SIRRIS – ADDHigh Value Manufacturing - IntroductionThierry Dormal
Agenda High Value Manufacturing – Nov. 1514h30 Introduction                             Thierry Dormal (Sirris)14h50 Cas c...
B2B – Session d’échanges thématiquesConception orientée additive manufacturingLaser Cladding, Laser Melting, EBM, 3DP meta...
TipTopLam partnershipResearch centers and universities:SIRRIS   CSL    ULg     CRM     CEWACIndustrial partners:Techspace ...
TipTopLam – Phase 1 Technology selection & masteringObjectives:- Titanium, Stainless steel, Inconel, Aluminium materials- ...
TipTopLam – Phase 1  Machines selectionLaser Cladding (Laser metal deposition):        Optomec, Trumpf, Accufusion, POM, I...
Laser claddingPrincipleNo powder bedLocal deposition of fused metalPowder feeding in the laser beam3 types of applications...
Cladding head                8
Laser melting process                               Pictures from ILT- Powder bed system- Full melting of the powder- Full...
MTT (SLM Solutions) SLM 250HL- Laser Power: 400W- Materials: Ti, Al, Inconel,CoCr, SS, Tool Steel- Z axis: 350mm- Pre heat...
Laser melting - Quality control   Two examples of Melting mastering problems    (from SLM/DMLS/Cusing manufacturers benchm...
3D Scanner GOM ATOS IProjecteur de franges + 2 CCD- 2 Mpix/scan (1624 x 1236 pixels)- 3 volumes de mesure Volume de     Ré...
Scanner METRIS LC60D (adapté au FGM)Avantages <> génération précédente:- ESP3, ajustage continu des paramètres de chaque p...
TipTopLam – Phase 2FGM Functionally graded materials- Summary of FGM cases and patents in the world- Summary of ideas from...
Sirris ADD capacities & competenciesADD (1990 – 2012)  • 15 engineers and technicians  • Two locations: Liège (10 p.) and ...
Additive Manufacturing – E-learning & Handbook• KTRM Leonardo project• Partners:  ASCAMM, SIRRIS, ASERM, iSmithers, Materi...
Additive Manufacturing        Merci pour votre attentionContact: Thierry Dormal   thierry.dormal@sirris.be                ...
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2012 11-15-high-value-manufacturing-sirris-dormal

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2012 11-15-high-value-manufacturing-sirris-dormal

  1. 1. SIRRIS – ADDHigh Value Manufacturing - IntroductionThierry Dormal
  2. 2. Agenda High Value Manufacturing – Nov. 1514h30 Introduction Thierry Dormal (Sirris)14h50 Cas concrets d’application des Matériaux à Gradient Fonctionnel (FGM) dans différents secteurs industriels Julien Magnien (Sirris)15h10 L’allègement par les techniques additives: une nouvelle manière de concevoir. Denis Gravet (Sirris)15h30 Pièces métalliques à porosité contrôlée fabriquées par 3D-Printing Bruno Verlee (Sirris)15h45 Pause16h00 Témoignages industriels: AEI, Flying Cam, Group T Formula Racing16h45 Visites & échanges thématiques individuels18h00 Drink 2
  3. 3. B2B – Session d’échanges thématiquesConception orientée additive manufacturingLaser Cladding, Laser Melting, EBM, 3DP metal SIRRISCaractérisation microstructurale et thermophysique Ulg (MMS)Caractérisation mécanique, fatigue,… CRMContrôle non-destructif, tomographie CEWACMesure 3D, Imagerie thermique, mesure de déformations CSL / SIRRIS 3
  4. 4. TipTopLam partnershipResearch centers and universities:SIRRIS CSL ULg CRM CEWACIndustrial partners:Techspace Aero, FN Browning, Sabca, Sonaca,Precimetal, Breuer, Flying Cam, Carat Duchatelet,Euro Heat Pipes, Secopra, Précical, PrécisionLiégeoise, Jtekt. 4
  5. 5. TipTopLam – Phase 1 Technology selection & masteringObjectives:- Titanium, Stainless steel, Inconel, Aluminium materials- Combination of small details and high productivity- Solutions for FGM experimentationWP1 Technology selection and installationWP2 Real time process controlWP3 Building with Laser Cladding & Laser MeltingWP4 Analysis of microstructures and mechanical propertiesWP5 Post-milling & post processing 5
  6. 6. TipTopLam – Phase 1 Machines selectionLaser Cladding (Laser metal deposition): Optomec, Trumpf, Accufusion, POM, IrepaLaser… Irepa EasyClad DuoCladLaser Melting: EOS, MTT (MCP), ConceptLaser, Phenix,… MTT (SLM Solutions)Scanning 3D: ExaScan, Metris, GOM, Minolta,… GOM + Metris head LC60D 6
  7. 7. Laser claddingPrincipleNo powder bedLocal deposition of fused metalPowder feeding in the laser beam3 types of applications- Coatings: enhancement of hardness, wear resistance and anti-corrosion- Repair of damaged expensive parts- Full 3D building of partsLarge range of materials availableFGM (dual feeding system) 7
  8. 8. Cladding head 8
  9. 9. Laser melting process Pictures from ILT- Powder bed system- Full melting of the powder- Full density © sirris 2010 | www.sirris.be | info@sirris.be | 9
  10. 10. MTT (SLM Solutions) SLM 250HL- Laser Power: 400W- Materials: Ti, Al, Inconel,CoCr, SS, Tool Steel- Z axis: 350mm- Pre heating build platform:up to 200°C- AutoFAB Software (Marcam)- Layer thickness: 30•m(20•m) up to 100•m
  11. 11. Laser melting - Quality control Two examples of Melting mastering problems (from SLM/DMLS/Cusing manufacturers benchmarks!) Ti-6Al-4V Al-SiSirris works are based on process simulation and microstructure analysisDensity: > 99 % and a fine microstructure due to fast coolingCompetence required and efficient quality control as well 11
  12. 12. 3D Scanner GOM ATOS IProjecteur de franges + 2 CCD- 2 Mpix/scan (1624 x 1236 pixels)- 3 volumes de mesure Volume de Résolution Précision mesure (mm) (mm) 500x400x400 0.3 0.05 250x200x200 0.15 0.02 120x96x80 0.07 0.01- Plateau tournant (100Kg max)- Référencement par micro-cibles(gommettes) 12
  13. 13. Scanner METRIS LC60D (adapté au FGM)Avantages <> génération précédente:- ESP3, ajustage continu des paramètres de chaque point du scan- productivité: 75000pts/s au lieu de 25000pts/s- stabilité car prisme statique, pas de miroir mobile- pas de préchauffage car compensation thermique- bande de 60mm, profondeur de champ 60mm- Précision 15 •m (1σsphere fit) 13
  14. 14. TipTopLam – Phase 2FGM Functionally graded materials- Summary of FGM cases and patents in the world- Summary of ideas from industrial partners- New format file required (STL AMF)- Selection of material combinations for FGM- Selection of gradient types (thermal, physical, mechanical)- Sample testing, validation and microstructure analysis 14
  15. 15. Sirris ADD capacities & competenciesADD (1990 – 2012) • 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)In-house additive technologies • Stereolithography (normal & hi-res) • Paste polymerisation for ceramics and metals (2 Optoform) • 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal) • Laser sintering of polymeric powder (PA,…): P360 – P390 • Objet Connex 500: bi-material • Laser Melting (MTT/SLM Solutions) SLM 250 HL • EBM Arcam A2 (Titanium & CoCr) • Laser Cladding (Irepa Laser EasyCLAD) • 3D Printing of wax (Thermojet) • Makerbot Replicator & Fab@home • 3D scanning & metrology (GOM, Metris, Wenzel) 15
  16. 16. Additive Manufacturing – E-learning & Handbook• KTRM Leonardo project• Partners: ASCAMM, SIRRIS, ASERM, iSmithers, Materialise, ULPGC, ITIA• Handbook (220 pages) and e-learning courses (17 modules)• Introduction• 13 AM Technologies• Design and Analysis• AM Materials• Business models for AM• Conclusions Contact: Thierry Dormal thierry.dormal@sirris.be 16
  17. 17. Additive Manufacturing Merci pour votre attentionContact: Thierry Dormal thierry.dormal@sirris.be 17

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