteel PH1 Hardenable stainless 15-5 / 1.4540

Functional prototypes and series parts; engineering and medical

EOS StainlessSteel 316L Stainless steel 1.4404

Functional prototypes and series parts; lifestyle, aerospace, medical

Nickel Alloy

EOS NickelAlloy IN718 Inconel™ 718, UNS N07718, AMS 5662, W.Nr 2.4668 etc.

Functional prototypes and series parts; high temperature turbine parts etc.

EOS NickelAlloy IN625 Inconel™ 625, UNS N06625, AMS 5666F, W.Nr 2.4856 etc.

Functional prototypes and series parts; high temperature turbine parts etc.

EOS NickelAlloy HX UNS N06002 Severe thermal conditions and high risk of oxidation, e.g. combustion chambers,

Cobalt ChromeEOS CobaltChrome MP1 CoCrMo superalloy,

UNS R31538, ASTM F75 etc. Functional prototypes and series parts; engineering, medical, dental

EOS CobaltChrome SP2 CoCrMo superalloy Dental restorations (series production)

TitaniumEOS Titanium Ti64 Ti6Al4V light alloy Functional prototypes and series parts;

aerospace, motor sport etc.

EOS Titanium Ti64ELI Ti6Al4V ELI (grade 23) Medical Implants

Aluminium EOS Aluminium AlSi10Mg AlSi10Mg light alloy Functional prototypes and series parts; engineering, automotive etc.

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Orvar supreme (1.2344) Stavax (1.2083) 1.2343 (H13) 1.2709 (MS1)

Yield strength (Rp 0.2 %) [Mpa]

1250 1290 1400 1930

Tensile strength [] 1400 1780 1600 2050

Elongation at break [%] 13 na 3-5 4-6

Modulus of elasticity [GPa]

210 210 215 200

Hardness [HRC] 52-54 48-52 52-54 52-54

Density[Kg/dm3] 7,8 7,74 7,8 8,0

Coefficient of thermal expansion [m/mK]

12,6x10-6

11x10-6

11,3x10-6

10,3x10-6

Corrosion resistance yes yes no yes

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Thank You

Questions?

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Leslie Langnau Managing Editor Design World [email protected]

Maximilion Eils Application Development Consultant Electro Optical Systems [email protected]

Robert Chiari Regional Sales Manager Renishaw, Inc. [email protected]

Metals in Additive Manufacturing Questions?

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Thank You q  This webinar will be available at

designworldonline.com & email

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Working with metals in 3D printing

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