opportunities and chances different approaches

voestalpine Additive Manufacturing Centervoestalpine Additive Manufacturing Centerwww.voestalpine.com

OPPORTUNITIES AND CHANCESDIFFERENT APPROACHES

Dr. Eric Klemp

voestalpine Additive Manufacturing Center| |

Agenda

1. Overview voestalpine HPM

2. AM - Value Chain

3. Process Chain / Influences

4. Products

5. Conclusion

3D printing Event - Geleen, NL17.04.20192


voestalpine AG

3D printing Event - Geleen, NL

Key figures for 2017/18

Employees 51,621

Revenue EUR 12,898 million

EBITDA EUR 1,954 million

EBIT EUR 1,180 million

EBIT margin 9.1 %

Sales by regions Sales by industries

Business year 2017/18 Business year 2017/18

66% European Union

(of which Austria 7%)8% Asia

8% Rest of world

4% South America

14% NAFTA

3% Aerospace

11% Railway systems

34%Automotive

ENERGY 13%

9% Building/ Construction

14%Other

9% Mechanicalengineering

5% White goods/ Consumer goods

MOBILITY: 49%

17.04.20193


voestalpine AG


Global quality leaderin premium steel strip and cast products, and the

global leading supplier of heavy plate

SectorsAutomotive industry and suppliers, energy,

household appliances, construction industry

Global market leader in turnout technology and a leading partner for

rails, processed wire, seamless tubes and welding

consumables

SectorsRailway systems, energy, automotive industry,

mechanical engineering and steel construction

industries

Global market leaderfor tool steel and a leading partner for high-speed

steel, valve steel, special forged parts and

powdermetallurgical materials

SectorsToolmaking, automotive industry, oil & gas

exploration, aerospace

Global leading supplierof highly refined sections, tubes and precision strip

steel products as well as for ready-to-install system

components made of pressed, stamped and

rollformed parts.

SectorsAutomotive, construction and energy industries,

warehousing technology, mechanical engineering

and steel construction industries

Steel

Metal Engineering

High Performance Metals

Metal Forming

17.04.20194


HIGH PERFORMANCE METALS DIVISION AT A GLANCE


Global leading special

steel company with a

focus on

technologically

demanding product

segments

Global market leader in tool steel and global

leading supplier in high-

speed steel, valve steel

and other special steels

as well as

powdermetallurgical

materials

“One-stop shop”With additional services

including heat

treatment, coating and

additive manufacturing.

8 production sites in

Europe, North and

South America, and a

sales and service

network with 160

warehouse and

service sites in 45

countries on all five

continents

Supplying customers

worldwide in the

sectors:

» Automotive

» Power generation

» Oil & gas exploration

» Mechanical

engineering

» Consumer goods

» Aircraft manufacture

» and other selected

industry segments

17.04.20195


Agenda


2. AM - Value Chain


4. Products

5. Conclusion



ADDITIVE MANUFACTURING @ voestalpine HPMOUR APPROACH

17.04.20197

Additive Manufacturing Center

Customer Consulting

Powder development

Powder productionDesign &

engineeringAM-Parts

Heat treatment & post processing


SOLUTION PROVIDER ALONG THE VALUE CHAIN FOR POWDERS & PARTS

voestalpine Additive Manufacturing Center| |17.04.2019 3D printing Event - Geleen, NL8

2013 2019

4x

Staff involved: 5 Staff involved: 20 Staff involved: 30 Staff involved: 50 +

Idea to concept Concept to product / service Market launch/introduction

ADDITIVE MANUFACTURING @ voestalpine HPMAM HISTORY - TIMELINE


Alloy development Powder productionDesign/Engineering -

Applicationexpertise

AM-Parts productionAM specific post

processing

N

2

N

2

H2

O

H2

OH2

O

H2

O

ADDITIVE MANUFACTURING @ voestalpine HPMEXAMPLES & HIGHLIGHTS ALONG THE VALUE CHAIN


Multiple locations, markets & technologies

…Powder bed fusion

…Direct metal deposition

…Powder production

Hagfors, S

Kapfenberg, A

Düsseldorf, D

Singapore, SIN

Nantou, TW

Toronto, CAN

Houston, USA

ADDITIVE MANUFACTURINGHIGH PERFORMANCE METALS AM NETWORK

…EOS M290

…EOS M400


DEVELOPMENT & PRODUCTION OF HIGH QUALITY METAL

POWDERS AT BÖHLER EDELSTAHL & UDDEHOLM

17.04.201911 3D printing Event - Geleen, NL

Atomising rigs at Böhler & Uddeholm

» Production started 2016

» In total a yearly capacity of roughly 200 tons of metal powder will be available for AM

» VIM with max. batch size of 500 kg

» Atomization with inert gas

» Flexible production plant – open for customized solutions (chemistry)

» Atomization of broad range of steel and Ni-Base alloys possible

Facts

Source: voestalpine


THE CHALLENGE WITH ALL THE AM TECHNOLOGIES» The interaction of material, design, process and equipment is much

stronger than with traditional manufacturing technologies

Part

Performance

Material

Process Equipment

Design

12 3D printing Event - Geleen, NL17.04.2019


Agenda


2. AM - Value Chain


4. Products

5. Conclusion



MATERIAL PROPERTIES


Source: voestalpine

Density ~95% Density ~99.97%

Technical progress:» Laser technology» Optics» Software» Efforts in R&D

Several years ago Today

Mechanical properties close to bulk material


POWDER IS POWDER – REALLY?

=

≠

?

» Shape

» Particle sizedistribution

» Hollow structure

» Humidity

» Oxygen content

» Chemistry

» Flowability

Source: voestalpine



Parameter Development – Proceeding

17.04.201916

Analysis of alloy

PROCESS STAGE 1 - SCREENING

PROCESS STAGE 2 - REPRODUCIBILITY

PROCESS STAGE 3 - MANUFACTURING

Shipping andaccounting



» Qualifying new materials for LBM

requires extensive testing and

parameter development

» To manufacture a part via LBM ~200

different build parameters need to be

considered

» A procedure was developed to reduce

parameter development costs and set

a quality standard


LBM parameter development

Different Parameter Volumes Segments


» The build process is affected by several influencing factors and process parameters.

» Analysis of the entire manufacturing process was conducted.

» An investigation of all critical process parameters was made

» Handbook and powder handling guide was created.

» Recommendations about the most influencing process parameters during LBM were established.


Influences LBM

Influencing Factors(temperature, humidity, coating speed, gas flow, …..)


Agenda


2. AM - Value Chain


4. Products

5. Conclusion



Applications & benefits through AM


Plastic injection molding

Aluminumdie-casting

Hot forming / press hardening

Prototype development

Special components

Fluid components

Source: voestalpine

voestalpine Additive Manufacturing Center| |21

SUPPORT OPTIMIZATION

» Topology and support

optimizations may allow great

material reduction but… can lead

to massive support and post

processing problems

» Build direction is essential to

minimize support, building time,

distortion and to optimize

platform utilization

21 17.04.2019 3D printing Event - Geleen, NL Source: voestalpine


MODULATION OF COOLING DENSITY

17.04.2019 3D printing Event - Geleen, NL22

» Tailored cooling by

using different channel

density and lattice

density

Source: GoetheLab for Additive manufacturing, voestalpine

High cooling

Medium cooling

Non / low cooling

Activecooling /heating

indirectcooling /heating

InletOutlet


CONFORMAL COOLING


APPLICATIONPlastic injection molding tool with conformal cooling

AM ADVANTAGES» Reduced cooling time 20s 6s» Simulation and advanced

channel design* guarantees best performance

» Lightweight design** to reduce cooling losses and reduce printing time

Source: voestalpine

* **


CONFORMAL COOLING FROM EXPERTS


Source: voestalpine

Parallel cooling often used when

space-saving is necessary but it is

very challenging to realize due to

» unbalanced mass flow rate

and flow speed

» powder removal

Expert knowledge in simulation

and post processing needed!


JET ARRAY COOLING DEVICE


N2N

2

H2OH2

OH2

O

H2O

APPLICATION

Cooling device for flat surface

AM ADVANTAGES

» Quick and homogeneously cooling

» Monolithic design to minimize size

» Combining of air and water

cooling channels

» High efficiency

Source: voestalpine


Jet Array cooling device


APPLICATION

Cooling device for flat surface

AM ADVANTAGES

» Quick and homogeneously cooling

» Monolithic design to minimize size

» Combining of air and water

cooling channels

» High efficiency

Source: voestalpine

AM first version new version “common rail”

simulationcross-section of “common rail”

17.04.201926


Initial Design suggestion

Design optimization

Manufacturing

Evaluation & further optimization (if necessary)

flowsimulation

part configuration

thermal simulation

AM-Design ≈ 4 weeks

Simulations ≈ 1 week

Build time ≈ 76 hrs for 2 Jet Arrays

Part weight ≈ 1.6 kg

Design engineering and outlook


voestalpine Additive Manufacturing Center| |17.04.201928 3D printing Event - Geleen, NL

Feeder elbow pipe

conventional cast design

AM design

APPLICATION

Transport pipe for abrasive fluids

AM PART

» High wear resistant material

» Inner flow path optimized

» Wall reinforcement at areas with

high wear

lever

axis

reinforcement

Source: voestalpine

voestalpine Additive Manufacturing Center GmbH| |

» Design and material were changed to

achieve high wear resistance and

good printability

» Elbow pipe is in active service since

18.12.2017

» Conventional part only lasts between

4-6 weeks


Elbow pipe

Elbow Pipe in Use


Tools with coating

http://oewf.org/en/portfolio/amadee-18/


http://oewf.org/en/portfolio/amadee-18/


Technology Showcase - lightweight

Source: voestalpine



hood hinge - Essential success factors

» Toolless high flexible manufacture» Investment minimal for small series» update-capable production

» Ultra lightweight design» CAE topology optimization» AM just ultra-lightweight design

» Maximal functional integration» Fragile structure for freedom of

movement» No complex kinematics

» Tool-free high flexible manufacturing

» Ultra lightweight design

» Maximal functional integration

» Sustainability & resource efficiency



LightHinge+: Weight optimisationAdditive manufacturing only works economically if the highest degree of

functional integration in the component is possible

» Topology analysis without consideration a. of the functional integration b. of the manufacturing conceptbrings the design engineer on a "wrong mechanical track"

Principle "breakaway structure" instead of "kinematics“= Success factor for weight minimization



Lightweight design – hood hinge

APPLICATION

Automotive hood hinge

AM ADVANTAGES

» Weight reduction of 50%

» optimized structure - strength,

warpage & minimal support

» integrated predetermined

breaking point for pedestrian

protection

3D printing Event - Geleen, NL Source: voestalpine, EDAG17.04.201934

voestalpine Additive Manufacturing Center| |35 3D printing Event - Geleen, NL

Topology optimization –hood hinge

Source: voestalpine

17.04.201935

voestalpine Additive Manufacturing Center| |36 3D printing Event - Geleen, NL

Process optimisation for AM

Source: voestalpine

Optimized Orientation

Additive Manufacturing

Process Simulation

17.04.201936


Functional tests» Degrees of freedom for designers:

they enable the integration of an

active hood function in the flat

design of the front end

» Breakaway fractural structure acts

as an ultra-light, printed kinematics

in interaction with the pyrotechnic

triggered spring elements

» Active bonnet will lift approx. 50

mm in the area of the hinges



Agenda


2. AM - Value Chain


4. Products

5. Conclusion



FinallyApplication and benefits


design freedom/fast development

Improved life cycle / maintenance

lightweightintegration of

functions/sensors

less time-to-market

porous structures/ ventilation / damping

Graduated materials / wear

resistance

temperature / flow optimization

separation/mixing of fluids

Source: DMRC, voestalpine

17.04.201939

voestalpine Additive Manufacturing Center| | 3D printing Event - Geleen, NL

Don’t try to use AM for parts which are dedicated to

other manufacturing technologies!

AM is only economically if you can

add value to the part!

17.04.201940


FOR FURTHER INFORMATION PLEASE CONTACT

Dr. Eric Klemp

voestalpine Additive Manufacturing Center GmbH

Hansaallee 321

40549 Düsseldorf

Germany

T.: +49 (211) 522 2331

[email protected]


mailto:[email protected]

opportunities and chances different approaches

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