WIXLIB

WEBINAR:Introduction to AdditiveManufacturing (AM) usingmetals to SMEsLars Nyborg, Emmanuel Onillon, Paul Häyhänen, Karolina KazmierczakThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

AgendaThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Introduction Aim: To introduce AM possibilities for SMEs through the EU project MANUELA MANUELA - Additive Manufacturing using Metal Pilot Line – offerings for companiesvia “Open Call”This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Additive Manufacturingusing Metal Pilot LineLars Nyborg, ChalmersThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

MANUELA consortiumThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

WhyBENEFITS OF METAL AMThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

HowKEY INNOVATIONS OF MANUELAThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

HowSERVICESThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

HowSINGLE ENTRY POINT Can act as neutral node Will not need to carry theinfrastructure Can start as project office Can form agreements withthe nodes (CSEM, POLITO,FU, CHALMERS) and others Possible to create a legalentityThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Design flowProcess simulationDEVELOPDesign & OptimizationAnalysisExperimental DataQUALIFYTestingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Dashboard and Digital Thread ManagementThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT CHALMERS (Sweden)WHAT Dedicated printers (metals,polymers and composites) CAM2 competence centre (hostedby Chalmers) Application centre underdevelopment (hosted by RISE IVF) Design, pre-processing andprocess modelling software(CAD, Magics, Ansys, Simufact, ) Materials and powdercharacterisation Materials testing Post-processingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT POLITO (Italy)WHATPrinterBuild. 0*215LPBFAl-based,Ni-based,Ti-based,SteelsMagicsN2 or ArEOSM400400*400*400LPBFCoCr alloyIn718AlSi10MgMagicsN2 or -based MagicsN2 or ArPrintsharp sMagicsN2 or EBM Dedicated printers (metals,polymers and composites) CIM4.0 Competence CenterVacuum Design, pre-processing andprocess modelling software(CAD, Magics ) Material development (gasatomisation) Materials and powdercharacterisation Materials testing Post-processing (Heat treatments,HIP and finishing)This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT POLITOWHATOther metal equipment PSI Gas atomisation system Quintus Hot Isostatic Pressing (HIP) Ovens for post processingPolymer based AM systems SLS EOS Formiga (Nylon and Nylon matrix composites) FDM (ABS, PC, PLA, Nylon ) 3ntr A4 Stratasys F370 and Dimension Elite Markforged Mark Two DLP StereolithographyThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT FAU (Germany)WHATPrinterAtheneA2Q10 plusFreemeltOnePictureBuild. Vol. (mm)120 120 200200 200 200200 200 200130 200(Ø reelyprogrammableVacuum, 6 kW,BSE-detector urematerialsArcam &MagicsVacuumArcam &MagicsHigh brightnesscathode: LaB6(higher print resolution,long service time)FreelyprogrammableVacuum, 6 kW,LaB6 cathodeonline monitoring,small build ited Dedicated printers (metals,composites) Design, pre-processing andprocess modelling software(CAD, Magics ) Application centre (ZMP) Materials and powdercharacterisation Materials testing Post-processing (Heat treatments)This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT FAUWHATDevicePictureFunctionFEI – Helios NanoLab 600i FIBWorkstationHigh-resolution Scanning Electron Microscope (SEM) equipped withEnergy-Dispersive X-ray spectroscopy (EDX), Electron BackScatterDiffraction (EBSD) and Focused Ion Beam (FIB). Dedicated printers (metals,composites)Microprobe Jeol JXA 8100Electron Probe MicroAnalyzer (EPMA) for the chemicalanalysis with high local resolution.Frauenhofer EZRTCT Alpha systemComputed Tomography (CT) for three-dimensional imagingof complex parts. Design, pre-processing andprocess modelling software(CAD, Magics )Ovens (vacuum, inert gas)for heat treatmentsFCT - Pressure sintering furnace;Gero – HTK 25 sintering furnace;Gero – LHTM 250/300 vacuum glowing furnaceOptical & laser microscopesCarl Zeiss – Axio A1m Imager; Carl Zeiss – SteREO;Olympus – Lext OLS 4000; Carl Zeiss – Axio M1m ImagerMalvern – Mastersizer 3000Sigmatest – Creep testerLaser diffractometry for the determination of particle sizedistribution from 0.01 to 3500 µm Application centre (ZMP) Materials and powdercharacterisation Materials testing Post-processing (Heat treatments)Characterization of creep properties of metallic compoundsThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

RESOURCES AT RISE IVF (Sweden)WHATThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Thank youThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Use Case – AerospaceEmmanuel Onillon, CSEMThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Overview Which tools will be available? What will be the design flow? What optimization can bring? Slip ring and helmet mounting device examplesThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Design tools Covers the full development process: Design analysisDesign optimization (APEX GD)Process simulation (Simufact)Manufacturing followingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Design flowProcess simulationDEVELOPDesign & OptimizationAnalysisExperimental DataQUALIFYTestingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Aerospace design example – rotor slip ring (Ruag space) Rotor – reduction of number of parts and assembly time Possibility of Copper printingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Aerospace design example - stator slip ring (Ruag space) Definition of interfaces andnon-design space: Definition of design space(max. volume for topologyoptimization) Problem setup: objective andconstraints Part simulation &manufacturing (Al10SiMg)Design spaces in blue and non design spaces in redThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Thank youThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

AM benefitsLars Nyborg, ChalmersThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Additive Manufacturing ASTM categorizes additive manufacturing into sevenprocess categories: Binder jettingDirected energy depositionMaterial extrusionMaterial jettingPowder bed fusionSheet laminationVat photopolymerizationThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Powder bed fusion Powder bed fusion — an additive manufacturing process in which thermalenergy selectively fuses regions of a powder bed Materials: Metal, polymer and ceramic powder Powder bed fusion: the most growing technique laser or electron beam is used to melt and fuse material powder together layer bylayer presence of the support structures – needs to be removed after AM fabrication anisotropy – grain growth in the built direction typically requires post-treatment – heat treatment, hot isostatic pressing, etc. inorder to relieve residual stresses and minimize number of defects (pores, lack offusion, etc.).This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Laser Based Powder Bed Fusion - Metal LB-PBF/m: performed under protective gaslarger built plates - 800 x 400 x 500 mm (x,y,z)variety of materials availablepowder recyclabilityfine powder – 20-80 µm is used – possibility tobuilt small channels and obtain finer surfaces possibility to use number of laserssimultaneously – increase productivityThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Key features of materials produced by AM Fine columnar microstructure Anisotropy in Z (build) direction Typically densities of 99.9% are reached for optimized processesThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

316L Stainless SteelProperties similar or better than wrought material for establishedmaterials/processesC. Pauzon et al., Materials and Design, V179(2019), 107873This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Microstructure of AM materials – LPBF-316L Large elongated grains in building direction Small grains close to the surface Random orientationBuild angle: 45 Build angle: 30 Design of the component taking into account AM microstructureA. Leicht etc., Materials Characterisation, V143, pp.137-143This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Robust Powder for Additive ManufacturingTechnologyPBF-LPBF-EBAlloysAluminum: Al-10Si-Mg, Al-12Si, Al-7Si-0.6Mg, Al-9Si-3Cu, ScalmalloyCobalt: Co-Cr, Co-Cr-WCCopper: Cu, Cu-10SnNickel: IN625, IN718, IN939, HXTitanium: Ti, Ti-6Al-4VStainless Steels: 15-5 PH, 17-4 PH, 316L SS, INVAR 36Tool Steels: Maraging Steel, H13Miscellaneous: Gold, Platinum, SilverCobalt: Co-CrNickel: IN718Titanium: Ti, Ti-6Al-4V# ofAlloys244Absence of powder developed for AM!Design of the powder material for AM!This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.

Additive ManufacturingThis project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement n 820774.