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Additive Manufacturing
Constructeursdag
‘Out of the Box ontwerpen’
De Fabrique, Utrecht, 19 november 2013
Philippe Reinders Folmer
General Manager Benelux
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3D CAD
Additive Manufacturing – Laser Melting
Materialise Magics .STL AM250 .MTT -Orientation
-Supports
-Nesting
-Machine parameters
• AM opens the box
• Metal powders
• Design considerations
• Applications
• Renishaw’s approach
• Design for process
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Slide 3 11/21/2013
AM – the process
De vertoonde video van de AM250 lasermelting
machine is te bekijken op:
www.renishaw.nl/lasermelting
Of bekijk dezelfde video via deze QR-code op uw
mobile telefoon:
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• Design driven Manufacturing or Manufacturing driven Design..?
– Limitations by current production methods
• Benefits for ‘Designing out of the box’:
– Reducing the number of components
– Optimising design
– Increasing functionality
– Reducing weight
– Optimising flow
– Increasing reliability
• AM is an additional metalworking method in combination with current
production methods like milling, turning, polishing
Additive Manufacturing opens the box
Slide 4 11/21/2013
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The process uses gas atomised metallic powders like:
316L, 17-4 PH and Maraging steel
Cobalt Chrome and dental CoCr
Inconel 718
Titanium Al64V *
Aluminium AlSi10Mg *
No pre-treatments or binders are used
* Reactive materials require ultra low oxygen levels
What metals can be processed?
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• Atomisation – a molten metal
stream is disintegrated into fine
particles after colliding with a
high velocity stream of
atomising medium like water, air
or inert gas.
• Mechanical – during milling
forces act on the material to
reduce the particles.
• Chemical – by reduction of
metallic oxides, thermal
decomposition or by means of
electrolytic deposition.
Slide 6 11/21/2013
Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
Metal powder production methods
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Each method results in powders with
different characteristics and appearance:
• Water atomising
irregular shape, but no internal porosity
• Gas atomising
spherical shape and no internal porosity
• Oxide reduction
irregular shape, large surface area and
substantial internal porosity
• Electrolytic
high purity with dentritic morphology
Slide 7 11/21/2013
A Chemical; Sponge Iron-Reduced Ore
B Electrolytic: Copper
C Mechanical: Milled Aluminium Powder
Containing Disperoids (17)
D Water Atomization : Iron
E Gas Atomization: Nickel-Base Hardfacing Alloy.
Source "Atomization - The Production Of Metal
Powders" A. Lawley, MPIF.
The atomisation process allows for the production of
pre-alloyed powders. The chemical composition of the
feed material and alloy additions to the molten bath
allow for the formulation of an almost unlimited
combination of alloy compositions.
Particle characteristics
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Slide 8 11/21/2013
Ti6Al4V
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Slide 9 11/21/2013
CoCr (ASTM75)
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Slide 10 11/21/2013
Design considerations for production
Manage the re-design process
• Layerthickness & detail versus speed
• Orientation & functionality versus nesting & quantity
• Add fixturing items for post-processing
Manage the process
• Maintain file integrity
• Safety (separate powder handling from production)
• Manages production (compare ‘build to master’ and ‘build to build’)
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Small bespoke series components
dental crowns & bridges, implants etc
Complex geometries & structures
Thermal management, medical implants, transition to composite structures
Hidden internal features
conformal cooling, valve bodies etc.
Nobel materials & alloys
materials difficult to machine & hazardous to process via other methods
Short series or one off components for test & development
Suitable applications – where does it works best?
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Slide 12 11/21/2013
Renishaw’s approach = production process
Use of vacuum chamber, pure Argongas
• Ultra low oxygen level (<0,01%) from start to finish
• Short start-up time (12 minutes from start)
• Low gas consumption (average 30 to 50 ltr/hr)
Glove access, external hopper and off-line preparation
• Operator safety and material integrity
• Re-use and refill during process
• File integrity
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Slide 13 11/21/2013
Identify & position
key features
Create a structurally
optimised design
Consider
part/process
orientation demands
Design for process – pump housing redesign
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Original DFP3 pump front plate part
• Weight Removal • Part consolidation • Reduction in manufacture and assembly time
Aim
Design for process – assembly front plate
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Improved flow path smoothness through CFD simulation of fuel flow velocity a) original flow paths b) redesigned flow paths
Delphi Design for process – assembly front plate
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• Pressure test = 2mm wall section • Built on Renishaw AM250 in Ti6Al4V • 54% reduction in volume • 21% reduction in overall packaging area • 5 non-value added assembly operations eliminated
Delphi Design for process – assembly front plate