Date post: | 13-Apr-2017 |
Category: |
Engineering |
Upload: | design-world |
View: | 671 times |
Download: | 2 times |
#DWwebinar
#DWwebinar
Metals in Additive Manufacturing
#DWwebinar
q This webinar will be available afterwards at www.designworldonline.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar
Before We Start
#DWwebinar
Leslie Langnau Managing Editor
Design World
Maximilion Eils Application Development
Consultant Electro Optical Systems
Robert Chiari Regional Sales Manager
Renishaw, Inc.
Metals in Additive Manufacturing Meet your speakers
#DWwebinar
Metals Additive Manufacturing
A Renishaw Perspective
#DWwebinar
Overview > Benefits of AM > Industries > Materials > Design for Process – Two Case Studies
#DWwebinar
Benefits of AM > Freedom of design > Light-weighting of parts; less material, integrated lattice structure > Lower high cost of tooling, and additional re-tooling costs when design changes are required > Significant reduction in tooling lead times
#DWwebinar
Benefits of AM (continued) > Faciliates design changes
- more iterations = better products - shorten design cycle = faster to market - less ECO’s and recalls = high quality brand recognition
- all lead to higher profitability
#DWwebinar
Benefits of AM (continued) > Supports JITM (Just-In-Time Manufacturing) Methodology
- minimal stocking and handling - reduce warehousing square footage requirements - less capital tied up in inventory > Low to mid-volume production
- 1 off custom design, 100’s, 1000’s, 10,000’s
#DWwebinar
Industries > Aerospace – commercial, custom jet, military, MRO > Automotive – Motorsports Racing > Medical – Devices, Implants, Maxillofacial, Dental > Consumer Products – Electronics, Toys, Footwear, Jewelry > Conventional Manufacturing Processes – jigs, fixture, tooling
- Inserts for injection molding tooling, with integrated conformal cooling
#DWwebinar
Materials > Renishaw platform is a Fiber Laser based system, commonly referred to as powder bed fusion > LM – Laser Melting process produces full melt of powder layer to layer resulting in fully dense metal parts > Typical properties range between that of a cast part and a forged part > Only Renishaw offers a True Open Architecture platform
#DWwebinar
Materials (continued)
For a complete list of available materials and mechanical properties please visit our website www.Renishaw.com
#DWwebinar
Materials (continued) > Secondary processes:
- Heat treating - Peening - HIPing
All of the above will further enhance the material properties of AM produced parts
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
#DWwebinar
Thank you!
For more information please visit www.renishaw.com
#DWwebinar
Industrial 3D printing EOS North America
#DWwebinar
Content • Introduction into 3D-printing • Paradigm shift from rapid prototyping to serial production • Benefits of 3D printing: Freedom of design and freedom of
production • Example Case Studies • Metal process characteristics and design constrains • Metal material properties: Example MS1
#DWwebinar
§ Processofmakingathree-dimensionalobjectdirectlyfroma3DCADmodel
§ Partisproducedlayerbylayer
§ Dependingonpartrequirements,differentpost-processescanbeapplied
§ WithinAMtherearedifferenttechnologieswithdifferentprocessmethods,produc=vityandqualitylevels
2.JobPrepara@on(STL/STI/JZData)
1.Design(CADData)
3.Produc@on
FinalPart
4.Finishing
#DWwebinar
DirectedEnergyDeposi@on
Process:§ Laserbeamfusesselectedareasofapowderbed
Markets:§ RapidPrototyping,serialproduc=on
Advantages:§ Highmechanicalproper=es§ Highdetailresolu=onDisadvantages:§ Limitedbuildspace§ Highcost
Laserbeam
ScannerLaserSource
PowderRecoater
#DWwebinar
Prototyping
§ Plas=candmetalprototypes§ Func=onalandnonfunc=onal§ Onlysmalldesignadjustments
SerialProduc@on
Volumes
Requirements
Applica@onfields
§ Smallvolumesupto100partsperyear
§ Highflexibility(''oneofakind'')§ Fastturnover=me§ Focusonsurfacestructure§ Similar(butnotiden=cal)parts
§ Plas=candmetalcomponents§ DesignOp=miza=onandintegra=onoffeatures(e.g.laVce)
§ Serialproduc=onwithvolumesofupto100.000partsperyear
§ 100%Quality,repeatable§ Produc=vityincrease§ Highdegreeofautoma=on§ Integratedintomanufacturingchain
RapidPrototyping Serial
Produc=on
VS
#DWwebinar
#DWwebinar
Tradi@onalManufacturing
Addi@veManufacturing
Addi@veManufacturing1
4
2
3
#DWwebinar
Complexityadvantage
AM
Volume
€/Unit
Tradi@onalManufacturing
ComplexityofDesign
€/Unit
AM
Tradi@onalManufacturing
Volumeadvantage
Strongcostadvantageforsmallvolumeproduc=on
Strongcostadvantageforcomplexcomponents
#DWwebinar
Func@onalIntegra@on
Custo-miza@on
ComplexGeometries
Customizedproducts
Integratedandcomplexfunc@ons
Lightweightstructures
Newandcomplexdesigns
Pa@entspecificrestora@ons
#DWwebinar
#DWwebinar
1)Comparedtolastseasonswheelsuspensionsmanufacturedwithinvestmentcas=ngSource:RennteamUniStu^gart,Within,EOS
WheelsuspensionApplica@on§ Extremelightands=ffwheelsuspension§ Topologyop=mized&customizeddesign
§ Incoopera=onwithWithinsoaware
Productdetails§ Weight: Front435g/Rear390g§ Max.forces:ca.100MPa§ Material: Aluminum
Advantages§ Weightsavings22%(front),35%(rear)1)
§ Increaseds=ffnessof20%§ Fastproduc=onandhighaccuracy
Examplelightweight
#DWwebinar
CableBracketComponents Assembled&InstalledCableBracket
#DWwebinar
CableBracketSitua@on/Challenges§ Secondarystructuredesignwithhigh
weightandsignificantcomplexity§ Unacceptablyhighproduc=onlead=me§ AMre-designandmanufacturingwithin2
weeksSolu@on§ Dedicatedop=miza=ontosaveweight§ Re-designconsideringAMconstraints§ Jus=fica=onaccordingtocustomer’s
standardsBenefits/Results§ Establishmentofanintegralpart.§ Weightsavingsofmorethan30%§ Reduc=onofproduc=onlead=meand
costs
#DWwebinar
FlexibleProduc@onVolume
FlexibleProduc@onLoca@on
FlexibleProduc@on
Time
“Fromonetomany”
“Fromlocaltoglobal”
…ondemand”
“Smallandeconomic
produc@onruns”
“Fromjust-in-@meto…
$
#DWwebinar
AMDesignConstraints
Thedifferentaspectsofproper=esmustbeconsideredandponderedinordertoimprovethecharacterproper=es.Theresultaremeasuresformeaningfulorienta=on.
#DWwebinar
Buildability:Angletorecoater
recoater
x
y
z
Duringrecoa=ng,therecoaterbladeintroducesforcesintotheSupportwhenitaccidentallygetsincontactwith:• Bulgedareasduetointernalstress• Clumpsandsplashesofuninten=onally
sinteredpowder
x
z
yx
Plakorm
recoater
x
z
yx
Makesurethatthepartwillnotgrowtowardstherecoaterandthatnosharpedgesareorientatedtowardstherecoater.
#DWwebinar
Buildability:Changeofcrosssec@on
The heat buildup when crea=ng parts canaffect the geometry. If not controlled andan=cipateditcancause:§ Stress§ Distor=on§ Cracking§ Delamina=on
Assureaslowgradualchangeinsec=oninz-direc=on
Thermalgradient
#DWwebinar
Cost:Build@me
Thelargerthez-heightofthepart,thelongertheen=rebuildprocesslasts.Thisisduetotheincreasednumberofrecoaterpassesneededtoa^ainthedesiredheight.
Minimizethemaximumz-heightofthepartonthebuildplakormtoreducebuild=me
#DWwebinar
Cost:Powderamount
Theorienta=onofthepartwillgreatlydeterminetheamountofsuppor=ngmaterialneededforsuccessfulmanufacturing.SupportStructuresarewasterightaaerthebuildprocessandaconsiderablecost-driver
Reducedownward-facingareasforlessaddi=onalSupportStructures
SupportStructures
#DWwebinar
Cost:Suitabilityfornes@ng
Tomakeuseofthefullcapacityofthebuildplakormnestpartsasdenseaspossible.ButspacemustbeleaforSupport,wherenecessary
Inthecasethatapartshallbeproducedinhigherquan==es,theimportanceofnes=ngbecomesobvious:§ Buildmorepartsinonego§ Saveset-upcostsBeforenes=ngpartstogether,makesuretheprocessisfullycontrolledtopreventexpensivejobcrashes
#DWwebinar
Quality:DimensionalAccuracy
The heat buildup when crea=ng parts canaffect the geometry. If not controlled andan=cipateditcancause:§ Stress§ Distor=on§ Cracking§ Delamina=on
Assureaslowgradualchangeinsec=oninz-direc=on
Thermalgradient
#DWwebinar
Quality:SurfaceRoughness
Reducedownward-facingareastoavoidsurfacedegrada=onbySupport
Preferesteepwallstominimizethenega=veeffectsofthestaircaseeffect
Formerlysupportedareaseitherhavepoorsurfacequalityorrequireaddi=onalpost-processing.
SurfaceaaerremovalofBlockSupport
Slicingoccursalongthever=calaxis.Therefore,thevaria=onsofthepartalongthisaxiswilldictatethelevelofaccuracyor“stepping”thatwilloccur.
#DWwebinar
Material Group Brand name Material type Typical applications
Maraging Steel EOS MaragingSteel MS1 18 Mar 300 / 1.2709 Injection moulding series tooling; engineering parts
Stainless Steel
EOS StainlessSteel GP1 Stainless steel 17-4 / 1.4542
Functional prototypes and series parts; engineering and medical
EOS StainlessSteel PH1 Hardenable stainless 15-5 / 1.4540
Functional prototypes and series parts; engineering and medical
EOS StainlessSteel 316L Stainless steel 1.4404
Functional prototypes and series parts; lifestyle, aerospace, medical
Nickel Alloy
EOS NickelAlloy IN718 Inconel™ 718, UNS N07718, AMS 5662, W.Nr 2.4668 etc.
Functional prototypes and series parts; high temperature turbine parts etc.
EOS NickelAlloy IN625 Inconel™ 625, UNS N06625, AMS 5666F, W.Nr 2.4856 etc.
Functional prototypes and series parts; high temperature turbine parts etc.
EOS NickelAlloy HX UNS N06002 Severe thermal conditions and high risk of oxidation, e.g. combustion chambers,
Cobalt ChromeEOS CobaltChrome MP1 CoCrMo superalloy,
UNS R31538, ASTM F75 etc. Functional prototypes and series parts; engineering, medical, dental
EOS CobaltChrome SP2 CoCrMo superalloy Dental restorations (series production)
TitaniumEOS Titanium Ti64 Ti6Al4V light alloy Functional prototypes and series parts;
aerospace, motor sport etc.
EOS Titanium Ti64ELI Ti6Al4V ELI (grade 23) Medical Implants
Aluminium EOS Aluminium AlSi10Mg AlSi10Mg light alloy Functional prototypes and series parts; engineering, automotive etc.
#DWwebinar
Orvar supreme (1.2344) Stavax (1.2083) 1.2343 (H13) 1.2709 (MS1)
Yield strength (Rp 0.2 %) [Mpa]
1250 1290 1400 1930
Tensile strength [] 1400 1780 1600 2050
Elongation at break [%] 13 na 3-5 4-6
Modulus of elasticity [GPa]
210 210 215 200
Hardness [HRC] 52-54 48-52 52-54 52-54
Density[Kg/dm3] 7,8 7,74 7,8 8,0
Coefficient of thermal expansion [m/mK]
12,6x10-6
11x10-6
11,3x10-6
10,3x10-6
Corrosion resistance yes yes no yes
#DWwebinar
Thank You
Questions?
#DWwebinar
Leslie Langnau Managing Editor Design World [email protected]
Maximilion Eils Application Development Consultant Electro Optical Systems [email protected]
Robert Chiari Regional Sales Manager Renishaw, Inc. [email protected]
Metals in Additive Manufacturing Questions?
#DWwebinar
Thank You q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com
#DWwebinar