Metal Additive Manufacturing principes en toepassingen

Transcription

1 Metal Additive Manufacturing principes en toepassingen Henk Buining T High-tech Systems & Materials Afdeling: Equipment for Additive Manufacturing 15 medewerkers op AM 45 medewerkers op supporting technology e.a.

2 3 Equipment for Additive Manufacturing References For example: Workshops, technology transfers, research projects 4 Projectvorm: Technologie Cluster Minstens vijf bedrijven en een Innovatief onderwerp Overdracht TNO kennis Uitwerken praktijkcases Ontwerpmethoden voor AM: unit cells topologie optimalisatie Graded structures Start: begin 2016

3 5 EU Reseach Projects - TNO Finished projects Current projects Funding programs CassaMobile 6 Outline Additive manufacturing definition Direct metal additive manufacturing Applications Indirect metal AM technologies

4 7 Additive Manufacturing: Definition The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms Additive Manufacturing (AM) Additive Fabrication (AF) Rapid Manufacturing (RM) Digital Manufacturing Direct Digital Fabrication Free Form Fabrication (FFF) 3D-Printing Layer Manufacturing 8 Hits on synonyms nov 2010 dec 2011 april 2013 Rapid Prototyping hits Digital Manufacturing hits 3D-Printing (3DP) hits Additive Manufacturing hits Free Form Fabrication hits Rapid Manufacturing (RM) hits Additive Fabrication (AF) hits Layer Manufacturing hits Direct Digital Fabrication hits 8 Bron: Google

5 9 Hits on google 3D Printing 10 Courtesy to: gartners.com

6 11 Courtesy to: gartners.com Gartners hype cycle July Van CAD naar slice-file 3D CAD file STL file Slice file Additive Manufacturing

7 13 Additive Manufacturing = Laagsgewijs produceren CAD Slice file Onderdeel 14 AM TECHNOLOGIES DEFINED BY MACHINE TOOL BUILDERS Afkorting Techniek Fabrikanten SLA Stereo Lithography 3D-Systems SLS DMLS SLM Selective Laser Sintering Direct Metal Laser Sintering Selective Laser Melting Laser Sintering Laser Cusion FDM Fused Deposition Modelling Stratasys 3D-Systems EOS SLM Solutions,Realizer Phenix (3D-systems) Concept Laser DLP Digital Light Processing EnvisionTec 3DP 3D-Printing Z-corp, Voxeljet, ExOne Fcubic 3D material jetting 3D material jetting 3D-systems (Projet), Stratasys (Objet)

8 15 ASTM F42 Powder bed fusion Vat Photopolymerization Material jetting Binder Jetting Material extrusion Sheet lamination Direct energy deposition SLM, SLS, DMLS of EBM Stereo Lithography, DLP Stratasys ObJet, ProJet, Solidscape Digital metal, VoxelJet, XOne FDM LOM Cladding: LENS, Skiarc 16 Metal Additive Manufacturing Direct Indirect SLM: Selective Laser Melting DMLS: Direct Metal Laser Sintering Laser Cusing SLS: Selective Laser Sintering Electronbeam melting Cladding EOS Concept Laser 3D-Systems Realizer Rennishaw SLM Solutions Phenix Sisma ARCAM Irepa Laser Trumpf POM OPTOMEC LENS DMG MORI

9 17 Metal Additive Manufacturing Direct Indirect SLM: Selective Laser Melting DMLS: Direct Metal Laser Sintering Laser Cusing (SLS: Selective Laser Sintering) Electronbeam melting Cladding EOS Concept Laser 3D-Systems Realizer Rennishaw SLM Solutions Phenix Sisma ARCAM DMG MORI Easyclad / Irepa ; Optomec; Sciaky; Trumpf; POM; LENS (Optomec); Deloro Stellite; InnsTek; Laser Consolidation; Electron Beam Free Form Fabrication; Plasma Transferred Arc; Deloro Stellite; Precision Optical Manufacturing; Reis Lasertec; Huffman Corporation; Trumpf; Sulzer Metco; Laser Line; 18 Powder Bed Fusion Laser Based SLM, DMLS, Laser Cusion

10 Important process limits Layers Melting depth Powder Bottom layer bonus material & rough surface Support structure needed Accuracy and roughness: Mostly post machining needed (included thermal treatments) Limited number of materials applicable Bottom layer different! Support or building plate needed!!

11 21 Powder Bed Fusion work flow Example - Custom Lugs Charge bikes 22 Powder Bed Fusion work flow Design for metal AM Pre processing & Building Charge bikes

12 23 Powder Bed Fusion work flow Powder removal Charge bikes 24 Support Structures Fixing the part Heat drain to build plate

13 25 Powder Bed Fusion work flow Near netshape technology: Post treatments needed Digital model Near Net Shape Part Net Shape Part Lens - Optomec 26 Arcam - Electron Beam Melting 26

14 27 Direct Energy Deposition: Laser cladding Traditional application: surface layer and repair Also used in critical applications (e.g. turbine tip repair) 28 PBF Metal Unique possibilities Function Integration Internal geometries Light weight Special surfaces Innovative materials Complex parts in advanced equipment Human related parts Thermal stabilized parts (of super alloys)

15 29 General Electric Aviation Additive Manufacturing of functional parts for Aircraft Engines Acquired in 2012: Morris Technology Avio spa (20 DMLS & 2 Arcam EBM systems) (12 Arcam EBM systems) 30 General Electric Additive Manufacturing of functional parts Made with Selective Laser Melting Patented design

16 31 General Electric Aviation Additive Manufacturing of functional parts for Aircraft Engines 19 Additive fuel nozzles to be installed on every CFM LEAP engine (over 4500 sold) Additive parts will be manufactured by GE Aviation by D printing machines currently in use across GE 32 Optimisation Helicopter Frame Main mechanic structure

17 33 Optimisation Helicopter Frame Aluminium frame Manufactured with Selective Laser Melting 34 Optimisation Helicopter Frame Topology Optimization Volume and Constraints Modelling and Optimization Smoothing

18 35 Optimisation Helicopter Frame Specifications: Dimensions: 128 x 160 x 147 mm Material: AlSi12 Process: Selective Laser Melting (MTT) Production Time: 68 hr. Cost: Material 65 Production Hydraulic Manifolds (Im)possible Crossing

19 37 Hydraulic Manifolds Flow channel optimization to reduce pressure drop Conventional production method Optimized flow channel 38 Hydraulic Manifolds Flow test to validate advantage in pressure loss Conditions: Temperature: 80 C Oil speed 10 m/s = 170 l/min. Kin. viscosity: 32 cst. Density: 0,88 kg/dm3 Burst pressure: 1400 Bar Lower weight 20kg =) 1 kg!! Smaler volume 23x23x5 =) 8x8x5cm!! 4x less presure loss!!

20 39 Metal Additive Manufacturing Direct Indirect Binder jetting Other technologies for lost model production Metal sheet lamination (LOM) Metal parts Sand molds and cores Lost models Sintered in separate oven Sand casting Lost Model casting Digital Metal ExOne Voxeljet Prometal Z-Corp Voxeljet PMMA PrimeCast (SLS) Quick cast (SLA) Rapid Shape (SLA) Solidscape Projet / Polyjet (Stratasys /3DS) Fabrisonic 40 Binder jetting: Principle

21 41 Binder jetting of metal powder ExOne (v.h. Prometal) 41 Printing binder on stainless steel 42 Prometal process steps Prometal post process steps Debinding Sintering Infiltrating 42 Courtesy ProMetal

22 43 Binder jetting of metal powder: Högenäs Digital Metal Similar technology with higher resolution and improved density 44 Binder jetting for sand mold and sand core printing

23 45 Binder Jetting for lost model production Voxeljet: PMMA + lost model casting 46 Other technologies for lost model casting SLS: Selective Laser Sintering (e.g. EOS Polysyrene (Prime Cast)) SLA: Quick Cast, Envisointec, Rapid Shape Material Jetting: Solidscape, 3D-systems, Stratasys (Objet),

24 47 Powder Bed Fusion Laser Sintering / melting / cusing 48

25 49 50

26 51 52 Vat Photopolymerization Stereo Lithography (SLA)

27 53 Stereo Lithography (SLA) Vat Photopolymerization 54 Vat Photo polymerization SLA: Quick Cast

28 55 Vat Photo Polymerization Envisiontec (PIC 100) and casting 56 Material Jetting

29 57 Binder Jetting for lost model casting