Laser Based Additive Manufacturing

Transcription

1 Laser Based Additive Manufacturing 2016 Manufacturing Summit March 16, 2016 Scott M. Thompson, Ph.D.

2 Additive Manufacturing a process of joining materials to make objects from 3D model data, usually layer upon layer - ASTM Standard F a Material extrusion Material jetting Binder jetting Vat photopolymerisation Sheet lamination Powder bed fusion Directed energy deposition dupress.com/articles/additive-manufacturing-3d-opportunity-in-aerospace/

3 Additive Manufacturing Plastics metal sintering Metals printing emergence Commercialization of 3D printing technology Metals printing commercialization Production-grade metallic parts sought Rapid/visual prototyping, hobbyists, science projects Part production, defense applications

4 Material Extrusion Fused filament fabrication, Fused deposition modeling, 3D printing Stratasys, MakerBot Thermoplastics, nylon < 570 ºF, heated nozzle (liquid on delivery) Home, office or industry By John Abella - CC BY 2.0, By Zureks - Own work, GFDL,

5 Material Jetting Drop-on-demand, 3D printing Similar to inkjet, 2D printing Liquid photopolymer that is cured Home, office or industry

6 Sheet Lamination Ultrasonic additive manufacturing, laminated object manufacturing Sheets/ribbons of material bound via ultrasonic welding Low-temperature Non-structural parts

7 Additive Manufacturing of Metals Selective Laser Melting Direct Laser Deposition Powder Bed Fusion & Directed Energy Deposition Powder and wire feedstock Laser based methods Powder Bed Fusion Laser, e.g. Selective Laser Melting Direct Laser Deposition, e.g. Laser Engineered Net Shaping Multi-material Good surface feeding finish High build precision rates Parts Very repair complex geometries Thompson, S.M., Bian, L, Shamsaei, N., Yadollahi, A., 2015, An Overview of Direct Laser Deposition for Additive Manufacturing; Part I: Transport Phenomena, Modeling and Diagnostics, Additive Manufacturing, 8, pp DOI: /j.addma

8 Additive Manufacturing of Metals: Large Potential Customize parts for specific applications Biomedical implants, heat exchangers Fabricate complex geometries Repair expensive parts Manufacture in remote locations Submarines, battlefield, ships, space Reduce weight and cost of parts Aerospace Potential economic rewards: New skilled jobs created in U.S. Restored U.S. strength in manufacturing Trade deficit reduction

9 Additive Manufacturing of Metals: The Bottleneck Challenge: Mechanical behavior of AM parts not easily predictable or trustworthy. This is hampering widespread adoption of AM parts. Process-property relationships must be learned for each new material, machine, geometry, etc. Experimental trial-and-error ($$) Parts consist of porosity Process quality control lagging Material properties during manufacture unknown Minimal standards and regulation for production and end-parts Powder, machine variability

10 Additive Manufacturing: Trending blog.purisllc.com/blog 10

11 Economic Growth Where is Mississippi in this global market?

12 Biomedical Applications in Additive Manufacturing Biomedical industry is getting interested in AM Large market potential MSU has already researched biomedical supply chains in MS Have initiated some preliminary research collaboration with MSU Vet School and UMMC in Jackson, MS.

13 Facilities at MSU/CAVS Direct Laser Deposition (DLD) Donated by Army c OPTOMEC LENS 750 w/ 1 kw laser and multicamera thermal monitoring Multi-powder feeder for functional-grading Laser Powder Bed Fusion Renishaw AM 250 w/ 400 W laser Materials characterization equipment Mechanical testing (fatigue, tension, etc.) Microstructural characterization EBSD, Microscopy, X-Ray tomography

14 Advanced Laser-Based Additive Manufacturing Our Approach The Complexity of Additive Manufacturing It s is not a printer, it is a mini foundry

15 Mechanical Testing of Additive-Manufactured Parts Strain Life Curve: Wrought & LENS Ti-6Al-4V An order of magnitude shorter fatigue lives for additive-manufactured samples as compared to wrought samples. Sterling, A.J., Torries, B., Lugo, M., Shamsaei, N., Thompson, S.M., 2015, Fatigue Behavior of Ti-6Al-4V Alloy Additively Manufactured by Laser Engineered Net Shaping, 56th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference Kissimmee, FL. DOI: /

16 Thermal Monitoring and Control By FY2018, develop process metrology, in-process sensing methods, and real-time process control approaches to maximize part quality and production throughput in Additive Manufacturing (AM). - National Institutes of Standards and Technology (NIST.gov)

17 Dual Thermal Monitoring of LENS

18 Porosity & X-Ray Computed Tomography

19 Simulation via High Performance Computing at MSU deposited track substrate powder bed Fluid dynamics, solidification, high heat flux diffusion, microstructural evolution Effects of laser velocity for laser power of 2 W (substrate response) Time scale ~ μs ( million time steps) Space scale ~ 1 μm (resolution smaller than laser) Masoomi, M., Elwany, A., Shamsaei, N., Bian, L., Thompson, S.M., 2015, An Experimental-Numerical Investigation of Heat Transfer during Selective Laser Melting, 2015 Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, Austin, TX.

20 Additive Manufacturing Research Team Nima Shamsaei Assistant Professor Mechanical Engineering Fatigue & microstructure characterization Scott M. Thompson Assistant Professor Mechanical Engineering Process thermal modeling and monitoring Steve R. Daniewicz Professor, ASTM Fellow Mechanical Engineering Fracture mechanics, joining methods Linkan Bian Assistant Professor Industrial & Systems Engineering Statistical modeling, uncertainty propagation, supply chains Shuai Shao Post-Doctoral Associate Center for Advanced Vehicular Systems Microstructural characterization, multi-scale modeling Jutima Simsiriwong Post-Doctoral Associate Center for Advanced Vehicular Systems Fatigue & mechanical behavior

21 Additive Manufacturing at Mississippi State National leadership Organizing joint workshop with ASTM & NIST in 2016 Organizing ASME s Symposium on Additive Manufacturing MSU is leading certification efforts AM parts with Federal Aviation Administration (FAA) MSU Faculty serving as Guest Editors of Special Issue in Additive Manufacturing ASTM Representative on U.S. National Committee on Theoretical and Applied Mechanics: Supervisory Role in Additive Manufacturing CAVS is now a member of America Makes Sponsored AM research projects from NSF, NASA, Army and industry

22 Thanks! Questions?