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John robinson university of wolverhampton
- 1. Developments in Metal Additive Manufacturing Materials John Robinson – j.robinson12@wlv.ac.uk Senior Engineering Technician PhD Researcher 11th July 2019
- 2. CALMERIC Composites & Additive Layer Materials Engineering Research & Innovation Centre University of Wolverhampton School of Engineering Facilities Developments in Metal AM Materials Application Specific Materials
- 3. • CALMERIC is University of Wolverhampton and European Regional Development Fund (ERDF) project. • CALMERIC enables local companies to access advanced engineering facilities and expert staff to aid in the development of high performance materials and components. • The CALMERIC project is supporting Small & Medium Enterprises (SMEs) based within the Shropshire and Staffordshire counties. • The CALMERIC project is based at the School of Engineering Telford Innovation Campus. CALMERIC Composites & Additive Layer Materials Engineering Research & Innovation Centre
- 4. School of Engineering Design Analyse Manufacture Validate CAD and Simulation CFD & FEA CNC, SLS, SLA, Composites, Metal AM Microscopy, Powder analysis, CT, Mechanical Testing, 3D Scan, CMM,Wind Tunnel Telford Innovation Campus School of Engineering
- 5. 3 and 5 Axis CNC Manufacture:
- 6. SLA Based Additive Manufacture Composites Manufacture
- 7. CMM and Reverse Engineering 5 Axis CMM Materials Testing Optical and SEM Microscopy Faro Edge (Blue Laser)
- 8. Wind Tunnel – subsonic & supersonic facilities: Powder Particle Size and Shape Analysis
- 9. CT Scanning - X ray Microscopy • None Destructive 3D Analysis • Micron Resolution
- 10. • Powder Bed Fusion EOS M270 EOS M290 • Meltpool Monitoring In Process monitoring EOS Metal Materials • Aluminium – AlSi10Mg • Cobalt Chrome – MP1 and SP2 • Nickel – HX, IN625 and IN718 • Steel – MS1, 316L, PH1, 174PH, CX and GP1 • Titanium – Ti6Al4V, ELI and TiCP • Tungsten – W1 Metal Additive Manufacture:
- 11. Launcher CuCrZr alloy rocket engine chamber and injector manufactured by 3T Application Specific AM Materials – Copper Pure copper heat exchanger produced by Farsoon Technologies Complex geometries 0.5 mm wall thickness 30% Weight Reduction 35% Cost Reduction 20 times higher heat transfer than Inconel
- 12. Application Specific AM Materials – Pure Silver ? Pure Silver Highest thermal conduction Highest electrical conduction Bio inert Highly reflective Sterling Silver ring fabricated using an EOS M080 Sterling Silver finger print pendant fabricated using an EOS M080
- 13. Microscopy – Optical and Scanning Electron – Pure Silver Powder Optical microscopy images (a, b) pure silver 99.9% (c, d) sterling silver 92.5%. SEM images of (a, b) pure silver 99.9% (c,d) sterling silver 92.5%.
- 14. AM Material Research Powder Particle Size and Shape Analysis Particle analysis of atomised pure silver sieved between 10µm and 50 µm (a) Particle Volume Distribution (PVD) and (b) Particle Size Distribution (PSD).
- 15. Pure silver track produced using EOS M290. Application Specific AM Materials – Pure Silver EOS M290 X1 30 Micron Layer Thickness X1 Laser Pass A Range of Laser Powers A Range of Scan Speeds
- 16. Pure Silver tensile and biomedical lattice samples designed and fabricated by University of Wolverhampton using EOS M290. Application Specific AM Materials – Pure Silver EOS M290 30 and 60 Micron Layer Thicknesses A range of Hatch Distances A range of Scan Speeds
- 17. X ray Microscopy • None Destructive 3D Analysis • Micron Resolution CT Scan - Pure Silver Lattice Structure Pure Silver Lattice Structure as Built Application Specific AM Materials – Pure Silver
- 18. Optimised AM parameters for none AM materials High strength Aluminium (Al7075) Metal Matrix Composites - TiSiC Research Commercialisation Application Specific Materials AM Materials – What’s Next? Aluminium 7075 – Additive Manufactured microstructure. Fabricated by University of Wolverhampton using EOS M270.
- 19. CALMERIC Composites & Additive Layer Materials Engineering Research & Innovation Centre Enabling local companies to access advanced engineering facilities and expert staff. University of Wolverhampton School of Engineering Facilities - Manufacture and Validate Manufacture - CNC, SLS, SLA and Metal AM Validation - Microscopy, Powder, Mechanical Testing, 3D Scan, CMM,Wind Tunnel Developments in Metal AM Application Specific Materials AM Material Research – Pure Silver Research Commercialisation – Optimised parameters and application specific materials
- 20. John Robinson – j.robinson12@wlv.ac.uk Senior Engineering Technician PhD Researcher 2nd July 2019 Questions ?