d1 2 materials datasheets 8 10.pdf

Materials datasheets

(Ti6Al4V, ASTM F75 Cobalt

Chrome, CL20, CL50, DSM

Somos 18420, DSM Somos

Next, PA 2200 and

PA3200)

DL 1.2

FP7-SME-2008-2

GRANT AGREEMENT No

243631

KARMA DL 1.2

2/40

Table of contents.

1. GENERAL INTRODUCTION .............................. ........................ 5

2. LASER CUSING ...................................... .................................. 6

2.1. CL 20 (316L) ...................................... ................................................... 6

2.1.1. General characteristics ................................................................. 6

2.1.2. Applications................................................................................... 6

2.1.2.1 Powder specification ......................................................................... 6

2.1.2.2 Physical and chemical properties ..................................................... 7

2.1.2.3 Stability and reactivity ....................................................................... 7

2.1.3. Chemical specification .................................................................. 7

2.1.4. Mechanical properties ................................................................... 8

2.1.5. Post processing ............................................................................ 8

2.1.6. Safety measures ........................................................................... 8

2.1.6.1 Hazard identification ......................................................................... 8

2.1.6.2 First aid measures ............................................................................ 8

2.1.6.3 Fire-fighting measures ...................................................................... 8

2.2. CL 50/60WS (Hot Work Steel) ....................... ...................................... 9

2.2.1. General characteristics ................................................................. 9

2.2.2. Applications................................................................................... 9

2.2.3. Powder specification ..................................................................... 9

2.2.3.1 Physical and chemical properties ................................................... 10

2.2.4. Chemical specification ................................................................ 11

2.2.5. Mechanical properties ................................................................. 11

2.2.6. Post processing .......................................................................... 11

2.2.7. Safety measures ......................................................................... 12

2.2.7.1 Hazard identification ....................................................................... 12

2.2.7.2 First aid measures .......................................................................... 13

2.2.7.3 Fire-fighting measures .................................................................... 13

2.3. Bibliography ...................................... ................................................. 13

3. ELECTRON BEAM MELTING (EBM ®) .................................... 14

3.1. Ti6Al4V ELI - EBM ® Titanium Alloy.................................... ............... 14

3.1.1. General characteristics ............................................................... 14

3.1.2. Applications................................................................................. 14

3.1.3. Powder specification ................................................................... 14


3.1.3.2 Stability and reactivity ..................................................................... 15



3.1.6. Post processing .......................................................................... 17

3.1.7. Safety measures ......................................................................... 17

3.1.7.1 CAS Registration ............................................................................ 18


3.1.7.3 First aid measures and accident prevention.................................... 19


3.2. CoCr - EBM® Alloy ................................. ........................................... 20


3.2.2. Applications................................................................................. 20

KARMA DL 1.2

3/40

3.2.3. Powder specification ................................................................... 21




3.2.6. Post processing .......................................................................... 24

3.2.7. Safety measures ......................................................................... 24

3.2.7.1 CAS Registration ............................................................................ 24


3.2.7.3 First aid measures and accident prevention.................................... 25


3.3. Bibliography ...................................... ................................................. 26

4. STEREOLITHOGRAPHY ................................. ........................ 27

4.1. ProtoGen™ 18420 ................................... ........................................... 27


4.1.2. Applications................................................................................. 27

4.1.3. Liquid properties ......................................................................... 27

4.1.4. Optical properties ........................................................................ 27


4.1.6. Thermal properties ...................................................................... 28

4.1.7. Post processing .......................................................................... 28

4.1.8. Safety measures ......................................................................... 29




4.2. Somos ® NeXt ..................................................................................... 30


4.2.2. Applications................................................................................. 30

4.2.3. Liquid properties ......................................................................... 31

4.2.4. Optical properties ........................................................................ 31



4.2.7. Post processing .......................................................................... 32

4.2.8. Safety measures ......................................................................... 32




4.3. Bibliography ...................................... ................................................. 33

5. SELECTIVE LASER SINTERING ......................... ................... 34

5.1. PA2200 ................................................................................................ 34


5.1.2. Applications................................................................................. 34

5.1.3. Powder properties ....................................................................... 34



5.1.6. Post processing .......................................................................... 36

5.1.7. Safety measures ......................................................................... 36



KARMA DL 1.2

4/40


5.2. PA3200 GF (PA12 20-30%fv) ......................... .................................... 37


5.2.2. Applications................................................................................. 37

5.2.3. Powder properties ....................................................................... 37



5.2.6. Post processing .......................................................................... 39

5.2.7. Safety measures ......................................................................... 39




5.3. Bibliography ...................................... ................................................. 40

KARMA DL 1.2

5/40

1. General Introduction

According to the work plan and proposal of KARMA, the most relevant technologies of additive fabrication are studied. The idea of KARMA, among other purposes, is to offer the necessary background information on the most used additive technologies to the end user. Data related to these technologies will be stored in a KBE database to help the end user choose the most appropriate combination of machine-material-build parameters for his/her product. Also, after mechanical testing, the processed material for all these technologies will be characterized mechanically and thermally. All these data will also be available in the KBE database.

Present document provides a general overview of the properties of the materials used in these technologies, namely the Laser Cusing, Electron Beam Melting, Stereolithography and Selective Laser Sintering. For each of the materials its general characteristics, major properties, application areas and post-processing used after manufacturing with this material are outlined. Special chapters provide the information on the hazards one should understand and safety measures one should take when working with these materials. For each of the materials references to the sources of information are presented in a separate chapter.

This document is a part of the deliverables package providing the information about the materials that would be stored in the database. Present document is introductory and provides general overview of the issues related to the materials used in the four technologies listed above. Its purpose is in providing the reader with initial information, facilitating better understanding and assessment of the technologies and supplying certain references for further reading. It is not intended for in-depth studies of the technologies involved. In cases when deeper understanding of technologies and processes is needed, one should consult the documents provided by the developers of the technologies and manufacturers of the corresponding equipment.

KARMA DL 1.2

6/40

2. Laser Cusing

2.1. CL 20 (316L)

2.1.1. General characteristics

CL 20 is a powder material for the production of acid- and corrosion resistant parts or components for pre-production moulds. It is corresponding to the stainless steel 316L standards.

2.1.2. Applications

Due to a significant content of Molybdenum, 316L material is resistant to corrosion particularly in the atmospheres chemically aggressive outlet gases or salty environment. Therefore, typical applications include:

• Food preparation equipment particularly in chloride environments;

• Pharmaceuticals;

• Marine applications;

• Architectural applications;

• Medical implants, including pins, screws and orthopaedic implants like total hip and knee replacements;

• Fasteners.

2.1.2.1 Powder specification

CL 20 powder has a Gaussian distribution of spherical form particles, ranging from 25 to 53 µm.

KARMA DL 1.2

7/40

Figure 1. Powder particle size distribution.

2.1.2.2 Physical and chemical properties

The basic physical properties are shown in the following table.

Form powder

Viscosity not applicable

Colour grey

Solubility in water insoluble

Odour odourless

Bulk density (g/cm3) 4-6

Table 1. Physical properties of CL 20 powder.

2.1.2.3 Stability and reactivity

Conditions to be avoided nothing specified

Substances to be avoided Aldehyde, Nitrate, oxidizing agents, halogens, acids

Hazardous decomposition products

nothing specified

Table 2. Stability of CL 20 powder.

2.1.3. Chemical specification

CL20 is a 316L-like Stainless Steel based in Iron, Nickel, Chromium and Molybdenum. The chemical specification of CL 20 is shown in the following table.

Component % (source:

CL) % (source: independent)

316L norm

Carbon 0,015 0,03 <0,03 Sulphur 0,007 0,01 <0,03 Silicium 0,7 0,78 <1 Manganese 0,54 0,83 <2 Nickel 11,55 11,42 10-14 Copper 0,029 - - Chromium 16,53 17,72 16-18 Molybdenum 2 2,64 2-3 Vanadium 0,06 - - Cobalt 0,062 - -


KARMA DL 1.2

8/40

2.1.4. Mechanical properties

The following table brings the nominal properties of CL 20 powder provided by the technology fabricant.

yield point Rp 0,2 [N/mm2] 470 tensile strength Rm [N/mm2] 570 Hardness [HRC] 20 E-modulus [N/m m2] at 20°C - Elongation [%] >30 Thermal contuctivity [W/mK] at 20°C 15


2.1.5. Post processing

Apart from usual surface finishing and polishing, no special heat treatment is recommended for CL 20 parts.

2.1.6. Safety measures

2.1.6.1 Hazard identification

Hazard designation Xn Injurious to health

Hazards for humans and environment

R 40 Suspicion on carcinogenic effect (Cat. III).

R 43 Sensitization by skin contact possible.

Water hazards Generally not hazardous for water

Table 5. Hazard identification CL20.

2.1.6.2 First aid measures

After eye contact rinse out with plenty of water. If pain persists, call in ophtalmologist.

After skin contact wash off with plenty of water. Remove contamined clothing.

After swallowing caution if victim vomits. Risk of aspiration! Call in physician.

After inhalation fresh air. Call in physician.

Table 6. First aid measures CL20.

2.1.6.3 Fire-fighting measures

Suitable extinguishing media

metal fire powder. Cover with dry sand.

KARMA DL 1.2

9/40

Unsuitable extinguishing media

CO2, Water, foam, powder.

Special risks not known.

Special protective equipment for fire fighting

not known.

Table 7. Fire-fighting measures CL20.

2.2. CL 50/60WS (Hot Work Steel)


CL 50/60WS is a powder material for the production of components as well as tool components of production moulds for plastics.

2.2.2. Applications

Parts made of CL 50/60WS steel are characterized with high hardness and wear resistance after tempering. This fact qualifies CL 50/60WS for applications in any field that demands these characteristics such as injection moulds for plastics and for pressure die casting.

2.2.3. Powder specification

CL 50/60WS powder has a Gaussian distribution of spherical form particles, ranging for 25 to 53 µm.

Figure 2. Powder particle size distribution.

KARMA DL 1.2

10/40


The basic physical properties are shown in the following table.

Form powder


Colour grey


Odour odourless

Bulk density (g/cm3) 4-6

Table 8. Physical properties of CL 20 powder.

KARMA DL 1.2

11/40


CL50/60WS is hot-work steel based in Iron, Nickel, Cobalt and Molybdenum. The chemical specification of CL 50/60WS is shown in the following table and corresponds to 1.2709 standard.

Component % (source:

AIMME) % (source:

independent) 1.2709 norm

Carbon 0,036 0,019 <0,03 Sulphur 0,020 0,0081 <0,01 Silicium 0,087 0,223 <0,1 Manganese 0,041 0,041 <0,15 Nickel >6,60 17,69 17-19 Copper 0.073 - - Chromium 0,150 0,195 0,25 Molybdenum >2,88 4,70 4,5-5,2 Vanadium 0,020 - - Cobalt >2,52 9,23 8,50-10

Table 9. CL 50/60WS composition.


The following table brings the nominal properties of CL 50/60WS powder provided by the technology fabricant.

untempered Tempered

@ 490ºC Tempered @ 540ºC

Yield point Rp 0,2 [N/mm2] 950 1.800 1.550 Tensile strength Rm [N/mm2] 1.100 1.900 1.650 Hardness [HRC] 35-40 54 48 E-modulus [N/mm2] at 20°C 140 160 160 Elongation [%] 4,0 >2-3 >2-3 Thermal contuctivity [W/mK] at 20°C 14 14 14

Table 10. Nominal mechanical properties of CL 50/60WS.


The alloying elements favour the formation of a fully martensitic microstructure. Hardening to the operational condition is performed by an easy, single stage, heat treatment process at 490°C for 6 hours + 1 hour for every 10mm workpi ece thickness. No vacuum or special atmosphere is needed in the furnace. Because 1.2709/UHF3 is not austenized and quenched as the traditional chromium hot work tool steels, distortion is minimal. After EDM’ing on an already heat treated part, heat treatment for 3 hours again is recommended to get the same surface hardness as the bulk material.

KARMA DL 1.2

12/40

The recommended heat treatment for the parts fabricated of CL 50/60WS can be, though, described through the following steps:

1. heat up 50°C/h

2. keep 8 hours (6-10 hours; depends on the building part´s size) at 490°C (or 540°C)

3. cool down 50°C/h

Figure 3. Heat treatment cycle.

After the heat treatment the mechanical resistance increases 60-90%, while the hardness experiments an increase of 35-50%.



Hazard designation Xn Injurious to health


R 40 Suspicion on carcinogenic effect (Cat. III).

R 43 Sensitization by skin contact possible.

Water hazards Generally not hazardous for water

Table 11. Hazard identification CL20.

KARMA DL 1.2

13/40


After eye contact rinse out with plenty of water. If pain persists, call in ophthalmologist.

After skin contact wash off with plenty of water. Remove contamined clothing.

After swallowing caution if victim vomits. Risk of aspiration! Call in physician.

After inhalation fresh air. Call in physician.

Table 12. First aid measures CL20.



metal fire powder. Cover with dry sand.


CO2, Water, foam, powder.

Special risks not known.


not known.

Table 13. Fire-fighting measures CL20.

2.3. Bibliography

• Material Safety Data Sheet CL 20ES, Concept Laser, 2009

• Material Safety Data Sheet CL 50/60WS, Concept Laser, 2009

• Concept Laser materials, overview of characteristics, 2008

• AIMME inform on chemical composition of CL20, CL50/60WS and CL91WS, 09-09-2008

KARMA DL 1.2

14/40

3. Electron Beam Melting (EBM ®)

3.1. Ti6Al4V ELI - EBM ® Titanium Alloy


Ti6Al4V ELI - EBM® is a powder material for the production of corrosion resistant low weight high strength parts or components with Electron Beam Melting (EBM®). It is similar to the Ti6Al4V alloy but has lower oxygen, nitrogen, carbon and iron content that makes it better suitable for the biomedical applications. Designator ELI in the alloy name stays for “Extra Low Interstitials”.

3.1.2. Applications

The high strength, low weight ratio and outstanding corrosion resistance inherent to titanium and its alloys has led to a wide and diversified range of successful applications which demand high levels of reliable performance. Typical applications include:

• Biomedical applications and surgery, in particular

o Medical implants, including pins, screws and orthopaedic implants like total hip and knee replacements;

• Aerospace industry;

• Automotive industry, in particular:

o Components to high performance vehicles;

• Chemical and petrochemical industry;

• Oil and gas extraction and production;

• Power generation;

• Sports and adventure technologies;

• Military applications.


Silver- grey, odourless powder.

In the EBM® Process Ti6Al4V ELI supplied by ARCAM AB is used (designator Ti6Al4V ELI - EBM®). Ti6Al4V ELI powder is in general much more suitable for biomedical applications as compared to TiAl4V. Following specifications compare the manufacturer specification for Ti6Al4V ELI - EBM® with the requirements for Ti6Al4V ELI according to ASTM F136.

Ti6Al4V ELI - EBM® powder has a Gaussian distribution of regular-shaped particles with average particle size of ca 75 µ.

KARMA DL 1.2

15/40

Figure 4. Powder particle size distribution for Ti6Al4V ELI - EBM®.


The basic physical properties of the powder are shown in the following table.

Form powder


Colour grey or silver-grey


Odour odourless

Apparent density (g/cm3) 2.5*

Specific density (g/cm3) 4.4

* Typical value quoted by the manufacturer

Table 14. Physical properties of Ti6Al4V ELI - EBM® powder.

3.1.3.2 Stability and reactivity

Conditions to be avoided

nothing specified

Substances to be avoided

Oxidizing agents, strong acids

Hazardous decomposition products

nothing specified

Table 15. Stability of Ti6Al4V ELI - EBM® powder.

KARMA DL 1.2

16/40


Ti6Al4V is one of the most widely used Titanium alloys. The chemical specification of Ti6Al4V ELI - EBM® is shown in the following table in comparison with the TiAl4V ELI composition required by the ASTMF136 standard.

Component TiAl4V ELI - EBM® *,

% ASTMF136 required,%

Aluminum, Al 6.0 5.5-6.5 Vanadium, V 4.0 3.5-4.5 Carbon, C 0,03 <0.08 Iron, Fe 0,1 <0.25 Oxygen, O 0.10 <0.13 Nitrogen, N 0,01 <0.05 Hidrogen, H <0.003 <0.012 Titanium, Ti balance to 100 balance to 100

*Typical properties quoted by the manufacturer;

Table 16. The chemical composition of Ti6Al4V ELI and Ti6Al4V ELI - EBM®


Generally, the mechanical properties of materials produced in the EBM® process are comparable to wrought annealed materials and are better than cast materials. In the following table mechanical properties of the Ti6Al4V ELI - EBM® are shown in comparison with the requirements by the ASTMF136 standard.

TiAl4V ELI - EBM® * ASTMF136 required

Yield Strength (Rp 0.2) 930 MPa 795 MPa Ultimate Tensile Strength (Rm) 970 MPa 860 MPa Rockwell Hardness 32 HRC 30-35 HRC Elongation 16% >10% Reduc tion of Area 50% >25% Fatigue Strength @ 600 MPa >10,000,000 cycles >1,000,000 cycles Modulus of Elasticity 120 GPa 114 GPa

*Typical properties quoted by the manufacturer; Table 17. Mechanical properties of Ti6Al4V ELI and Ti6Al4V ELI - EBM®.

KARMA DL 1.2

17/40

Figure 5. Typical results of the Ti6Al4V ELI - EBM® Rotation Beam Fatigue Test provided by the manufacturer.


1.1.6.1 Heat treatment

Hot Isostatic Pressing (HIP) is recommended for fatigue-loaded components.

The following HIP parameters are recommended:

� 920° C

� 1000 bar

� 120 minutes

1.1.6.2 Machining

Ti6Al4V ELI - EBM® parts manufactured by Electron Beam Melting feature good machinability and can be machined without additional operations.

1.1.6.3 Welding

Ti6Al4V ELI - EBM® may be welded by a wide variety of conventional fusion and solid-state processes, although its chemical reactivity typically requires special measures and procedures.


Hazard symbol: F

KARMA DL 1.2

18/40

3.1.7.1 CAS Registration

CAS Registration number: multiple, see below

Active ingredients:

Titanium, CAS # 7440-32-6

Aluminum, CAS # 7429-90-5

Vanadium, CAS# 7440-62-2


Not a hazardous product according to Directive 67/548 EEC.

Explosion and fire risks Though Ti6Al4V - EBM® powder passes static discharge ignition tests, limited possibility of fire and explosion remains if fine fractions of the powder are suspended in the air at high concentration.


For humans: Inhalation of powder:

Ti exposure limits for humans - 10 mg/m3

Al exposure limits for humans - 10 mg/m3

V exposure limits for humans – 0.5 mg/m3

May cause skin irritation.

May cause eye irritation.

Lifting heavy loads- powder transportation and storage containers.

Environment: water Generally not hazardous for water

Table 18. Hazard identification for Ti6Al4V ELI - EBM®.

KARMA DL 1.2

19/40

3.1.7.3 First aid measures and accident prevention

Human hazard: After eye contact

rinse out with plenty of water. If pain persists, call in ophtalmologist.

Human hazard: After skin contact

wash off with plenty of water. Remove contaminated clothing.

Human hazard: After swallowing

caution if victim vomits. Risk of aspiration! Call in physician.

Human hazard: After inhalation

fresh air. Call in physician.

Human hazard: Preventive measures

Keep powder in the sealed containers;

Wear respirator (face mask) and protection gloves to avoid powder inhalation and skin contact;

Use fork lift and dedicated loading trolley to handle powder containers.

Accidental powder release: measures

Immediately clean up powder spillage;

Use only explosion protected vacuum cleaners;

Do not use ordinary vacuum cleaners.

Table 19. First aid measures for Ti6Al4V ELI - EBM®.

KARMA DL 1.2

20/40


Suitable extinguishing media: metal fire

Cover with dry sand, use special fire extinguisher rated for metal fire (dry powder type).


Water, foam, CO2.

Special risks Small risks of potential explosion if suspended in the air.


not known.

Preventive measures Avoid significant powder spills;

Use dedicated Powder Recovery System (PRS);


Use proper grounding (body and equipment) preventing static discharge.

Table 20. Fire-fighting measures for Ti6Al4V ELI - EBM®.

3.2. CoCr - EBM® Alloy


CoCr – EBM® alloy complies with the ASTM F75 standard for CoCrMo alloys. It is a non-magnetic powder material for the production of components for the applications where the stiffness and highly polished and extremely wear-resistant surface is required.

3.2.2. Applications

Parts made of the CoCr – EBM® alloy are characterized with high hardness and wear resistance. While the majority of investment castings made from the cobalt super alloys are cast in an open atmosphere, Electron Beam Melting processing is done at vacuum providing a controlled environment and enabling superior material properties in the manufactured parts. Typical ASTM F75 CoCrMo Alloy applications include:

• Biomedical applications and surgery, in particular

o Medical implants, CoCrMo alloys are the materials of choice for applications such as knee implants, metal-to-metal hip joints and dental prosthetics;

• Aero- and land-based gas turbines;

• Particularly demanding applications such as fuel nozzles and vanes for fuel injection.

KARMA DL 1.2

21/40


CoCr – EBM® powder has a Gaussian distribution of regular-shaped particles with average particle size of ca 75 µ.

Figure 6. CoCr – EBM® powder particle size distribution.


The basic physical properties for the CoCr – EBM® powder are shown in the following table.

Form powder


Colour grey or silver grey


Odour odourless

Specific density (g/cm3) 4.15

Table 21. Physical properties of CoCrMo powder.

KARMA DL 1.2

22/40


The CoCr – EBM® powder is produced by gas atomization and its chemical composition complies with the ASTM F75 standard’s specification. The chemical specification of the CoCr – EBM® powder is shown in the following table in comparison with the requirements by the ASTM F75 standard.

Component CoCr – EBM® *,

%

ASTM F75 required, %

Cromium, Cr 28.5 27-30 Molibdenum, Mo 6 5-7 Nickel, Ni 0.25 <0.5 Iron, Fe 0.2 <0.75 Carbon, C 0.22 <0.35 Silicone, Si 0.7 <1 Manganese, Mn 0.5 <1 Tungsten, W 0.01 <0.2 Phosphorus, P 0,01 <0.02 Sulphur, S 0.005 <0.01 Nitrogen, N 0.15 <0.25 Aluminum, Al 0.05 <0.1 Titanium, Ti 0.01 <0.1 Boron, B 0.006 <0.01 Cobalt, Co balance to 100% balance to 100%

*Typical properties quoted by the manufacturer.

Table 22. Comparison of the CoCr – EBM® composition with the ones required by the standard.


Generally, the mechanical properties of materials produced in the EBM® process are comparable to wrought annealed materials and are better than cast materials. In the following table mechanical properties of the CoCr – EBM® are shown in comparison with the requirements by the ASTM F75 standard.

KARMA DL 1.2

23/40

CoCr -

EBM®, as built*

CoCr - EBM ®, after heat treatment*

ASTM F75-07,

requirements Rockwell Hardness 47 HRC 34 HRC 25-35 HRC

Tensile strength,

Ultimate

n/a 960 Mpa,

140,000 Psi

655Mpa,

95,000 Psi

Tensile strength,

Yield

n/a 560 Mpa,

80,000 Psi

450 Mpa,

65,000 Psi Elongation at break n/a 20% >8% Reduction of area n/a 20% >8% Fatigue limit, Rotating Beam Fatigue n/a >10 millon cycles

at 610 Mpa (90 ksi)

* Typical properties quoted by the manufacturer; ** NA = Not Applicable.

Table 23. Comparison of the CoCr - EBM® mechanical properties with the requirements by the ASTM F75 standard.

Figure 7. Typical results of the CoCr - EBM® Rotation Beam Fatigue Test quoted by the manufacturer.

KARMA DL 1.2

24/40


1.2.6.1 Heat treatment

The following heat treatment program is recommended:

1) Hot Isostatic Pressing (HIP) in a shared cycle, with the following parameters:

o 1200 °C

o 1000 bar argon

o 240 minutes.

2) Homogenisation (HOM) heat treatment, with the following parameters:

o 1200 °C

o 0.7-0.9 mbar argon

o 240 minutes.

3) Quenching with as high quenching rate as possible, from 1220°C to 760°C in 8 minutes maximum. The purpose is to dissolve carbides and improve the isotropy of the microstructure, reducing the brittleness of the as-built EBM® material.

1.2.6.2 Machining

CoCr – EBM® parts manufactured by the Electron Beam Melting feature good machinability and can be machined without additional operations.

1.2.6.3 Polishing

The excellent properties displayed by the CoCr – EBM® parts allow polishing to a mirror or optical finish for use in dies and other applications requiring a superior surface finish.


Hazard symbol: XN

3.2.7.1 CAS Registration

CAS Registration number: CAS # 12629-02-6

Active ingredients: Cobalt, CAS # 7440-48-4

Chromium, CAS # 7440-47-3

Molybdenum, CAS # 7439-98-7

KARMA DL 1.2

25/40


Explosion and fire hazard Though CoCr - EBM® powder passes static discharge ignition tests, limited possibility of fire and explosion remains if fine fractions of the powder are suspended in the air at high concentration.


For humans: Inhalation of powder: pure Co exposure safety limits for humans are 0.02-0.1 mg/m3. Though Co alloys are much less dangerous, use this value as a precaution.

May cause skin irritation.

May cause eye irritation.

Lifting heavy loads- powder transportation and storage containers.

Environment: water Generally not hazardous for water

Table 24. Hazard identification for CoCrMo - EBM®.

3.2.7.3 First aid measures and accident prevention

Human hazar d: After eye contact rinse out with plenty of water. If

pain persists, call in ophtalmologist. Human hazard: After skin contact wash off with plenty of water.

Remove contamined clothing. Human hazard: After swallowing caution if victim vomits. Risk of

aspiration! Call in physician. Human hazard: After inhalation fresh air. Call in physician.

Human hazard: Preventive measures

Keep powder in the sealed containers;

Wear respirator (face mask) and protection gloves to avoid powder inhalation and skin contact;

Use fork lift and dedicated loading trolley to handle powder containers.

Accidental powder release: measures

Immediately clean up powder spillage;


Do not use ordinary vacuum cleaners.

Table 25. First aid measures for CoCr - EBM®.

KARMA DL 1.2

26/40


Suitable extinguishing media: metal fire

Cover with dry sand, use special fire extinguisher rated for metal fire.


Water, foam, CO2.

Special risks Small risks of potential explosion if suspended in the air.


not known.

Preventive measures Avoid significant powder spills;

Use dedicated Powder Recovery System (PRS);


Use proper grounding (body and equipment) preventing static discharge.

Table 26. Fire-fighting measures for CoCr - EBM®.

3.3. Bibliography

• Arcam Ti6Al4V ELI Titanium Alloy datasheet, ARCAM AB, 2010;

• ASTM F75 CoCr Alloy datasheet, ARCAM AB, 2010;

• Chapter 1, Arcam EBM® machines manual: “Safety”;

• Arcam Ti6Al4V ELI Powder Material Safety Data sheet.

• Arcam F75 CoCrMo powder Material Safety Data sheet.

KARMA DL 1.2

27/40

4. Stereolithography

4.1. ProtoGen™ 18420


DSM Somos® ProtoGen™ 18420 is a liquid, ABS-like, photopolymer that produces accurate parts ideal for general purpose applications. ProtoGen resins are the first stereolithography resins to demonstrate different material properties based on machine exposure control. Based on Somos Oxetane™ chemistry, ProtoGen 18420 offers superior chemical resistance, a wide processing latitude and excellent tolerance to a broad range of temperatures and humidities, both during and after build.

4.1.2. Applications

This high-temperature resistant, ABS-like photopolymer is used in solid imaging processes, like stereolithography, to build threedimensional parts. Somos ProtoGen 18420 provides considerable processing latitude and is ideal for the medical, electronic, aerospace and automotive markets that demand accurate RTV patterns, durable concept models, highly accurate and humidity & temperature resistant parts.

4.1.3. Liquid properties

Appearance White

Viscosity ~350 cps @ 30°C

Density 1,16 g/cm3 @ 25°C

Table 27. Liquid properties Protogen™ 18420

4.1.4. Optical properties

Ec 6,73 mJ/cm2 critical exposure

Dp 4,34 mils slope of cure-depth vs. In(E) curve

E10 67,6 mJ/cm2 exposure that gives 0,254 mm (,010 inch) thickness

Table 28. Optical properties Protogen™ 18420

KARMA DL 1.2

28/40


Protogen™18420

UV postcure at HOC-2

ASTM Method Property Description Metric

D638M Tensile Strength 42,2 -43,8 MPa

D638M Tensile Modulus 2180-2310 MPa

D638M Elongation at Break 8-16%

D638M Poisson’s Ratio 0,43-0,45

D790M Flexural Strength 66,7-70,5 MPa

D790M Flexural Modulus 1990-2130 MPa

D2240 Hardness (Shore D) 86-88

D256A Izod Impact-Notched 0,2-0,22 J/cm

D570-98 Water Absorption 0,68%

Table 29. Mechanical properties Protogen™ 18420

4.1.6. Thermal properties

Protogen™18420

UV postcure at HOC-2


E1545-00 Tg (Glass Transition Temperature) 57-59 ºC

D648 HDT @ 0,46 MPa

(Heat Deflection Temperature @0,46 Mpa)

53-56 ºC

D648 HDT @ 1,81 MPa


46-47 ºC

Table 30. Thermal properties Protogen™ 18420


After the part has been completed, the required post processing it depends on its intended use. Basically, post processing involves cleaning, post curing and part finishing.

• Cleaning entails the removal of excess liquid resin by solvent rinsing and the removal of the support structure from the object.

• Post curing is the final curing of the remnant liquid resin on the cleansed object by placing it inside a Post Curing Apparatus (PCA). There is an additional Thermal postcure that is recommended to increase mechanical/thermal and electric

KARMA DL 1.2

29/40

properties. It is not usually to make this thermal postcure. The thermal postcure consist of treat parts with this diagram of temperature. Thermal postcure process:

Figure 8. Thermal process Protogen™ 18420

• Finally, depending on the final application of the part, finishing may include sanding, buffing, painting, plating, bead-blasting, and dying.



The preparation is classified as dangerous according to Directive 1999/45/EC and its amendments.

Classifications R43

R52/53

Human health hazards May cause sensitisation by skin contact

Environmental health hazards Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic environment.

Physical/chemical hazards Combustible

Table 31. Hazard identification Protogen™ 18420.

80 ºC

T room

TIME

2 Hours 2 Hours 2 Hours

TEMP (ºC)

KARMA DL 1.2

30/40


General Protection of first-aiders: Put on appropriate personal protective equipment. Move exposed person to fresh air. Remove contaminated clothing and shoes.

Inhalation If inhaled, remove to fresh air. Obtain medical attention if symptoms occur.

Ingestion If swallowed, rinse mouth with water (only if the person is conscious). Obtain medical attention if symptoms occur.

Skin contact Take off immediately all contaminated clothing. Wash with soap and water. Get medical attention-

Eye contact Rinse with plenty of running water. Obtain medical attention if symptoms occur.

Table 32. Hazard identification Protogen™ 18420


Unusual fire/explosion hazards

Vapour is explosive in air at temperatures higher than the flash point.

Hazardous thermal decomposition products

In case of fire, may produce hazardous decomposition products such as carbon monoxide, carbon dioxide, (dense) black smoke, aldehydes, organic acids.

Special fire-fighting procedures

Fire water contaminated with this material must be contained and prevented from being discharged to any waterway, sewer or drain.

Protection of fire-fighters Wear suitable protective clothing. Self-contained breathing apparatus.

Table 33. Fire-fighting measures Protogen™ 18420

4.2. Somos ® NeXt

4.2.1. General characteristics Somos®NeXt is an extremely durable stereolithography(SL) resin that produces very accurate parts with high feature detail. Based on the DMX-SL technology, Somos®NeXtis a next generation of material that facilitates the production of tough, complex parts with improved moisture resistance and greater thermal properties.

4.2.2. Applications Somos®NeXt produces parts that are much more resistant to breakage than parts made with standard SL resins. It is ideal for use in functional testing applications as well as low-volume manufacturing applications where toughness is required. Market segments include aerospace,

KARMA DL 1.2

31/40

automotive, consumer products and electronics. This resin is ideal for: Functional end-use performance prototypes, like: snap-fit designs, impellers, duct work, connectors and electronic covers, automotive housings and dashboard assemblies, packaging and sporting goods.

4.2.3. Liquid properties

Appearance White

Viscosity ~1000 cps @ 30°C

Density 1,17 g/cm3 @ 25°C

Table 34. Liquid properties Somos® NeXt

4.2.4. Optical properties

Ec 12,0 mJ/cm2 critical exposure

Dp 5,80 mils slope of cure-depth vs. In(E) curve

E10 67,0 mJ/cm2 exposure that gives 0.254 mm (.010 inch) thickness

Table 35. Optical properties Somos® NeXt


Somos ®NeXt postcure


D638M Tensile Strength at break 31,0-34,6 MPa

D638M Tensile Modulus 2370-2490 MPa

D638M Elongation at Break 8-10%

D638M Poisson’s Ratio 0,42-0,44

D790M Flexural Strength 67,8-70,8 MPa

D790M Flexural Modulus 2415-2525 MPa

D2240 Hardness (Shore D) 82

D256A Izod Impact (Notched) 0,47-0,52 J/cm

D570-98 Water Absorption 0,39-0,41%

Table 36. Mechanical properties Somos® NeXt

KARMA DL 1.2

32/40


Somos ®NeXt postcure

ASTM Method

Property Description Metric

E1545-00 Tg (Glass Transition Temperature) 43-47 ºC

D648 HDT @ 0,46 MPa


55-57 ºC

D648 HDT @ 1,81 MPa


48-51 ºC

Table 37. Thermal properties Somos® NeXt


After the part has been completed, the required post processing it depends on its intended use. Basically, post processing involves cleaning, post curing and part finishing.



The preparation is classified as dangerous according to Directive 1999/45/EC and its amendments.

Classifications Xi; R36/38

R43

N;R51/53

Human health hazards Irritating to eyes and skin. May cause sensitisation by skin contact.

Environmental health hazards Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.

Physical/chemical hazards Combustible

Table 38. Hazard identification Somos® NeXt

KARMA DL 1.2

33/40


General Protection of first-aiders: Put on appropriate personal protective equipment. Move exposed person to fresh air. Remove contaminated clothing and shoes.

Inhalation If inhaled, remove to fresh air. Obtain medical attention if symptoms occur.

Ingestion If swallowed, rinse mouth with water (only if the person is conscious). Obtain medical attention if symptoms occur.

Skin contact Take off immediately all contaminated clothing. Wash with soap and water. Get medical attention-

Eye contact Immediately flush eyes with running water for at least 15 minutes, keeping eyelids open. Get medical attention if symptoms occur.

Table 39. Hazard identification Somos® NeXt


Small fire suitable Use dry chemical or CO2

Large fire suitable Use water, foam or dry chemical powder.

Unusual fire/explosion hazards

Vapour is explosive in air at temperatures higher than the flash point.

Hazardous thermal decomposition products

In case of fire, may produce hazardous decomposition products such as carbon monoxide, carbon dioxide, (dense) black smoke, aldehydes, organic acids, hydrogen chloride, chloride compounds.

Special fire-fighting procedures

Fire water contaminated with this material must be contained and prevented from being discharged to any waterway, sewer or drain.

Protection of fire-fighters Wear suitable protective clothing. Self-contained breathing apparatus.

Table 40. Fire-fighting measures Somos® NeXt

4.3. Bibliography

• Material Data Sheet Protogen™ 18420, DSM SOMOS

• Material Safety Data Sheet Protogen™ 18420, DSM SOMOS.

• Material Data Sheet Somos® NeXt, DSM SOMOS

• Material Safety Data Sheet Somos® NeXt, DSM SOMOS.

KARMA DL 1.2

34/40

5. Selective Laser Sintering

5.1. PA2200

5.1.1. General characteristics This whitish fine powder PA 2200 on the basis of polyamide 12 serves with its very well-balanced property profile a wide variety of applications. Laser-sintered parts made from PA 2200 possess excellent material properties:

• high strength and stiffness • good chemical resistance • excellent long-term constant behaviour • high selectivity and detail resolution • various finishing possibilities (e.g. metallisation, stove enamelling, vibratory

grinding, tub colouring, bonding, • powder coating, flocking) • bio compatible according to EN ISO 10993-1 and USP/level VI/121 °C • approved for food contact in compliance with the EU Plastics Directive

2002/72/EC (exception: high alcoholic Foodstuff) The recommended layer thickness is 0.15 mm. Unexposed powder can be reused. Depending on building time it has to be mixed with fresh powder by a ratio of 2:1 to 1:1 (old : new) in order to guarantee constant process parameters and persisting part quality.

5.1.2. Applications Typical applications of the material are fully functional plastic parts of highest quality. Due to the excellent mechanical properties the material is often used to substitute typical injection moulding plastics. The biocompatibility allows its use e.g. for prostheses, the high abrasion resistance allows e.g. the realization of movable part connections.

5.1.3. Powder properties

PA 2200 is a fine-powder on the basis of polyamide 12. In comparison to standard polyamide 12, PA2200 is characterized by higher cristallinity and higher melting point as result if specific production process. PA2200 contains stabilizers against oxidation.

Average grain size ISO 13320-11 56 µm

Laser diffraction 2,20 mil

Bulk density EN ISO 60 0.47 g/cm3

Density of laser-sintered part

EOS method 0,93 g/cm3

Table 41. Powder properties of PA2200 powder.

KARMA DL 1.2

35/40


Non reinforced PA2200 (Nylon 12)

Colour White

Mechanical Properties: Value Units Test Specification

Tensile modulus 1700 ± 150 N/mm2 or MPa DIN EN ISO 527

Tensile strength 45 ± 3 N/mm2 or MPa DIN EN ISO 527

Elongation at break 20 ± 5 % DIN EN ISO 527

Flexural modulus 1240 ± 130 N/mm2 or MPa DIN EN ISO 178

Charpy – Impact strength 53 ± 3,8 kJ/m2 DIN EN ISO 179

Charpy – Notched impact strength

4,8 ± 0,3 kJ/m2 DIN EN ISO 179

Izod – Impact strength 32,8 ± 3,4 kJ/m2 DIN EN ISO 180

Izod – Notched impact strength 4.4 ± 0.4 kJ/m2 DIN EN ISO 180

Ball indention hardness 77,6±2 DIN EN ISO 2039

Shore D hardness 75 ± 2 DIN EN ISO 868

Table 42. Mechanical properties of PA2200.


Non reinforced PA2200 (Nylon 12)

Thermal Properties: Value Units Test Specification

Melting Point 172-180 °C DIN 53736

Vicat softening temperature B/50 163 °C DIN EN ISO 306

Vicat softening temperature A/50 181 °C DIN EN ISO 306

Table 43. Thermal properties of PA2200.

KARMA DL 1.2

36/40


After the build process is finished the model is completely enclosed in a powder cake. The powder cake is carefully removed from outside, it demands patience and skill to clean sinter models especially those with internal hollow spaces, drillings and fine details. After the parts are cleaned in a so-called post-processing, the surface is treated further by manual polishing or sand blasting. There is a high risk of rounding sharp edge corners. Because sinter models are generally porous, all infiltrating surface sealings may be used. This includes all kinds of hard wax, epoxy resins, and also primers on an enamel base.



Hazard designation Injurious to health

Dusts Can form potentially explosive mixtures with air.

Melt Hot melt can cause skin burns.

Table 44. Hazard identification PA2200.


Inhalation On occurrence of irritation by vapours during thermal processing: ensure supply of fresh air, if necessary seek medical attention.

After inhaling product dust: ensure supply of fresh air.

Eye contact Wash with copious water.

Skin contact Cool molten polyamide on the skin with copious cold water. Do not pull solidified polyamide from the skin. Medical attention is required for skin burns caused by molten material.

Table 45. First aid measures PA2200.



Water spray, foam, CO2, dry powder.

Special hazards during fire -fighting

In case of fire, the following can be released: carbon monoxide, carbon dioxide, nitrogen oxide, organic decomposition products. Under certain fire conditions, traces of other toxic products cannot be excluded.

Special protective equipment during fire fighting

Wear suitable protective clothing

KARMA DL 1.2

37/40

Table 46. Fire-fighting measures PA2200

5.2. PA3200 GF (PA12 20-30%fv)


PA 3200 GF is a whitish, glass-filled polyamide 12 powder, which is characterized by an excellent stiffness in combination with good elongation at break. Laser-sintered parts made from PA 3200 possess excellent material properties:

• high stiffness • high mechanical wear-resistance • good thermal loadability • excellent surface quality • high dimensional accuracy and detail resolution • good processability • excellent long-term constant behavior

5.2.2. Applications A typical application for PA 3200 GF is the usage e.g. for final parts within the engine area of cars, for deep-drawing dies or any other application which requires particular stiffness, high heat distortion temperature and low abrasive wear.

5.2.3. Powder properties

Average grain size ISO 13320-11 57 µm

Laser diffraction 2,24 mil

Bulk density EN ISO 60 0,63 g/cm3

Density of laser-sintered part

EOS method 1,22 g/cm3

Table 47. Powder Properties PA3200GF

KARMA DL 1.2

38/40


Glass fiver reinforced PA3200 (Nylon 12)

Colour: Grey-White

Mechanical Properties: Value Units Test Specification

Tensile modulus 3200 ± 200 N/mm2 or MPa DIN EN ISO 527

Tensile strength 48 ± 3 N/mm2 or MPa DIN EN ISO 527

Elongation at break 6 ± 3 % DIN EN ISO 527

Flexural modulus 2100 ± 150 N/mm2 or MPa DIN EN ISO 178

Charpy – Impact strength 35 ± 6 kJ/m2 DIN EN ISO 179

Charpy – Notched impact strength

5,4 ± 0,6 kJ/m2 DIN EN ISO 179

Izod – Impact strength 21,3 ± 1,7 kJ/m2 DIN EN ISO 180

Izod – Notched impact strength 4,2 ± 0,3 kJ/m2 DIN EN ISO 180

Ball indention hardness 98 DIN EN ISO 2039

Shore D hardness 80 ± 2 DIN EN ISO 868

Table 48. Mechanical Properties PA3200GF


Glass fiver reinforced PA3200 (Nylon 12)

Thermal Properties: Value Units Test Specification

Melting Point 172-180 °C DIN 53736

Vicat softening temperature B/50

166 °C DIN EN ISO 306

Vicat softening temperature A/50

179 °C DIN EN ISO 306

Coefficient of thermal expansion

0,68 x 10-4 /K

Table 49. Thermal properties PA3200GF

KARMA DL 1.2

39/40


After the build process is finished the model is completely enclosed in a powder cake. The powder cake is carefully removed from outside, it demands patience and skill to clean sinter models especially those with internal hollow spaces, drillings and fine details. After the parts are cleaned in a so-called post-processing, the surface is treated further by manual polishing or sand blasting. There is a high risk of rounding sharp edge corners. Because sinter models are generally porous, all infiltrating surface sealings may be used. This includes all kinds of hard wax, epoxy resins, and also primers on an enamel base.



Emergency overview:

Dust may form explosive mixtures with air. Fumes from hot processing may be irritating to eyes and respiratory tract.

Potential Health Effects

Eye contact Fumes from hot processing may cause eye irritation.

Skin contact No hazard expected in normal use

Inhalation Dust of fumes from hot processing may cause irritation. Dust may cause irritation

Ingestion No hazard expected in normal use

Table 50. Hazard identification PA3200GF


Inhalation If inhaled, remove to fresh air. If breathing is difficult, give oxygen. If unconscious, evaluate the need for artificial respiration. Get immediate medical attention.

Eye contact In case of contact, immediately flush eyes with plenty of water. Obtain medical attention if irritation develops.

Skin contact Wash with water

Ingestion Not applicable: not an expected route of exposure

Table 51. First aid measures PA3200 GF.


Autoignition Temperature >350ºC

KARMA DL 1.2

40/40

Other flammable Properties: Dusts at sufficient concentrations can form explosive mixtures with air.

Extinguishing Media: Use water spray or fog, foam, dry chemical or CO2

Fire Fighting Procedures: As if any fire, wear self-contained positive-pressure breathing apparatus, (MSHA/NIOSH approved or equivalent) and full protective gear.

5.3. Bibliography

• EOS GmbH - Electro Optical Systems Website, http://www.eos.info/

• PA2200 technical data sheet, http://eos.materialdatacenter.com/eo/en

• PA3200 technical data sheet, http://eos.materialdatacenter.com/eo/en

• PA2200 safety data sheet, http://eos.materialdatacenter.com/eo/en

• PA3200 safety datasheet, http://eos.materialdatacenter.com/eo/en

d1 2 materials datasheets 8 10.pdf

Documents