Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Metal Additive Manufacturing Manufacturing

2,397 views

Published on

Miguel Godino Martinez, sirris, esitys "3D-tulostuksen mahdollisuudet liiketoiminnassa"-seminaarissa Porissa 4.5.2016.

Published in: Business
  • Be the first to comment

  • Be the first to like this

Metal Additive Manufacturing Manufacturing

  1. 1. Metal Additive Manufacturing Manufacturing & case studies.M.Sc. Miguel Godino Martinez
  2. 2. Agenda for today 1.What does Sirris do? 2.Why Metal Additive Manufacturing? 3.Which metal AM technology fits me? 4.Several metal AM case studies for aerospace 5.An innovative case study for the automotive sector 6.More case studies 2
  3. 3. What does Sirris do? 3
  4. 4. What does Sirris do? 2485 SME’s (<250 employees) 2500 companies 115 big companies (>250 employees) > WHAT ? To help companies implement technological innovations > WHY ? To reinforce the long-term competitive position of companies > TO WHOM ? Belgian technology industry and at European level 4
  5. 5. Within four domains of technology 5 METALS COMPOSITES PLASTICS & HYBRIDS COATINGS NANOMATERIALS ECO-MECHATRONICS SENSORIZED FUTURE MODEL BASED DESIGN FACTORIES OF FUTURE WORLD CLASS TECHNOLOGIES ADDITIVE MANUFACTURING SOFTWARE ENGINEERING CLOUD COMPUTING DATA INNOVATION
  6. 6. TEAM OF 20 INDEPENDENT EXPERTS, 25+ YEARS OF EXPERIENCE METALS, POLYMERS & CERAMICS MORE THAN 10 Additive Manufacturing TECHNOLOGIES IN-HOUSE ADDITIVE MANUFACTURING AT SIRRIS 6
  7. 7. Why metal additive manufacturing? 7
  8. 8. Some things to remember about metal AM… Redesign, understand possibilities & limitations of technology Full chain from design, process/materials optimization, AM technology & post treatments Get CAD Design, Press print and done! You are fully done by buying a metal machine 8 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  9. 9. Re-design Design, optimize, convert Technology Selective Laser Melting and Electron Beam Melting Orientation Right 3D position for the right process Support Heat transfer and structural support Manufacture Process parameters, material optimization Thermal treatments Residual stresses Post-finishing Surface finishing Some things to remember about metal AM… 9 Process chain example for additive manufacturing of metals M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  10. 10. Advantages • ‘Reduced time design-to-manufacturing’ 10 CAD • Design your CAD .STL conversion and edit • .STL is the format used for Additive Manufacturing • Edit your part, redesign it, place support structures Slice your part • Slicing for a given layer thickness and hatching Manufacture • Depending on several factors, a normal built will take between 6-60h M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  11. 11. Advantages • Complex geometries possible – Avoid welding and assembly steps for your part. – Internal channels. 11 ‘Almost no geometrical constraints anymore’ M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  12. 12. Advantages • Reduce material Only melt powder where needed to build the 3d part. Powder not meltedpowder recupered & reused. • Produce ‘overnight on Sundays’ 12 EOS center
  13. 13. Which metal additive manufacturing technology fits me ? 13
  14. 14. 4 main metal additive manufacturing technologies in a nutshell 1- Metal Binder Jetting ‘Similar to paper2D printing. Able to produce big parts very fast by joining metal layers together thanks to a binder. Gives a green part that needs to be sintered afterwards.’ 2- Direct metal deposition/ cladding `A moving nozzle deposits and melt powder at the same time. Very useful for difficult welding reparations. Naval industry.` 14 ILT, Fraunhoufer M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  15. 15. 3- Selective Laser melting Powder bed technology that melts layer by layer using a laser beam. Highly complex parts with a high resolution, limited in size 4- Electron Beam Melting ‘ Powder bed technology that melts layer by layer using an electron beam. Highly complex metal parts limited in size, fast.’ 15 4 main metal additive manufacturing technologies in a nutshell Video: Solid Concept Video: Oak Ridge LabM.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  16. 16. EBM (ARCAM A2 available at Sirris) SLM (SLM 250HL available at Sirris) 1. Re-Design 2. Technology 3. Reorientation 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing Electron beam source High preheating Temperature (~700C) Need less supports Less as-built thermal stresses Difficult for building internal channels Laser beam source Low preheating Temperature (<200 C) More need of supports Finer resolution Wider material pallet (Al,Ti,Inox,tool steel…) 16M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference picture: EOS
  17. 17. A more detailed comparison: Some numbers 17 SLM EBM Size building chamber (mm) typical 250 x 250 x 350 Ø 210 x 350 up to 500 x 280 x 325 Ø 350 x 380 Layer thickness (µm) 30 to 90 50 to 90 Min wall thickness (mm) 0.2 0.6 Accuracy (mm) +/- 0.1 +/- 0.3 Build rate (cm³/h) 5 - 20 80 Surface roughness (µm) 5 - 15 20 - 30 Type of parts High resolution, difficult for massive parts More massive parts, less detailed. 1. Re-Design 2. Technology 3. Reorientation 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  18. 18. 1. Re-Design 2. Technolo gy 3. Reorienta tion 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing 18 ‘Need of support structures for EBM and SLM technologies’ Support goal Importance for SLM Importance for EBM Hold part against thermal stresses- avoid delamination *** * Conduct the heat away-thermal transfer ** ** Physically hold the surfaces >45 over the powder bed *** * M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  19. 19. © sirris | www.sirris.be | info@sirris.be | 19 4/16/2015 1. Re-Design 2. Technolo gy 3. Reorienta tion 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing ‘Supports will decrease the quality of the surface’ M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  20. 20. >45° © sirris | www.sirris.be | info@sirris.be | 20 1. Re-Design 2. Technolo gy 3. Reorienta tion 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing ‘So orient the part in the way that less supports will be needed’ M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  21. 21. ‘Aluminium Alloys compared to casting: Some data’ AlSi10Mg, SIRRIS data SLM SLM CAS T + AGE CAS T + AGE 21 1. Re-Design 2. Technolog y 3. Reorientat ion 4. Support generation 5. Manufacture 6. Thermal treatments 7. Post- finishing M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  22. 22. Lightweight and aerospace case studies 22
  23. 23. M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference Case1. Redesign for Additive Manufacturing: A satellite part Initial part Initial Mass ~ 457 g Targeted reduction by AM ~ 200 g! 23 ‘Unlock the potential of Topology Optimization thanks to the design freedom of Additive Manufacturing’
  24. 24. Volume space Initial part Non-modifiable areas Load cases 24 Case1. Redesign for Additive Manufacturing: A satellite part M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  25. 25. After Topol iteration and FEA analysis 240g< 457g x2 weight saving ! Size and massivity Suitable to be produced by Additive Manufacturing Final part 25 Case1. Redesign for Additive Manufacturing: A satellite part M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  26. 26. An innovative case study for the automotive industry 26
  27. 27. A cylinder head. An innovative solution for the automotive industry 27 ‘Lighter, complex and faster from design to manufacturing than conventional production’ M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  28. 28. Everything start with the redesign to get the most of the technology 28 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  29. 29. Correct orientation, correct support structures • Powder is less conductive than molten metal. • So supports are built below massive zones to dissipate the heat and avoid over-melting. 29 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  30. 30. Part after removing supports 30 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  31. 31. 3D Scan comparison 31 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  32. 32. More applications 32
  33. 33. Drillers AET-BMT ‘Smart drilling machines made of Titanium using EBM’ 33 Why metal additive manufacturing? Production cycle reduced up to 70% Maintenance cost reduced 80% Save of weight: high strenght vs weight ratio. Integration of functions M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  34. 34. Laser collimator: simplifying the assembly and adding performance 34 M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
  35. 35. Orthopedics, customized implants by Metal additive manufacturing 35 ‘Production of complex patient specific implants’ Play on porosity, roughness and randomness lattices to replicate bone conditions and promote cell growth M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference picture: ARCAM
  36. 36. Miguel Godino Process Engineer in Additive Manufacturing of Metals miguel.godino@sirris.be 36

×