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VTT Powder Piloting Service: Additive Manufacturing (AM)

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For more information, please visit: www.vtt.fi/powder. Development steps from powder to product.

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VTT Powder Piloting Service: Additive Manufacturing (AM)

  1. 1. 1 Powder Piloting Service Material solutions, from powder to product. VTT Technical Research Centre of Finland Ltd Service for Additive Manufacturing (AM) www.vtt.fi/powder
  2. 2. 2 Service for introducing new material compositions to SLM from materials to performance validated product.  Utilization of AM technologies such as Selective Laser Melting increases rapidly  Number of commercially available AM customized powders is limited and pricing of is high Additive Manufacturing (AM) www.vtt.fi/powder
  3. 3. 305/12/2017 3  Selection of material composition meeting demands of component operation conditions  Evaluation of material suitability to SLM process (thermodynamics, phase structures) 2 1 3 4 5 Material selection and design Powder processing & modification to SLM Processing parameters for SLM Processing of test components Design and manufacturing of real component Development steps from powder to product: Additive Manufacturing (AM)  Is there powder commercially available with needed properties?  modification of power properties to meet demands of SLM  production of powder with desired specs  Processing and modification of powders to meet process demands  Design of experiment (DoE) for process parameter mapping  DoE based processing parameter optimization  Heat treatments, HIP, grinding, machining, polishing  Specimens for lab material testing e.g. tensile test specimens in different orientations  Design and optimization of component for SLM process and for operation conditions  Manufacturing and post treating of component  Component performance testing (lab and/or field testing) www.vtt.fi/powder
  4. 4. 405/12/2017 4 Development steps from powder to product: Additive Manufacturing (AM) Does processing parameters lead to desired properties? GATE2. Does material properties meet demands of component? GATE3. Does powder fill demands of SLM process? GATE1. www.vtt.fi/powder 2 1 3 4 5 Material selection and design Processing parameters for SLM Processing of test components Design and manufacturing of real component Powder processing & modification to SLM
  5. 5. 505/12/2017 5  Demands and restrictions from operation conditions  Strength, corrosion etc.  Demands and restrictions of SLM process  Thermodynamics, prediction of phase structures, need for preheat,…  Powder properties, flowability, packing density, particle size distribution STEP 1. Material selection & design Additive Manufacturing (AM) www.vtt.fi/powder
  6. 6. 605/12/2017 6 Can be done by “light” more traditional way or by ICME approach. STEP 1. Material selection & design Additive Manufacturing (AM) www.vtt.fi/powder
  7. 7. 705/12/2017 7  Is there powder commercially available with needed properties?  If yes, modification of power properties to meet demands of SLM  If no, production of powder with desired specs  Possible technologies  Atomization, milling, air classification, plasma spheroidization,…  Characterization of properties STEP 2. Powder processing & modification Additive Manufacturing (AM) www.vtt.fi/powder
  8. 8. 805/12/2017 8 400 600 800 1000 1200 100 150 200 250 300 Scanningspeed(mm/s) Power (W) VED 50 VED 100 Experimental designs Using D-optimal design of experiments. Printing samples and measuring density using image analysis. Fitting a numerical model and calaculating the optimal parameters. 90 100 110 120 130 140 150 400 900 Hatchwidth(µm) Scanning speed (mm/s) VED 50 VED 100 Hatchwidth(µm)Scanningspeed(mm/s) Scanning speed (mm/s) Power (W) STEP 3: Processing parameters for SLM Additive Manufacturing (AM) www.vtt.fi/powder
  9. 9. 905/12/2017 9  Post treatment  Heat treatments according to targeted structural properties  Densification and homogenization by hot isostatic pressing if necessary  Surface grinding & polishing  Desired performance testing Heat treatment Procedure Hardness Stress relief anneal Held at 650°C for 2h 45 HRC Hardening and tempering Held at 1030°C for 30min + quench in oil Tempered at 400°C for 2+2h 55 HRC Conventionally manufactured (Reference) Held at 1025°C for 30min + quench in air Tempered at 550°C for 2+2h 52 HRC 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Stress(MPa) Initial Optimized Reference Ultimate tensile strength (Horizontal) As built Stress relief annealed Hardened and tempered STEP 4: Processing of test components Additive Manufacturing (AM) www.vtt.fi/powder
  10. 10. 1005/12/2017 10  Co-creation with VTT experts  Re-design for AM, topological optimization  Real, printed case component  Component performance testing  Cost estimation of manufacturing of case component Component selection Redesign 3D printing Cost estimation STEP 5: Design and manufacturing of real component Additive Manufacturing (AM) www.vtt.fi/powder
  11. 11. 111105/12/2017  Material H13 tool steel  Optimized mass: 489 g (compared to original mass 1.446 kg)  66% reduction  No drilling  no pluging  no leaking!  Better fluid flow due to optimized fluid channels  Will be still further optimized  Final version will be tested in operative conditions Case 3D printed optimized hydraulic valve block Additive Manufacturing (AM) www.vtt.fi/powder
  12. 12. 1205/12/2017 12 Topology optimization + Additive Manufacturing Additive Manufacturing (AM) www.vtt.fi/powder
  13. 13. 13 For more information please visit our website. Interested? VTT Technical Research Centre of Finland Ltd www.vtt.fi/powder

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