Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
In situ metal alloying by Direct Metal Deposition
Institute for Applied Laser, Photonics and Surface Technologies ALPS
Thorsten Kramer,
Marco Fasel, Matthias Steck, Dr. Hossein Najafi, Prof. Dr. Valerio Romano
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Quelle: Fraunhofer ILT
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Process Principle
Photonics in Industrial Production
Quelle: Fraunhofer ILT
Quelle: TWI
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Photonics in Industrial Production
Local Metallurgy
Intrinsic Heat Treatment
alloy bulk com
positions
microstructures
Rapid Alloy Development
In-situ Alloy FormationPowder Blending
LD
MD
Laser Cladding
3D printing
Additive Manufacturing
Gradient Materials
properties
Rapid Manufacturing
Rapid Prototyping
chem
ical
com
position
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Photonics in Industrial Production
Fiberlaser
Processing Gases
Powder Feeder
Working Head
Laser Control
Motion Control
Positioning System
Layered Workpiece
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Conventional ODS Production
Photonics in Industrial Production
Hot
Compaction
Mechanical
Alloying
Subtractive
ShapingProduct
Matrix
Oxide
Laser Additive
Manufacturing
Powder
MixingProduct
Matrix
Oxide
Finishing
Laser Additive Manufacturing
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Photonics in Industrial Production
Conventional
Route
Mechanical Alloying
~48 h
Time for Mixing
Flowability of Powder
Adapted
Route
Ball Milling
~4 h
New
Route
Laser Synthesis Processing
~1 h
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Introduction
Scalmalloy®
Photonics in Industrial Production
▶ Aluminium-
Magnesium-
Scandium-Legierung
▶ Dichte 2,67 g/cm³
▶ Zugfestigkeit 520 Mpa
▶ Bruchdehnung 13%
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Idea | In-Situ Metal Alloying
Photonics in Industrial Production
▶ Generation of alloy composition
by adjusting powder ratio
of Aluminum and Nickel
during LDMD process
▶ Gradient Materials
▶ Adaption to
▶ base plate material
▶ part geometry
Powder Feeder
Working Head
Valve Ni
Valve Al
Powder Mixture
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Objectives
Photonics in Industrial Production
Temperature
1800
400
1600
1400
1200
1000
800
600
0 10 20 30 40 50 60 70
Atomic % Aluminum
80 90 100
Ni Al
1638 °𝐶
1360 °𝐶1133 °𝐶
854 °𝐶
640 °𝐶700 °𝐶
1362 °𝐶
AlNi
AlN
i3
Al 3
Ni
Al 3
Ni 2
Al 3
Ni 5
▶ Phase Diagramme
Nickel-Aluminum
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Nickel-Powder CNPC-Ni 100-300
Photonics in Industrial Production
Frequency
18
0
16
14
12
10
8
6
4
2
40 55 70 85 100 115 130 145
Grain Diameter | µm
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Aluminum-Powder 60 HPS
Photonics in Industrial Production
Frequency
30
0
25
15
10
5
5 14 23 32 41 50 59 68
Grain Diameter | µm
20
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Aluminum-Powder Toyo Aluminum K.K. A1070-80BB
Photonics in Industrial Production
Frequency
20
0
16
14
12
10
8
6
4
2
10 40 55 70 85 100 115 145
Grain Diameter | µm
18
25 130
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Experimental Setup
Photonics in Industrial Production
Fiberlaser
IPG Photonics YLS-2000Fiber 300 µm
Powder Feeder
GTV PF 2/2Working Head
Trumpf BEO50
with Powder Nozzle
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Preliminary Results AlNi3
Photonics in Industrial Production
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Preliminary Results AlNi3
Photonics in Industrial Production
354 HV10
320 HV10
288 HV10
283 HV10
326 HV10
354 HV10
445 HV10
2 mm 1 mm
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
Rapid Alloying by LDMD
Providing Solutions
Define Specification and
Characteristics locally
▶ Density
▶ Yield Strength
▶ Ductility
▶ Microstructure
▶ Gradient
according to requirements
Photonics in Industrial Production
create product
design product
define specification
Berner Fachhochschule | Haute école spécialisée bernoise | Bern University of Applied Sciences
