1. SIRRIS – ADD
High Value Manufacturing - Introduction
Thierry Dormal

2. Agenda High Value Manufacturing – Nov. 15
14h30 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 Pause
16h00 Témoignages industriels: AEI, Flying Cam, Group T Formula Racing
16h45 Visites & échanges thématiques individuels
18h00 Drink
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3. B2B – Session d’échanges thématiques
Conception orientée additive manufacturing
Laser Cladding, Laser Melting, EBM, 3DP metal SIRRIS
Caractérisation microstructurale et thermophysique Ulg (MMS)
Caractérisation mécanique, fatigue,… CRM
Contrôle non-destructif, tomographie CEWAC
Mesure 3D, Imagerie thermique, mesure de déformations CSL / SIRRIS
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4. TipTopLam partnership
Research centers and universities:
SIRRIS CSL ULg CRM CEWAC
Industrial partners:
Techspace Aero, FN Browning, Sabca, Sonaca,
Precimetal, Breuer, Flying Cam, Carat Duchatelet,
Euro Heat Pipes, Secopra, Précical, Précision
Liégeoise, Jtekt.
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5. TipTopLam – Phase 1
Technology selection & mastering
Objectives:
- Titanium, Stainless steel, Inconel, Aluminium materials
- Combination of small details and high productivity
- Solutions for FGM experimentation
WP1 Technology selection and installation
WP2 Real time process control
WP3 Building with Laser Cladding & Laser Melting
WP4 Analysis of microstructures and mechanical properties
WP5 Post-milling & post processing
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6. TipTopLam – Phase 1
Machines selection
Laser Cladding (Laser metal deposition):
Optomec, Trumpf, Accufusion, POM, IrepaLaser…
Irepa EasyClad DuoClad
Laser Melting:
EOS, MTT (MCP), ConceptLaser, Phenix,…
MTT (SLM Solutions)
Scanning 3D:
ExaScan, Metris, GOM, Minolta,…
GOM + Metris head LC60D
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7. Laser cladding
Principle
No powder bed
Local deposition of fused metal
Powder feeding in the laser beam
3 types of applications
- Coatings: enhancement of hardness, wear resistance and anti-
corrosion
- Repair of damaged expensive parts
- Full 3D building of parts
Large range of materials available
FGM (dual feeding system)
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8. Cladding head
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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. 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. Laser melting - Quality control
Two examples of Melting mastering problems
(from SLM/DMLS/Cusing manufacturers benchmarks!)
Ti-6Al-4V Al-Si
Sirris works are based on process simulation and microstructure analysis
Density: > 99 % and a fine microstructure due to fast cooling
Competence required and efficient quality control as well
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12. 3D Scanner GOM ATOS I
Projecteur 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)
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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)
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14. TipTopLam – Phase 2
FGM 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
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15. Sirris ADD capacities & competencies
ADD (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)
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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
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17. Additive Manufacturing
Merci pour votre attention
Contact: Thierry Dormal thierry.dormal@sirris.be
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