Sirris_am in aviation and aerospace_arcam additive manufacturing with ebm - the route to production

Additive Manufacturing with EBM- The Route to Production

2014-05-13 1Insight into 3D printing in the aerospace industry

”Arcam develops, manufactures and sells productiontechnology for Additive Manufacturing in metal”

Mission statement

Focusing on

• Aerospace components• Orthopedic implants


Success factors for production

• Reliability - Stable machine systems

Stable manufacturing process

• Economy - High production rate

Competitive powder cost

• Quality - Material quality

Geometric accuracy

Surface quality


• Added values - Freedom in designwith AM Cellular structures

Metal powder

• CE-certified acetabular cups with integratedTrabecular Structures™ since 2007

• Implants with US-FDA clearance since 2010

•

EBM® production of implants

•• > 40,000 cups implanted

• 2% of the global production of acetabularcups is now manufactured with EBM®


Adler Ortho, IT2007-

Lima, IT2007-

Exactech, US2010-

Height ~30 mmDiameter ~50 mm

3D Cellular Structures


Diamond shape layout

3D Cellular Structures


Courtesy of North Carolina State University

Biocompatibility

Pictures of bone growing into EBM-manufacturedtitanium implants with Trabecular Structures™

Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials,University of Gothenburg.


Acetabularcup with

porous surfacemade with EBM

University of Gothenburg.

System and process stability

• The graph below shows development of system reliability forEBM systems in serial production of acetabular cup implantsover more than three years during production ramp up.over more than three years during production ramp up.


based on more than 45.000 running hours

Monthly success rate of production runs from log files from all builds

Sub-system example:Powder dispatcher failure rate


Based on ~40.000 running hours in six EBM systems

EBM Productivity:Stacking of Parts

• Cups have excellent geometryfor stacking.

• Production example 80 cups:• Production example 80 cups:

• Non-stacked: 126 h

• Stacked: 82 h

• Build time reduction: ~35%


Production cost of cups

Implants built with EBM

• High productivity

• Excellent material properties• Excellent material properties

• No mechanical support structure (hot process)

• No secondary coating operation


EBM® - Electron Beam Melting

• The electron beam gun generates ahigh energy beam (up to 3.000 W)

• The beam melts each layer of powder• The beam melts each layer of powdermetal to the desired geometry

• Extremely fast beam translation withno moving parts

• High beam power -> high melt rate(up to 80 cm3/h) and productivity

• Vacuum process -> eliminates impuritiesand yields excellent material properties


and yields excellent material properties

• High process temperature (650 ºCfor titanium) -> low residual stressand no need for heat treatment

The EBM® Machine

EB Gun

Heat Shield

Powder Rake

PowderContainer

Build ChamberVacuum build chamber


Powder Rake

Build Platform

Control UnitBuild Tank

• To maintain the correct build temperaturein all parts of the geometry throughoutthe build, thermal modeling integrated inthe control software dynamically adjusts

EBM® process: Temp control

the control software dynamically adjustsspeed and current to ensure:

• Uniform material properties

• No grain growth, e.g. above certaintransformation temperature

• Low amount of evaporation ofalloying elements

• Dimensional stability


• Dimensional stability

• The use of integrated thermal modelingcombined with the elevated buildtemperature are key factors behind thefast and accurate build process

System interior,heat distribution

Advantage of hot processfor bulk melting

Fast beam & higher powerSlow beam Fast beam Fast beam & warm bulk (& lower power)

Surface

Tmelt

Tboil

TempTemp

Tmelt

Tboil

Surface

Melt depth

Surface

Melt depth

Melt depth

Surface

Melt depth

Tmelt

Tboil

TempSurface

Melt depth

Bulk temperature


TimeTime

Melt depth

Time

Increased bulk temperature reduces gradient,allowing for higher speed with preserved quality

Production case for aerospace:

Turbine blades in -TiAl

• Cooperation agreement with Avio (Italy)

• Prototype turbine blades in -TiAl

•• 325 mm build height

• Dimensional tolerance: 0.1 mm

• Turnaround time: 7,5 h / blade


Courtesy of Avio SpA

EBM® -TiAl: microstructures

Courtesy of Avio SpAand Politecnico di Torino

As-built by EBM

HIP 1260 C, 1700 bar, 4hEquiaxed


Equiaxed Grain size <20 m Heat Treatment

DuplexLamellar colonies ~100 mEquiaxed grains ~15 mLamellar fraction ~ 40%

Production focus

• Series production allows process optimization in each specificproduction case (geometry)

• Parameters such as layer thickness may for this reason be• Parameters such as layer thickness may for this reason bedifferent for different production cases

• Arcam actively supports our customers in setting up the mostoptimal process for each production case


Overview: Arcam machinegenerations

EBM S12 (2003)S-series

Arcam A2 (2008)Arcam A1 (2009) Arcam A2X / A2XXA2 derivatives with modified build volumes

A-Series


Arcam Q10 (2013) Arcam Q20 (2013)

Q-SeriesCurrently in production

Arcam Q10 / Arcam Q20


Design for Production

• The Arcam Q10 / Q20 are developed in collaborationwith leading implant and aerospace manufacturers

• Arcam Q10 is the EBM system designated forvolume production of orthopedic implants

• Arcam Q20 is the EBM system designated forvolume production of aerospace components


Arcam Q - Highlights

• Higher productivity

• Improved resolution• Improved resolution

• Reduced risk of operator mistakes

• Quality verification with Arcam LayerQam™

• Closed powder handling


• Closed powder handling

• Software adapted to volume production

• Use of high brightness cathodes LaB6

• 500+ hours operating time in EBM

• Single crystalline high brightness filament

New EB gun design

• Single crystalline high brightness filament

• State-of-the-art manufacturing

• 8-10 times higher brightness than W3%Re

• 1800 °K (2600 °K)

• 5-6 W heating power (30 W)

• Improved vacuum design

• Improved beam formation


Electron beam size

• Improved spot quality at high beam powerenables faster processing of high quality surfaces


Arcam Q20build time, customer part

Arcam Q20 vs. Arcam A2XX

Arcam A2XXbuild time, customer part


~ 85 h ~ 130 h

New Software

• New man-machine interface, with two user modes

• Engineering mode

• Production mode, fully automated• Production mode, fully automated


Operator Assistance Systems

• Prevention of operator mistakes

• Automatic measurement of available build height

• Detection of powder hopper blinds• Detection of powder hopper blinds

• Automatic calculation of remaining filament life

• Automatic detection of heat shield


Arcam LayerQam™

• Camera-based quality verification system

• Additive Manufacturing provides a new melted surface for each layer• Additive Manufacturing provides a new melted surface for each layer

• The melting depth is thicker than the layer of powder

• Camera-based monitoring of each melted layer provides porositycontrol of the entire produced part

• Monitoring each layer hence provides a unique capability to verifythe full density of EBM-produced components


Arcam LayerQam™

- demo, sample with deliberately generated defects

Microtomography

Filteredcameraimages


New Powder Recovery System

• Part removal

• Automated sifting

• Automated refill of powder hoppers• Automated refill of powder hoppers


Streamics™ (optional add-on)

• “...is easily integrated in an automation systemand allows centralized processing...”

MagicsBuild

processor

AM preparation Slice Hatch BuildQualityControl

EBMControl


EBM® and aerospace- Long-term development

• Faster processing and Larger build envelope

• The available beam power restricts build area and build rate

• The need for higher electron beam current is thus twofold:

• More power for heating to enable larger build envelope

• More power to enable more Arcam MultiBeam™ spots

• An EU FP7 project, FastEBM, has developed a prototypeelectron gun for EBM with more than three times higherbeam power than for current systems

• The prototype gun is under testing on an Arcam Q platform


• The prototype gun is under testing on an Arcam Q platformto evaluate potential for system development

Electron beam –powder interaction model

• The FastEBM project also developeda powder-based interaction model,based on the Lattice Boltzman Method,based on the Lattice Boltzman Method,to support EBM process development

• Development partner: Erlangen University


• Project aim: 2D 3D

Contact

Thank you for your attention!

Arcam AB

Krokslätts Fabriker 27A

SE-431 37 Mölndal, Sweden

Phone: +46 31 710 32 00

Web site: www.arcam.com

E-mail: [email protected]

Thank you for your attention!


Arcam - CAD to Metal®

Date post:	21-Nov-2014
Category:	Technology
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Sirris_am in aviation and aerospace_arcam additive manufacturing with ebm - the route to production

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