Sirris_am in aviation and aerospace_arcam additive manufacturing with ebm - the route to production
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The document discusses additive manufacturing using electron beam melting (EBM) technology. It describes how EBM is used to produce metal orthopedic implants and aerospace components. Key advantages of EBM include the ability to design complex cellular structures, high production rates, and excellent material properties without requiring post-processing. New EBM systems like the Arcam Q10 and Q20 are designed for high volume production and include features like improved resolution, quality verification cameras, automated powder handling, and process monitoring software.
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Sirris_am in aviation and aerospace_arcam additive manufacturing with ebm - the route to production
- 1. Additive Manufacturing with EBM - The Route to Production 2014-05-13 1Insight into 3D printing in the aerospace industry
- 2. ”Arcam develops, manufactures and sells production technology for Additive Manufacturing in metal” Mission statement Focusing on • Aerospace components • Orthopedic implants 2014-05-13 2Insight into 3D printing in the aerospace industry
- 3. Success factors for production • Reliability - Stable machine systems Stable manufacturing process • Economy - High production rate Competitive powder cost • Quality - Material quality Geometric accuracy Surface quality 2014-05-13 3Insight into 3D printing in the aerospace industry • Added values - Freedom in design with AM Cellular structures Metal powder
- 4. • CE-certified acetabular cups with integrated Trabecular Structures™ since 2007 • Implants with US-FDA clearance since 2010 • EBM® production of implants • • > 40,000 cups implanted • 2% of the global production of acetabular cups is now manufactured with EBM® 2014-05-13 4Insight into 3D printing in the aerospace industry Adler Ortho, IT 2007- Lima, IT 2007- Exactech, US 2010- Height ~30 mm Diameter ~50 mm
- 5. 3D Cellular Structures 2014-05-13 5Insight into 3D printing in the aerospace industry Diamond shape layout
- 6. 3D Cellular Structures 2014-05-13 6Insight into 3D printing in the aerospace industry Courtesy of North Carolina State University
- 7. Biocompatibility Pictures of bone growing into EBM-manufactured titanium implants with Trabecular Structures™ Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg. 2014-05-13 7Insight into 3D printing in the aerospace industry Acetabular cup with porous surface made with EBM University of Gothenburg.
- 8. System and process stability • The graph below shows development of system reliability for EBM systems in serial production of acetabular cup implants over more than three years during production ramp up.over more than three years during production ramp up. 2014-05-13 8Insight into 3D printing in the aerospace industry based on more than 45.000 running hours Monthly success rate of production runs from log files from all builds
- 9. Sub-system example: Powder dispatcher failure rate 2014-05-13 9Insight into 3D printing in the aerospace industry Based on ~40.000 running hours in six EBM systems
- 10. EBM Productivity: Stacking of Parts • Cups have excellent geometry for stacking. • Production example 80 cups:• Production example 80 cups: • Non-stacked: 126 h • Stacked: 82 h • Build time reduction: ~35% 2014-05-13 10Insight into 3D printing in the aerospace industry
- 11. Production cost of cups Implants built with EBM • High productivity • Excellent material properties• Excellent material properties • No mechanical support structure (hot process) • No secondary coating operation 2014-05-13 11Insight into 3D printing in the aerospace industry
- 12. EBM® - Electron Beam Melting • The electron beam gun generates a high energy beam (up to 3.000 W) • The beam melts each layer of powder• The beam melts each layer of powder metal to the desired geometry • Extremely fast beam translation with no moving parts • High beam power -> high melt rate (up to 80 cm3/h) and productivity • Vacuum process -> eliminates impurities and yields excellent material properties 2014-05-13 12Insight into 3D printing in the aerospace industry and yields excellent material properties • High process temperature (650 ºC for titanium) -> low residual stress and no need for heat treatment
- 13. The EBM® Machine EB Gun Heat Shield Powder Rake Powder Container Build Chamber Vacuum build chamber 2014-05-13 13Insight into 3D printing in the aerospace industry Powder Rake Build Platform Control Unit Build Tank
- 14. • To maintain the correct build temperature in all parts of the geometry throughout the build, thermal modeling integrated in the control software dynamically adjusts EBM® process: Temp control the control software dynamically adjusts speed and current to ensure: • Uniform material properties • No grain growth, e.g. above certain transformation temperature • Low amount of evaporation of alloying elements • Dimensional stability 2014-05-13 14Insight into 3D printing in the aerospace industry • Dimensional stability • The use of integrated thermal modeling combined with the elevated build temperature are key factors behind the fast and accurate build process System interior, heat distribution
- 15. Advantage of hot process for bulk melting Fast beam & higher powerSlow beam Fast beam Fast beam & warm bulk (& lower power) Surface Tmelt Tboil TempTemp Tmelt Tboil Surface Melt depth Surface Melt depth Melt depth Surface Melt depth Tmelt Tboil Temp Surface Melt depth Bulk temperature 2014-05-13 15Insight into 3D printing in the aerospace industry TimeTime Melt depth Time Increased bulk temperature reduces gradient, allowing for higher speed with preserved quality
- 16. Production case for aerospace: Turbine blades in -TiAl • Cooperation agreement with Avio (Italy) • Prototype turbine blades in -TiAl •• 325 mm build height • Dimensional tolerance: 0.1 mm • Turnaround time: 7,5 h / blade 2014-05-13 16Insight into 3D printing in the aerospace industry Courtesy of Avio SpA
- 17. EBM® -TiAl: microstructures Courtesy of Avio SpA and Politecnico di Torino As-built by EBM HIP 1260 C, 1700 bar, 4h Equiaxed 2014-05-13 17Insight into 3D printing in the aerospace industry Equiaxed Grain size <20 m Heat Treatment Duplex Lamellar colonies ~100 m Equiaxed grains ~15 m Lamellar fraction ~ 40%
- 18. Production focus • Series production allows process optimization in each specific production case (geometry) • Parameters such as layer thickness may for this reason be• Parameters such as layer thickness may for this reason be different for different production cases • Arcam actively supports our customers in setting up the most optimal process for each production case 2014-05-13 24Insight into 3D printing in the aerospace industry
- 19. Overview: Arcam machine generations EBM S12 (2003) S-series Arcam A2 (2008)Arcam A1 (2009) Arcam A2X / A2XX A2 derivatives with modified build volumes A-Series 2014-05-13 25Insight into 3D printing in the aerospace industry Arcam Q10 (2013) Arcam Q20 (2013) Q-Series Currently in production
- 20. Arcam Q10 / Arcam Q20 2014-05-13 26Insight into 3D printing in the aerospace industry
- 21. Design for Production • The Arcam Q10 / Q20 are developed in collaboration with leading implant and aerospace manufacturers • Arcam Q10 is the EBM system designated for volume production of orthopedic implants • Arcam Q20 is the EBM system designated for volume production of aerospace components 2014-05-13 27Insight into 3D printing in the aerospace industry
- 22. Arcam Q - Highlights • Higher productivity • Improved resolution• Improved resolution • Reduced risk of operator mistakes • Quality verification with Arcam LayerQam™ • Closed powder handling 2014-05-13 28Insight into 3D printing in the aerospace industry • Closed powder handling • Software adapted to volume production
- 23. • Use of high brightness cathodes LaB6 • 500+ hours operating time in EBM • Single crystalline high brightness filament New EB gun design • Single crystalline high brightness filament • State-of-the-art manufacturing • 8-10 times higher brightness than W3%Re • 1800 °K (2600 °K) • 5-6 W heating power (30 W) • Improved vacuum design • Improved beam formation 2014-05-13 29Insight into 3D printing in the aerospace industry
- 24. Electron beam size • Improved spot quality at high beam power enables faster processing of high quality surfaces 2014-05-13 30Insight into 3D printing in the aerospace industry
- 25. Arcam Q20 build time, customer part Arcam Q20 vs. Arcam A2XX Arcam A2XX build time, customer part 2014-05-13 31Insight into 3D printing in the aerospace industry ~ 85 h ~ 130 h
- 26. New Software • New man-machine interface, with two user modes • Engineering mode • Production mode, fully automated• Production mode, fully automated 2014-05-13 38Insight into 3D printing in the aerospace industry
- 27. Operator Assistance Systems • Prevention of operator mistakes • Automatic measurement of available build height • Detection of powder hopper blinds• Detection of powder hopper blinds • Automatic calculation of remaining filament life • Automatic detection of heat shield 2014-05-13 39Insight into 3D printing in the aerospace industry
- 28. Arcam LayerQam™ • Camera-based quality verification system • Additive Manufacturing provides a new melted surface for each layer• Additive Manufacturing provides a new melted surface for each layer • The melting depth is thicker than the layer of powder • Camera-based monitoring of each melted layer provides porosity control of the entire produced part • Monitoring each layer hence provides a unique capability to verify the full density of EBM-produced components 2014-05-13 45Insight into 3D printing in the aerospace industry
- 29. Arcam LayerQam™ - demo, sample with deliberately generated defects Micro tomography Filtered camera images 2014-05-13 46Insight into 3D printing in the aerospace industry
- 30. New Powder Recovery System • Part removal • Automated sifting • Automated refill of powder hoppers• Automated refill of powder hoppers 2014-05-13 47Insight into 3D printing in the aerospace industry
- 31. Streamics™ (optional add-on) • “...is easily integrated in an automation system and allows centralized processing...” Magics Build processor AM preparation Slice Hatch Build Quality Control EBM Control 2014-05-13 48Insight into 3D printing in the aerospace industry
- 32. EBM® and aerospace - Long-term development • Faster processing and Larger build envelope • The available beam power restricts build area and build rate • The need for higher electron beam current is thus twofold: • More power for heating to enable larger build envelope • More power to enable more Arcam MultiBeam™ spots • An EU FP7 project, FastEBM, has developed a prototype electron gun for EBM with more than three times higher beam power than for current systems • The prototype gun is under testing on an Arcam Q platform 2014-05-13 52Insight into 3D printing in the aerospace industry • The prototype gun is under testing on an Arcam Q platform to evaluate potential for system development
- 33. Electron beam – powder interaction model • The FastEBM project also developed a powder-based interaction model, based on the Lattice Boltzman Method,based on the Lattice Boltzman Method, to support EBM process development • Development partner: Erlangen University 2014-05-13 53Insight into 3D printing in the aerospace industry • Project aim: 2D 3D
- 34. Contact Thank you for your attention! Arcam AB Krokslätts Fabriker 27A SE-431 37 Mölndal, Sweden Phone: +46 31 710 32 00 Web site: www.arcam.com E-mail: info@arcam.com Thank you for your attention! 2014-05-13 55Insight into 3D printing in the aerospace industry Arcam - CAD to Metal®