The document provides a comprehensive overview of the high-performance metal industry and metallic additive manufacturing, including strategies, new facilities, and capabilities. It emphasizes resource efficiency, low-cost input materials, thermal modeling for distortion control, and various metal production techniques such as cold spray and 3D printing. Additionally, it outlines industry engagement efforts and the establishment of an additive manufacturing network in Australia to enhance collaboration and innovation within the sector.

1. High Performance Metal Industry -
Metallic Additive Manufacturing
Comprehensive Overview
Chad Henry | Additive Manufacturing Operations Manager
Aug 2014
MANUFACTURING FLAGSHIP

2. Agenda
High Performance Metal Industry (Flagship Program)
Continuous Metal Production – TiRO and others
Metallic Additive Manufacturing
- Roadmaps and Strategies
- New Facility, Capabilities, and Engaging with Industry
- Low Cost Input Material
- Thermal Modelling for (Sciaky) Distortion Control
- Additive Manufacturing Network
ore to more

3. from ore to more
High Performance
Metal Industry
Metal
Production
Metal to
Product
Manufacturing Special Projects
TiRO
Alloys Process
Novel Alloy Design
BMG Prod/Proc
Sheet
Plates
Bars
Billets
Shaped Billets
Wire
Extrusions
Powder (for AM)
Cold Spray
Laser Assisted Machining
Additive Manufacturing
Lab 22
Modelling and Simulation
Online / In Situ Measurement
Thermally Assisted Machining
Victorian Productivity Network
SIEF Aero-engine Project
DMTC 1.9
Ti + XYZ alloys
Universal Powder Bed for R&D

4. Additive Manufacturing is...
layer-by-layer processing to make 3D objects directly from CAD files, as opposed to
using subtractive methods like traditional CNC machining.
Resource efficient and Sustainable
energy efficient
reduces waste

5. Lab 22 – Arcam High Speed Video - Contour

6. Lab 22 – Arcam High Speed Video – Fill Rastering

7. Metallic Additive Manufacturing Roadmap
Wire Powder
Database for Production
•Ti 6Al 4V
Low Cost Feedstock
Distortion Control
Management
In Situ Inspection
Methods
Microstructure
Manipulation
Additional Material Data
•Titanium, Steel or ?
Novel Titanium
Materials
(Bed or Spray)
Properties and Databases
for Production
Ex Situ Powder Bed
Powder Manipulation
In Situ Modelling &
Management
In Chamber Inspection
Methods
Microstructure
Manipulation
Novel Metallic Alloys
Additional Materials
Decrease final Component Cost
Increase the Application Space

8. Meltless Additive Manufacturing
Cold Spray
Additive Manufacturing Repair Coatings
Near Net Shape
Ti Pipe Seamless
Continuous
Ti Bike
Frame
Ti
Coupler
Composite
Dies
Defects
Repair
Corrosion
Resistant
Electroplating
Replacement
Design
Modification
Wear
Resistant
Biofowling
Composite
Coatings
Bulk
Billet
Forging
Pre forms
Reclamation
Materials
 Metals & Alloys: Ti, Ni, Fe, Cu, Al, Sn
 Ceramics + Metals: Al + TiB2
 Polymers

9. CSIRO Additive Manufacturing ... The 2+1 Strategy
Modelling and
Simulation
Feedstock and
Powder
New Material
Development
Distortion Management
Novel Sources
Physical Modification
The AX - Powder Flow
Industry
Engagement
AM Network
Build, Consult, SIEF
Derived from
Casting and
Welding
Derived from
Cold Spray,
TiRO, and Alloys
Processing

10. New and Improved Facilities for Metallic AM
• CSIRO has an open house policy to Industry and for R&D
• De-risk to aid in Industry Adoption and Growth
• Access our capital equipment
• Access our trained operators
• Trial and Learn Metallic AM
• AĐĐess us foƌ assistaŶĐe oŶ DeǀelopiŶg BusiŶess Cases aŶd Positiǀe ROI’s
• Access us for assistance on design (or re-designing) to take advantage of 3DP
(d)
Design Freedoms
• Access us for assistance on material science solutions
• Learn first-hand
• Technologies (next slides)
• Powder Beds – E-Beam and Laser
• Powder Spray – 3D Deposition, Cold Spray, and Laser Cladding
• Sand Printing – For Metallic Castings
P.S. – It needs a name. Contact me if you have a clever one that you are willing to share.

11. E-Beam AM Equipment
Arcam Model A1
- Electron Beam Melting (EBM)
- Powder Bed
- Vacuum
- Elevated Temp
- Low Distortion
- Excellent Properties
- Model A1
- 200mm x 200mm x 180mm
- Materials
- Ti and Ti Alloys
- CoCr
- Nickel Alloys (Inconel)
- Steel Alloys
- Others???
- CSRIO Level 3 Training

12. Concept Laser M2 cusing
• Laser fusion powder bed
• 250 x 250 x 280 (mm) chamber build volume
• 400W beam power
• Very good part roughness Ra 9-12mm, Rz 35-
40mm (Ti-64)
• <55cm3/h build rate (Ti-64)
• Inert gas environment
• Standard LaserCUSING materials include:
Stainless steel 1.4404 / CL 20ES
Aluminium alloy AlSi12 / CL 30AL
Aluminium alloy AlSi10Mg / CL 31AL
Titanium alloy Ti6Al4V / CL 40TI
Titanium alloy Ti6Al4V ELI / CL 41TI ELI
Hot-forming steel 1.2709 / CL 50WS
Rust-free hot-forming steel CL 91RW
Nickel-based alloy Inconel 718 / CL 100NB
Cobalt/chrome alloy remanium star CL
• Moderate residual stress
• Prototyping, design, customising, light-weighting

13. Optomec LENS MR-7
• IPG Fiďƌe Laseƌ ͞ďloǁŶ poǁdeƌ͟
• 300 x 300 x 300 (mm) chamber build volume
• 500W beam power
• Two powder feeder (layered composition profiles)
• Part roughness Ra 20-50mm (Rz 150-300mm)
• 22cm3/h build rate (Ti-64) (much higher build rates for
other LENS variants
• High purity inert gas (O2 ≤ ϭϬ ppŵ)
• High residual stress
• Optomec materials: *Non-standard Materials used in R&D
Titanium Nickel Tool Steel
CP Ti, Ti 6-4, Ti 6-2-4-2
Ti 6-2-4-6*, Ti 48-2-2*,
Ti 22AI-23Nb*
IN625,IN718,IN690*, Hastelloy
X*, Waspalloy, MarM247*,
Rene 142*
H13, S7, A-2*
Stainless Steel Refractories Composites
13-8, 17-4, 304, 316, 410,420,
15-5PH*, AM355*, 309*, 416*
W*, Mo*, N* TiC*, WC, CrC*
Cobalt Aluminum Copper
Stellite 21 4047 GRCop-84*, Cu-Ni*
• Repair, prototyping, design, customising, light-weighting,
alloy design, composite materials

14. Cold Spray Technologies
Plasma Giken PCS-1000
CGT Kinetiks 4000

15. Voxeljet

16. 9
Metal Additive Manufacturing Landscape Today
National Aeronautics and Space Administration
Langley Research Center

17. Must Understand ... One Size Does Not Fit All
Product Requirements  Manufacturing Processes
Material
Build Volume
Rate
Design and Unitization
Unique Shapes/Details (free)
Surface Finish
Inspection
Laser vs.
E-Beam vs.
Solid State
Powder Bed vs.
Powder Spray vs.
Wire Fed
All for ...
Production
Prototyping (form, fit, function)
Tooling
Rapid Design
Shop Aids
Ti
Ni
Al

18. Titanium Technologies and Lab 22 Achievements
• Since Sept of 2012, Lab 22 has 3D printed over 700 pieces in titanium from over 150 files
for 52 entities in 130 total Arcam EBM builds. That is an average of 1.5 builds per week.
Of these, 54% have been for industry, 21% have been for R&D, and 25% have been for
marketing, media, and education. In 2012 we hosted 134 visitors, in 2013 it was 216, and
at the end of the first quarter of 2014 it was over 100 (total >450).
• MPs - Adam Bandt, Julie Bishop, Anna Burke, Greg Combet
• EVP of the Lockheed Martin F-35 Joint Strike Fighter Program, Tom Burbage
• Lab 22 Chosen to be a Preferred Service Provider for Arcam EBM
• AM Fish Anchors Implemented (upcoming slide)
• AM Bicycle with Flying Machine (upcoming slide)
• AM Mining Drill Bit Holders
• AM Bugs (upcoming slide)
• AM Orthotic Horse Shoes
• AM Design Optimisation via student projects (upcoming slide)
• AM of Aero Engine Demonstration with SIEF (upcoming slide)
• AM Network (upcoming slide)

19. Rapid Design Iteration
Manufacture all of the design candidates at once in a single build.
Inexpensive physical testing was
employed to make decisions.

20. Making the Business Case with Flying Machine
Three Conditions Together Made the Product Marketable
 Design Change for Every Customer Possible
 Off-The-Shelf Tubing
 The Novelty
http://www.flyingmachine.com.au/2014/01/3d-printed-titanium-bike-of-the-future/
http://www.youtube.com/watch?v=_gOd3w69kh4

21. Topology and Design Optimisation
Same Performance ... Less Weight
Iteration 1 Iteration 6 Iteration 9 Iteration 13
Iteration 16 Iteration 20 Iteration 25 Iteration 29

22. SIEF Aero-engine AM Project with Monash University

23. I like big bugs ...

24. Sciaky DM Process (and CSIRO Modeling and Simulation)
13-00975-EOT

25. Sciaky DM Process and CSIRO Modeling and Simulation
 Electron Beam Freeform Fabrication (EBFFF) is an additive
manufacturing (AM) process that works efficiently with a variety
of weldable alloys.
 Residual stress and shape distortion are inherent features of AM,
particularly at high deposition rates, as a result of the large
thermal gradients.
 Fabricated parts are stress-relief heat treated both during and
after deposition to help relieve stresses, which adds to cycle time
and the overall cost.
 CSIRO has established and implemented modelling techniques
to predict distortion and stresses during and after deposition by
EBFFF as a first step towards developing an active distortion
management system.
 The model can be employed in a predictive mode to investigate
the effects of various tool paths and process parameters on the
(post-manufacturing) part distortion and residual stress.
13-00975-EOT

26. FEA Model of a T-shaped part
- Substrate plate: 600 mm long, 12.5 mm thick, 100 mm wide
- Deposit: 51 mm tall, 11.8 mm wide, single bead
- Process parameters:
• Speed: 12.7 mm/s
• EB power: 4.3 kW for preheat and 8.6 kW for deposit
• 18 layers per side; each layer is 2.83 mm high
• Substrate and wire have initial temperature of 30°C
Model of the part
12.5
T-shaped part built by EBFFF
13-00975-EOT

27. Neutron Diffraction Used to Improve Results
Prediction
200 MPa
- 135.2 MPa
- 94 MPa
Residual Stress
by ND (ANSTO)
235 MPa
 The predictive tool has been
recently refined further by
using an updated material
model.
 The predicted stress
distribution is in excellent
agreement with residual
stress measurements by
neutron diffraction at
ANSTO.
13-00975-EOT

28. One-sided Part Model
1923
300
Temperature (°K) – during build von Mises stress (MPa) – during build
800
0
von Mises stress (MPa) – cooling to below 90°C von Mises stress (MPa) – released from clamps
800
0
800
0
13-00975-EOT

29. Significance of the Predictive Tool
 Cost saving
‒ The predictive tool can perform virtual EBFFF. We can run a series of
Design of Experiments (DoE) without having to consume materials and
cost
‒ The tool can predict the expected distortion when deposition is made on
a pre-bent plate or when insulated clamps are used
‒ Combinatorial effects such as the effect of combining a substrate preheat
with half the building speed and insulated clamps can be predicted.
 Provides insight into the evolution of thermal and
stress distribution during and post build
 Identifies critical moments when defects such as
cracks and/or excessive distortion may occur
 The application of the predictive tool can be
extended to large deposition (wire or blown
powder) and other AM processes
Selected DoE Results
-96.6
-39.4
-27.7
0
-20
-40
-60
-80
-100
-120
Change in Distortion (%)
Option 1
Option 1 + Option 2 +
Option 3
Option 3
13-00975-EOT

30. Operational Cost Considerations of Additive
Manufacturing – Why work on materials?
2000
1500
1000
500
$ $
0
Today Future
2000
1500
1000
500
0
50% of the cost in operation is labour
20% is depreciation (i.e. Cost of the unit)
If the equipment cost comes down and
labour gets more productive
Powder becomes the mostly costly
component of AM

31. Where is ͞Cheap͟ TitaŶiuŵ Powder???
Armstrong Process – Cristal
FFC Process – Metalysis
TiRO
Alloys
CSIR
New Zealand
Hydride DeHydride
ADMA
China

32. Powder, Particles and Aggregate
Size
Size Range
Flow
Density
Alter Either or Both:
- Improve the Inexpensive Powder
- Alter the AM Equipment Operating Parameters

33. CSIRO Powder Manipulation
50
25
>1000 600 –
1000
400 –
600
250 –
400
150 –
250
100 –
150
75 –
100
45 –
75
25 –
45
< 25
E-Beam
AM
Laser AM,
Cold Spray
Weight
pct
Particle Size in mm
Before
After

34. Universal Powder Bed
External laboratory bench-top unit to allow for studies of how low cost input material actually
behaves without being encumbered by a full AM system.
Powder hopper
25 kg of Ti each
Powder table
Rake regulator
Optical
Camera
Heat shield
Rake
Build tank

35. Cold Spray Technology
CSIRO has developed a new
solid-state additive
manufacturing process using
Cold Spray Technology to
produce bulk 3D forms and
coatings from powder feed
stock that is both metallic
and non-metallic.

36. Process and applications
• During cold spray, powder particles (typically 10 to 50 μm) are
accelerated to high velocities (200 to 1200 m.s-1) by a
supersonic compressed gas jet at temperatures well below
their melting point. As the particles impact the surface they
undergo large plastic deformations, consolidating to produce
localised forge bonding, at spray rates up to several 100 g/min.
• The deposition efficiency is also very high, above 95% in most
cases.
• The technology is more efficient, cost effective and
environmentally friendly and can be applied to the aerospace,
biomedical, oil and gas, power generation, motor sport,
petrochemical and electronics industries.
• Our 3D simulation outcomes has proved to be highly cost
effective for optimization of the cold spray parameters.

37. Research at CSIRO
Preforms, Billet and Pipe
Coatings on polymer and metal
3D manufacturing of bulk
billet and preforms
Repair and modification
techniques for lightweight
aerospace alloys
Improved biocompatible
coatings for medical implants
Thick metallic coatings for
thermally sensitive substrates
Ballistic protection composite
coating for defence and space
application
Anti-fouling coatings for
marine application

38. Advantages of Cold Spray
 Solid-state deposition - no melting
therefore no solidification defects
 No vacuum required for oxygen
sensitive materials such as Ti
 Environmentally friendly process
 Cost effective - capital and
operation
Cold Sprayed CP Ti
Conventional CP Ti

39. Cold Spray for Pre-forms

40. Continuous Billet Production
CSIRO has the capability to produce 45 kg/hr of product via cold spray

41. The Additive Manufacturing Network
The hub for all things additive.
MISSION – Coordinate additive manufacturing for Australia.
The Additive Manufacturing Network is ...
- Public with participation from academia, industry, and
government welcome.
- To be self governed once established.
- Well poised to be a self supporting national asset.
GOAL – Market globally Australian additive manufacturing
capability, for both technology R&D and production for profit
in industry.
- Publish who has what equipment and corresponding capabilities.
- Create confidence in global customers investigating Australian potential.
- Collaborate efficiently for new Australian business, creating greater total
revenues in which to participate.
- Connect those with a need to those with a solution.
Per the mission statement:
co·or·di·nate (verb) - The act of
harmoniously combining and interacting
items to function effectively.
GOAL – Facilitate communication within
Australia on additive manufacturing.
- Use a network infrastructure, including focused
working groups, to conduct regular face-to-face and
web meetings.
- UŶdeƌstaŶd otheƌs’ ƌoadŵaps aŶd stƌategies.
- Coordinate and be efficient on resolving issues.
- Achieve a comprehensive and non-redundant R&D
project portfolio within the country.
- Accelerate the deployment of technologies to
industry.
Status
- A survey of industry was taken and interest existed.
- Kickoff Meeting
- Inaugural Committee of 10.
- Now Partnered with (i.e. handed over) to AMTIL.
For further information, please contact:
Chad Henry
CSIRO
Additive Manufacturing Operations Manager
Titanium Technologies Stream Leader
Gate 7 Normanby Road, Clayton 3168 VIC Australia
+61 3 9545 7844 (office)
chad.henry@csiro.au

42. Thank you
CSIRO Manufacturing Flagship
High Performance Metal Industry
ore to more
Chad Henry
Additive Manufacturing Operations Manager
+61 (03) 9545 7844
chad.henry@csiro.au
FUTURE MANUFACTURING FLAGSHIP