This document discusses metal additive manufacturing (AM) for aerospace and high-end applications. It provides examples of projects conducted by NLR MAMTeC, including for Dutch defense, wind tunnel models, and space applications. It also discusses developments in metal AM to improve powder quality control, optimize processes, and add process monitoring. Additionally, it explores using AM for hydraulic applications to optimize fluid flow, thermal control components, and structural parts to enable weight reduction. Limitations and opportunities of metal AM are discussed, including the entire lifecycle of metal powders from production to characterization and how storage and handling can impact properties. Mechanical properties, microstructure, and porosity of additively manufactured alloys are compared to conventionally manufactured

1. MAMTeC
Metal-AM for Aerospace and high-end applications
Developments in Metal Additive Manufacturing for
successful production of critical parts
NLR MAMTeC , 2018 Marc de Smit

2. NLR, MAMTeC 2018
Content
• Short introduction NLR & MAMTeC
• Examples of MAMTeC projects
• MAMTeC Activities
• Can Spare Parts be printed?
2

3. >95
639 employees
Innovative, engaged
and practical
One-stop-shop
€ 73 M revenue
Global player with
Dutch roots
For industry and
government
Extremely high
client satisfaction
Amsterdam,
Marknesse, Schiphol95 years young
Active in 33 countries
74% Dutch, 23% EU
and 3% international
For civil and
defence
NLR in brief
NLR, MAMTeC 2018 3

4. NLR, MAMTeC 2018
Manufacturing Technology Centre (MAMTeC)
Thé Metal AM Technology Centre in NL
• Unique combination of knowledge, experience
and facilities
• Qualification/Certification track record
• Focus on High tech High spec applications
• Part of Smart Industry Fieldlab ACM3
4

5. NLR, MAMTeC 2018
Examples of MAMTeC projects
• R&D for Dutch Defence
• Parts for wind tunnel models
• Space applications
• Prototyping for various applications
• Process development new materials
• Process development Multimaterial
AM
5

6. NLR, MAMTeC 2018 6
Developments in Metal Additive manufacturing for
successful production of critical parts
• Improved powder quality control
• Process optimisation
• Process monitoring

7. NLR, MAMTeC 2018 7
Developments in Metal Additive manufacturing for
successful production of critical parts
• Improved powder quality control
• Process optimisation
• Process monitoring
Scanner
MPM
system
Photodiodes
Laser Power
Monitoring

8. NLR, MAMTeC 2018 8
Additive Manufacturing of Hydraulic applications
• Fluid topology optimization
• Increase performance, Reduce pressure drop
• Also lighter hydraulic pump
• Minimize weight of channels
• Take design rules into account

9. NLR, MAMTeC 2018 9
Additive Manufacturing of Hydraulic applications
• Big advantage where weight and efficiency is an issue

10. NLR, MAMTeC 2018 10
Additive manufacturing for Thermal control
• Additive manufacturing of heat exchangers and other components
• When very stable temperatures and/or low mass are crucial
• Active thermal control (pump) or passive thermal control (heat pipes)

11. NLR, MAMTeC 2018 11
Additive Manufacturing of structural applications
• Redesign obsolete part
• Forging requires forging mould
• High cost and long lead time
• Design for AM: 34% weight reduction

12. NLR, MAMTeC 2018 12
Limitations and opportunities of Metal-AM…
• Laura Cordova

13. TOWARDS TECHNICAL LIMITATIONS AND
OPPORTUNITIES OF METAL-AM
Laura Cordova, Tiedo Tinga

14. Powder Production
Storage/
Handling
Additive
Manufacturing
Post-processing
Material
characterization
14
LIFE CYCLE OF METAL POWDERS FOR ADDITIVE MANUFACTURING
PROCESS

15. 03/10/2018l.cordovagonzalez@utwente.nl 15
LIFE CYCLE OF METAL POWDERS FOR ADDITIVE MANUFACTURING
PARAMETERS
Powder Production
• Morphology
• Size distribution
• Chemical composition
• Flowability
• Apparent/tap density
Additive
Manufacturing
• Thermal and radiation properties
• Scan pattern and speed
• Layer thickness
• Laser Power
• Melting temperature distribution
• Surface tension
• Melt viscosity
• Hatch distance
• …
Storage/ Handling
• Moisture content
• Oxygen & nitrogen pick-up
• Homogeneity
• Powder reuse / sieving
Post-processing
• Supports and powder
removal
• Surface roughness
• Residual stresses
• Porosity
Material
characterization
• Mechanical properties
• Microstructure
• Density
• Non-destructive testing

16. 03/10/2018l.cordovagonzalez@utwente.nl 16
IMPACT ON POWDERS HANDLING
ON LOCATION CASE
 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)
 Storage facilities (size, conditions)
Problem:
Highest impact
of moisture on
Al alloys
Solution: Drying
policy for Al
alloys.
Problem: Potential impact on
powder reuse for > 40 build jobs
Solution: “Rejuvenation” for
prolonged reuse.

17. 03/10/2018l.cordovagonzalez@utwente.nl 17
LIFE CYCLE OF METAL POWDERS FOR ADDITIVE MANUFACTURING
PARAMETERS
Powder Production
• Morphology
• Size distribution
• Chemical composition
• Flowability
• Apparent/tap density
Additive
Manufacturing
• Thermal and radiation properties
• Scan pattern and speed
• Layer thickness
• Laser Power
• Melting temperature distribution
• Surface tension
• Melt viscosity
• Hatch distance
• …
Storage/ Handling
• Moisture content
• Oxygen & nitrogen pick-up
• Homogeneity
• Powder reuse / sieving
Post-processing
• Supports and powder
removal
• Surface roughness
• Residual stresses
• Porosity
Material
characterization
• Mechanical properties
• Microstructure
• Density
• Non-destructive testing

18. ADDITIVE VS CONVENTIONAL MANUFACTURING
MECHANICAL PROPERTIES AND MICROSTRUCTURE

19. 19
POWDER MATERIALS
ALSI10MG AND SCALMALLOY
AlSi10Mg Scalmalloy
Material Al Fe Mg Mn Ni Sc Si Ti V Zr
AlSi10Mg
~bal 0.11 0.38 <0.01 <0.01 - 10.10 <0.01 - -
Scalmalloy
~bal 0.13 4.39 0.49 - 0.66 <0.01 0.021 0.013 0.31
Composition
03/10/2018l.cordovagonzalez@utwente.nl

20. 03/10/2018l.cordovagonzalez@utwente.nl 20
MICRO-TENSILE TEST
5 mm
z
x
y
Z specimen
XY specimen
1KN load
10x smaller than standards
1 mm
specimens Micro-tensile test set-up

21. IN-SITU TENSILE TESTING
ALSI10MG XY
03/10/201l.cordovagonzalez@utwente.nl 21

22. Scalmalloy XY Scalmalloy Z AlSi10Mg XY AlSi10Mg Z
150
200
250
300
350
400
450
500 UTS
Def.
UTSMPa
6
8
10
12
14
16
18
Def.%
03/10/2018l.cordovagonzalez@utwente.nl 22
MECHANICAL PROPERTIES
MICRO-TENSILE TEST, HARDNESS
Al7075
Def.~14%
Scalmalloy XY Scalmalloy Z AlSi10Mg XY AlSi10Mg Z
150
200
250
300
350
400
450
500 UTS
Def.
UTSMPa
6
8
10
12
14
16
18
Def.%
Al7075 (550MPa)
Al7075 Scalmalloy AlSi10Mg
70
80
90
100
110
120
130
140
150
160
170
180
190
200
Hardness(HV)
- T6
Hardness measured on the cross-sections.
The values are heat treatment dependent.

23. 03/10/2018l.cordovagonzalez@utwente.nl 23
MICROSTRUCTURAL FEATURES
MELT POOLS - GRAINS
AlSi10Mg XY AlSi10Mg Z
Scalmalloy ZScalmalloy XY
Al7075-T6
Al7075-T6
AlSi10Mg
Scalmalloy

24. 03/10/2018l.cordovagonzalez@utwente.nl 24
MICROSTRUCTURAL FEATURES
EXAMPLE: SCALMALLOY Z
Scalmalloy Z
Meltpool size ~100µm Grain size ~1µm
100µm

25. 03/10/2018l.cordovagonzalez@utwente.nl 25
POROSITY
POROSITY TYPE AND LEVEL
AlSi10Mg Scalmalloy Al7075-T6
200 µm100 µm
Porosity level AlSi10Mg Scalmalloy Al7075-T6
max 159µm 110µm ~30µm
min 33µm 30µm ~15µm
100 µm
Rounded porosity
Rounded porosity
Regular small porosity

26. 03/10/2018l.cordovagonzalez@utwente.nl 26
SUMMARIZE MECHANICAL PROPERTIES
ADDITIVE VS. CONVENTIONAL MANUFACTURING
Materials UTS (MPa) εbreak (%) HV
AlSi10Mg XY 202±13 15±2 72±5
AlSi10Mg Z 224±20 12±2 76±3
Scalmalloy® XY 462±17 16±2 147±3
Scalmalloy® Z 440±25 13±2 139±10
AlSi10Mg AM [1] 335 3 127
Scalmalloy® AM [2] 490 8 177
AlSi10Mg casted [3] 300-317 2,5-3,5 86
1. Material Data Sheet - AlSi10Mg. AIRBUS APWORKS GmbH, Taufkirchen, Germany.
2. Material Data Sheet - Scalmalloy®. AIRBUS APWORKS GmbH, Taufkirchen, Germany.
3. Matweb materials data. Web-Based Data, http://www.matweb.com/ ,Matweb, UK, as on 12.05.2018.

27. DYNAMIC ANALYSIS
ONGOING RESEARCH

28. 03/10/2018l.cordovagonzalez@utwente.nl 28
DYNAMIC ANALYSIS
ADDITIVE VS. CONVENTIONAL MANUFACTURING
Al7075
Extruded
Scalmalloy
As-built
Scalmalloy
Machined
Z
X

29. 03/10/2018l.cordovagonzalez@utwente.nl 29
SUMMARY
AM VS. CM
 AM offers an alternative to conventional manufacturing
 Storage and handling have an impact in the process planning
 AM means design freedom, weight and waste reduction, no
need for tooling, and opens material forming possibilities
 AM alloy systems can be tailored for specific applications
 Process parameters of AM techniques are specific for a group
of materials and mechanical properties (tailored)
CM is still necessary for certain applications, AM covers
potentially interesting niche markets

30. Laura Cordova
l.cordovagonzalez@utwente.nl