Additive manufacturing (aka 3D printing) of metallic materials Industrial applications and efficiency of technology

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1 Additive manufacturing (aka 3D printing) of metallic materials Industrial applications and efficiency of technology MANU Future digital manufacturing technologies and systems P6 Next Generation Manufacturing Task 1 Additive Manufacturing Heidi Piili D.Sc.(Tech.) Research Scientist Laboratory of Laser Processing; Lappeenranta University of Technology

2 Terminology According to ISO/ASTM comittee: 3D printing: fabrication of objects through the deposition of a material using a print head, nozzle, or another printer technology. Term often used in a non-technical context synonymously with additive manufacturing; until present times this term has in particular been associated with machines that are low end in price and/or overall capability. Additive manufacturing, AM process of joining materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies. Suggestion is to use word additive manufacturing about industrial fabrication of this technology!

3 Terminology Additive manufacturing of metallic materials can be divided into (according to F a): 1. Directed energy deposition (DED) an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited. Methods using dynamic wire feed or dynamic powder feed to laser beam are included to these technologies. 2. Powder bed fusion (PBF) an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed. Methods using laser beam or electron beam source of thermal energy are included to these technologies.

4 Terminology Additive manufacturing of metallic materials can be divided into (according to F a): 3. Material jetting an additive manufacturing process in which droplets of build material are selectively deposited These methods are based on bin.der which is jetted to metal powder. Binder is removed from work piece in post-processing, and this way formed porous material is filled with infiltrator. 4. Sheet lamination an additive manufacturing process in which sheets of material are bonded to form an object. Work piece is manufactured from thin, joined steel plates. Joining happenes for example via ultrasound or friction welding.

5 Finnish innovation One of methods used in additive manufacturing of metallic materials is Finnish innovation. This method is one of most used techniques in meatllic additive manufacturing. Top know-how of this field exists still nowadays in Turku, Finland.

6 Industrial applications Micro heat exchanger Freedom of desing: Design for demands of application, not design for demands of manufacturing! Optimization of structure: Material is manufactured to places where it is needed! Enhanced properties and lighter work pieces!

7 Industrial applications Aerospace industry

8 Understanding of production efficiency Input parameters Laser power Laser spot size Layer thickness Hatch distance Scanning speed Laser beammaterialinteraction Output parameters Penetration depth Bead width Bead height Metallurgical properties Understanding relations between input and output parameters (for example how laser power affect on penetration depth) Source: Master Thesis of Ville Matilainen (executed during MANU project )

9 Production efficiency Done in Master Thesis of Ville Matilainen during MANU P : Characterization of process efficiency improvement in laser additive manufacturing. Material 17-4 PH stainless steel. AM systems with maximum power of 200 W and 400 W were tested.

10 Production efficiency WDA = Width-depth-area of one scan Source: Master Thesis of Ville Matilainen (executed during MANU P6 project )

11 Production efficiency WDA [mm 2 ] Wide width, large penetration, WDA=0.035 mm Narrow width, small penetration, WDA=0.005 mm 2 Source: Master Thesis of Ville Matilainen (executed during MANU P6 project )

12 Production efficiency Production efficiency could increase as thicker layers can be formed Pentration issue needs depth further of one study! scan increases Source: Master Thesis of Ville Matilainen (executed during MANU P6 project )

13 Production efficiency Knowledge of process details increases possibility to do process optimization increases direct effect to increase of production efficiency

14 Industrial applications: Weldability Done in Master Thesis of Jukka Järvinen during MANU P6 2014: Weldability of stainless steel objects made with laser additive manufacturing. Material stainless steel 316L AM system with a maximum power of 200 W was used and the welding process was TIG-welding. Welding was also carried out for conventionally manufactured SS316L plates for reference values Destructive tests were executed in order to the mechanical properties of the weld joints Thesis will be ready 12/2014

15 Industrial applications: Weldability Source: Master Thesis of Jukka Järvinen (executed during MANU P6 project 2014)

16 Industrial applications: Weldability Analysis of the test results is still in progress. Thesis will be ready 12/2014 Bend test results indicate the welds in AM pieces are not brittle even though the elongation is low. A lower welding current had to be used for the AM test pieces. Source: Master Thesis of Jukka Järvinen (executed during MANU P6 project 2014)

17 Future aspects of metallic AM

18 Future aspects of metallic AM

19 Thank you for your attention! Do you have any questions? More information: Heidi Piili Research Scientist Tel ; Antti Salminen Professor Tel: ; Acknowledgements: FIMECC MANU P6 Consortium Personnel of LUT Laser