Sommersymposium 2018 am 28. Juni 2018 · Additive Manufacturing – Selective Laser Beam Melting...

Folie 1© Fraunhofer UMSICHT

Sommersymposium 2018am 28. Juni 2018

Gerhard WolfAbteilung Kreislaufwirtschaft

»Vernetzung von Kompetenzen in der Additiven Fertigung – Werkstoffe, Charakterisierung, Recycling«

»Cross-Linking Competencies in Additive Manufacturing – Materials, Characterization, Recycling«


Additive ManufacturingWhat means »Additive Manufacturing«?

Techniques for the manufacturing of parts directly from the construction drawing by the successivebuild-up of materials, better known under the name »3-D Printing«

A magnitude of technical variants exist on the base of

Direct printing (ink jet or filament)

Stereo lithography

Selective melting of powders

…

Source: CITIMPlastic molding tool



Technology examples

»Printer« for under 1.000 Euro up to industrial production systems for more than 500.000 Euro


Renkforce RF500 3D PrinterPlastics filaments from PLA, ABS, Polyamid (PA) …build space max. 210 mm x 135 mm x 170 mm

EOS M400 selective laser melting unitfor metals, 1 kW laser powerbuild space max. 400 mm x 400 mm x 400 mm Source: EOS GmbHSource: Conrad electronic SE




Technology examples

Industrial systems for metals mainly use powder bed based techniques

EOS M400 selective laser melting unitfor metals, 1 kW laser powerbuild space max. 400 mm x 400 mm x 400 mm Source: 3D SystemsSource: EOS GmbH


Additive ManufacturingWhat is specific for these technologies?

Extremely high degree in geometrical design

AM parts examples

Complex shapes and inner geometries which cannot produced via concurrent techniques Individually designed single parts (medical, jewelry, …) at lower costs (no tool manufacturing)

Source: 3D Systems Source: Arnd Sauter GmbH Source: Arnd Sauter GmbH



Direct manufacturing is performed

directly from the CAD data

in a layer-by-layer parts building technique

with unique and individual geometries (e.g. any desired innerstructures or person-specific adopted medical parts)

without the need of tool forms

with (nominally) no waste

Source: Fraunhofer IWS

Ressource efficient/sustainable

Predestinated for industry 4.0



Layer-by-layer manufacturing

Example: Powder bed based technique

Source: L.N. Carter et al.,J. Alloys and Compounds 615, 2014

Powder bed based selective laser beam melting (LBM)


Industrial powder bed based techniques

Size and quality restrictions

Limited availability of materials

Waste! Ressource efficient?

Additive ManufacturingWhat are the challenges?

Source: L.N. Carter et al.,J. Alloys and Compounds 615, 2014

Powder bed based selective laser beam melting (LBM)

parts residual loosepowder

Source: Buffalo Manufacturing Works/EWI


Additive Manufacturing – Selective Laser Beam MeltingWhere do we locate our competencies?

Relevant measures in the AM process chain

Werkstoff

Absorption der Laserstrahlung,

Wärmeleitfähigkeit,Schmelztemperatur,

Viskosität,Oberflächenspannung

Pulver

Partikelgrößenverteilung,Partikelform,

Oberflächenmorphologieund -chemie,

Mikrostruktur (Gefüge)

AM-Prozess / Bauteil

Pulverzufuhr / -auftrag,Schüttdichte,

Aufheiz-, Schmelz- und Erstarrungsverhalten,

Bauteilgefüge und -oberflächenqualität

MaterialsLaser energy absorption,

Heat conductivity,Melt temperature,

Viscosity,Surface tension

PowderParticle size distribution,

Particle shape,Surface morphology

and chemistry,Microstructure

AM process/partPowder supply,

Apparent density,Heating, melting and

solidification behaviour,Parts microstructureand surface quality

Parts quality andrange of applicationsfor industrial use


Additive Manufacturing – Selective Laser Beam MeltingWhere do we locate our competencies?

Long-term experience and specific facilities for metal powder manufacturing, materials development and recycling techniques

Powder manufacturing units with specific patented features

Gas and (reactive) hot gas atomization Rotating disc atomization

Innovative recycling technologies (e.g. iCycle)

Gas and hot gas atomizers

Engineering of production processes

Gas atomization

Molten particle jet

Rotating disk atomization

Coarse powder production

Made-to-measure powders

Gas atomized metal powder

Recycling technologies

iCycle process for mixed wastes


Additive Manufacturing – NetworksFraunhofer Alliance »Generative Fertigung«

Oberhausen

Dresden

Stuttgart

Freiburg

Magdeburg

Bremen

Berlin

Aachen

Darmstadt

Fertigungstechnik und Angewandte Materialforschung (IFAM)

Produktionsanlagen und Konstruktionstechnik (IPK)

Fabriktechnik und –automatisierung (IFF)

Keramische Technologien und Systeme (IKTS)Werkzeugmaschinen und Umformtechnik (IWU)Werkstoff- und Strahltechnik (IWS)

Umwelt-, Sicherheits-und Energietechnik (UMSICHT)

Produktionstechnologie (IPT)Lasertechnik (ILT)

Produktionstechnik und Automatisierung (IPA)Arbeitswirtschaft und Organisation (IAO)Grenzflächen- und Bioverfahrenstechnik (IGB)

Werkstoffmechanik (IWM)Kurzzeitdynamik, Ernst-Mach-Institut (EMI)

Graphische Datenverarbeitung (IGD)

BraunschweigSchicht-und Oberflächentechnik (IST)

AugsburgGießerei-, Composite- und Verarbeitungstechnik (IGCV)

Fraunhofer-Allianz Generative FertigungSprecher: Dr.-Ing. Bernhard MüllerGeschäftsstellec/o Fraunhofer IWU, Nöthnitzer Straße 44, 01187 Dresden (Germany)http://www.generativ.fraunhofer.de

Institutes or divisions of institutes with specificcompetencies cooperate in Fraunhofer allianciesin order to jointly work on, to promote and tomarket important technologies

http://www.generativ.fraunhofer.de/


Additive Manufacturing – NetworksFraunhofer Alliance »Generative Fertigung«

Main topics of Fraunhofer UMSICHT

Additive manufacturing with thermoplastics (focus in Oberhausen)

(Bio-)plastics and thermoplastic powders for AM Parts and process development for selective laser sintering processes (SLS)

Additive manufacturing with metals (focus in Sulzbach-Rosenberg)

Materials and powder manufacturing (metal alloys, thermoplastics) Recycling and re-use of aged powders and residues from powder bed based laser beam melting

(LBM, SLS) processesLight weight skateboard axisSimulation based development3-D printing technologies

Source: Fraunhofer Alliance»Additive Manufacturing«


Additive Manufacturing – NetworksAM network organized by OTH Amberg-Weiden

Regional network based on the initiative and under guidance of Prof. Blöchl (OTH Amberg)

Actors are predominantly industrial companies from the Oberpfalz area

SME and large size companies

Knowledge sharing and qualification of processes and parts

OTH initiative for the development of an universally usable test part

Fast and simple test method for measuring dimensional accuracy

Complete specification of position-dependent geometry parameters (drillings, bars, overhangs, …)

Source: Arnd Sauter GmbH


Additive Manufacturing – Selective Laser Beam MeltingResearch Activities and Networks at UMSICHT SuRo – BTHA-FV9

BTHA-FV9 – »New Materials for additive manufacturing«

Research cooperation with OTH Amberg (coordinator) and the universities of Pilsen and Ostrava

Intention: Materials related developments for AM parts

Investigations on the aging of powders during theAM process

Establishing new cross-border networks in theBavarian-Czech border area

Materials – Powders – Aging investigations – Recycling/Re-Use

AM-Process – Parts manufacturing and characterization – Simulation

Materials – Parts characterization – Corrosion and residual stress

Design – Parts testing and application – Simulation – Corrosion tests


Additive Manufacturing – Selective Laser Beam MeltingResearch Activities and Networks at UMSICHT SuRo – BTHA-FV9

BTHA-FV9 – »New Materials for additive manufacturing«

Research cooperation with OTH Amberg (coordinator) and the universities of Pilsen and Ostrava

Intention: Materials related developments for AM parts

Investigations on the aging of powders during theAM process

Establishing new cross-border networks in theBavarian-Czech border area

Role of Fraunhofer UMSICHT SuRo

Materials and powder related issues Aging and recycling/re-use investigations


Additive Manufacturing – Selective Laser Beam MeltingResearch Activities and Networks at UMSICHT SuRo – OpP3D

OpP3D – »Optimized powders for 3D printing«

Joint German-Belgian research cooperation

Enabling the processing of critical materialsby surface coating of powders

Copper

Aluminium alloys

funded via the AiF-IGF (project no. 161 EN) by the public service of Wallonia and by theGerman Ministry of Economics and Energy based on a decision of the German Bundestagas part of a transnational CORNET projecthttp://www.fem-online.de/en/content/OpP3D

http://www.fem-online.de/en/content/OpP3D



OpP3D – LBM of Copper parts

Werkstoff

Absorption der Laserstrahlung,

Wärmeleitfähigkeit,Schmelztemperatur,

Viskosität,Oberflächenspannung

Pulver

Partikelgrößenverteilung,Partikelform,

Oberflächenmorphologieund -chemie,

Mikrostruktur (Gefüge)

AM-Prozess / Bauteil

Pulverzufuhr / -auftrag,Schüttdichte,

Aufheiz-, Schmelz- und Erstarrungsverhalten,

Bauteilgefüge und -oberflächenqualität

MaterialsLaser energy absorption,

Heat conductivity,Melt temperature,

Viscosity,Surface tension

PowderParticle size distribution,

Particle shape,Surface morphology

and chemistry,Microstructure

AM process/partPowder supply,

Apparent density,Heating, melting and

solidification behaviour,Parts microstructureand surface quality

Parts quality andrange of applicationsfor industrial use




Low absorption of the laser light

High heat conductivity

Aggravating conditions for generating a stable melt bath and dense parts

C. Hoff et al., “Konditionierung von Kupferwerkstoffoberflächen zur Stabilisierung desDauerstrich-Lasermikroschweißens,” Metall, vol. 69, pp. 439–442, 2015.

>97 % laser light reflection




Solution 1:

Alloying of the pure copper powder

Pure copper (left) and CuNi3Si1 alloy from powderin the size range10-45 µm (right), porosity levels in %.

23.4 %

Parts built by fem,Forschungsinstitut für Edelmetalle und Metallchemie

3D test part

design

built by LBM

5.5 %

http://www.fem-online.de/de/content/additive-fertigung

http://www.fem-online.de/de/content/additive-fertigung


0

25

50

75

100

1 10 100

cum

ulat

ive

wei

ght

[%]

particle size d [µm]

2 - 15 µm

5 - 20 µm

5 - 25 µm

5 - 45 µm

10 - 45 µm



Solution 1:

Alloying of the pure copper powder

Solution 2:

with adjusted particle size range:10-45 µm 5.5 %, 10-25 µm 1.3 % porosity

Pure copper (left) and CuNi3Si1 alloy from powderin the size range10-25 µm (right), porosity levels in %.

1.3 %23.4 %





Low absorption of the laser light

High heat conductivity

Aggravating conditions for generating a stable melt bath and dense parts

Dramatic decrease of electricalconductivity already at low levels ofalloying elements

F. Pawlek and K. Reichel, Zeitschrift für Met., vol. 47, pp. 347–351, 1965(Download from Deutsches Kupferinstitut (accessed: 10-May-2018)https://www.kupferinstitut.de/de/werkstoffe/eigenschaften/niedriglegierte-kupferwerkstoffe.html

https://www.kupferinstitut.de/de/werkstoffe/eigenschaften/niedriglegierte-kupferwerkstoffe.html




Solution 3:

Coating of the powder particles forenhanced laser energy absorption Metallic (Materia Nova) Non-metallic (UMSICHT)

Pure copper (left) and < 100 nm Ti coated Cu powder(right), porosity levels in %.

23.4 % 3.5 %


Coatings developed byMateria Nova

Copper powderparticles coated with < 100 nm

copper sulfide and titanium coatings

Coatings developed byFraunhofer UMSICHT




Application:

Complexly shaped, miniature electrical inductioncoils (Unicorn Engineering GmbH: Intelligent solutions forelectrical energy storage systems)

Complexlyshaped coppercoil design

Parts built by fem,Forschungsinstitut für

Edelmetalle und MetallchemieDesigned byUnicorn Engineering GmbH

Miniature Cu alloyinductioncoilsmade by LBM


Additive Manufacturing – Selective Laser Beam MeltingResearch Activities and Networks at UMSICHT SuRo – 3D Cover

3D Cover – »Metallic Materials in the process chain of additive manufacturing«

Research cooperation with COMTES FHT a.s.Dobřany (coordinator)and OTH Amberg

Intention: Improving AM process chain and parts by materials and powder development for AM, focused on Aluminium alloys steels

AM process development for new materials and fine powders application and investigation of specific micro-characterization

methods (mechanical, structural)

process related simulation of microstructure and stress evolution residual stress and corrosion investigations, specific surface treatments

enhanced mechanical properties, surface qualities and corrosion resistance


Additive Manufacturing – Selective Laser Beam MeltingResearch Activities and Networks at UMSICHT SuRo – Perspective

Further profile raising by using and extending the presentexpertise and equipment in the direction to AM

Priority topics

Powder development

Recycling and re-use

Utilization of the present cooperations and networks andof the strategic developments within the UMSICHT sitesand the Fraunhofer group

Consequent continuation and marketing of successfuldevelopments with key customers

OberhausenUmwelt-, Sicherheits-und Energietechnik (UMSICHT)

Sulzbach-RosenbergInstitutsteil UMSICHT SuRo

Materials developmentProcesses

RecyclingMaterials development

Processes

Materials developmentProcessesRecycling

Sommersymposium 2018 am 28. Juni 2018 · Additive Manufacturing – Selective Laser Beam Melting...

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