This progress update summarizes work on package 1 which focuses on raw material conditions and failure behavior of printed parts. Regarding location, challenges of gas flow, moisture, contamination and their impact on process, supply chain and costs were analyzed. Results showed varying moisture levels and powder flow rates for different materials. Next steps are to identify effects on builds and mechanical properties. The framework presented examines failure mechanisms from raw materials through final properties. A top-down approach to select case studies of representative parts from partners will be used to understand and test for quality and potential failures under different materials and processes.

1. PROGRESS UPDATE WORK PACKAGE 1
LAURA CORDOVA GONZALEZ

2. AGENDA
1. ON LOCATION
2. FAILURE BEHAVIOR OF PRINTED PARTS

3. AGENDA
1. ON LOCATION
2. FAILURE BEHAVIOR OF PRINTED PARTS

4. 4
ON LOCATION (1/4)
CHALLENGES
l.cordovagonzalez@utwente.nl 14/12/2016
Information was gathered from:
 Additive Manufacturing literature review
 Specialist interviews (Additive Industries, NLR, Sirris, University of Twente)
• Gas flow
• Material condition
Environment
• Personnel
• Material condition
• Machine
Operation
Electrostatic behavior
Oxygen pick up
Moisture
Contamination
Powder reuse

5. 5
ON LOCATION (2/4)
IMPACT
l.cordovagonzalez@utwente.nl 14/12/2016
How raw materials condition is linked with the process and supply
chain:
 Environment (moisture, contamination)
 Storage conditions (time, containers, ambient)
 Supply (frequency, supplier, transportation, quality)
 Operation (powder reuse)
 Cost (quality vs. price?)
 Sustainability (energy & resources consumption)
 Supply (frequency, quality)
[1] http://www.3dprinterworld.com/
Rapid Prototyping labs in Afghanistan
and Fort Belvoir, USA [1]

6. 14/12/2016l.cordovagonzalez@utwente.nl 6
ON LOCATION (3/4)
RESULTS
0
0,5
1
1,5
2
2,5
3
3,5
4
A S RE CE I V E D DRY
FLOW(g/s)
HALL FLOWMETER ANALYSIS
Ti6Al4V Inconel 718 AlSi10Mg M2 M4
0,00%
0,02%
0,04%
0,06%
0,08%
0,10%
0,12%
0,14%
0,16%
AlSi10Mg Inconel 718 Ti64 Scalmalloy M2 M4
MOISTURE(%)
MATERIALS
MOISTURE ANALYSIS

7. 14/12/2016
[2] Aboulkhair, Nesma T. (2016) Additive manufacture of an aluminium alloy: processing, microstructure, and mechanical
properties. PhD thesis, University of Nottingham.
7
ON LOCATION (4/4)
WRAP-UP
 Various parameters have effect on
process and powder properties.
 The aim of the research is to identify
the most relevant ones and quantify its
influence.
 Next steps are identifying the effects in
AM builds and testing its influence on
the mechanical properties.
Evolution of pores with various scan speed [2]

8. AGENDA
1. ON LOCATION
2. FAILURE BEHAVIOR OF PRINTED PARTS

9. 14/12/2016l.cordovagonzalez@utwente.nl 9
FAILURE BEHAVIOR PRINTED PARTS (1/3)
FRAMEWORK
Raw materials Storing conditions
Re-use (sieving)
Quality assurance
Process and post-
process
Parameters
Gas flow
Powder spreading
Handling and treatments
Final properties
Quality
Failure mechanisms
Surface roughness
Repeatability

10. 14/12/2016l.cordovagonzalez@utwente.nl 10
FAILURE BEHAVIOR PRINTED PARTS (2/3)
DISCUSSION
• Top-down approach for
parts selection
• Narrow to few potential –
interesting cases
• Representative to SINTAS
project partners:
 Failure
 Material
 Shape / Design
Case study
• Selection of spare parts to
print from a reduced group
• Adjust material, process
and parameters
• Understand and perform
quality testing depending
on:
 Potential failures
 Material properties
Part printed

11. 14/12/2016l.cordovagonzalez@utwente.nl 11
FAILURE BEHAVIOR PRINTED PARTS (3/3)
POSSIBILITIES
≠ Failures ≠ Techniques Repeatability
SLM
SLM
SLM
EBM

12. THANK YOU
12