2015-10-28 metal 3dp possibilities

MT 3DYour Partner in Metal 3D Printing

28/10/2015 Metal Technics 3D 1

Company Info

Location:

Pieter verhaeghestraat 12

BE - 8520 Kuurne

Services:

- Consultancy:

- Engineering:

- Production

Goal: Help potential customers to understand the different technologies and possiblities.Hereby creating a long term relationship to deliver engineering and production services in the future.


Technology


LBM EBM LFM/EFM

Technology


Technology


LBM

Binder Direct

SLM

DMLS

DMP

….

Sintering

Technology


ADVANATGES DRAWBACKS

LBM-Very complex internal cavities-Highest precision -lowest roughness

-High energy Thermal Stresses-Slowest Technology

EBM-Kenic energy + Preheating lowerThermal Stresses-Faster than LBM

-Complex internal cavities not possible-Rougher texture and less precise than LBM

LFM/EFM

-Highest speed-Large parts possible with smaller hardware-different materials can be used in thebuild direction

-Rougher texture and less precise than both LBM and EBM-Lack of powder bed limits geometrical complexity-No ability to influence material properties through the layers

Terminology


Technology Principle Companies /trade -names

Laser Beam Melting(LBM)

Heat transferring laser MELTS Metal powder in powder bed

SLM solutions (SLM); Renishaw (MAM); 3D Systems (DMP); concept laser (Laser Cusing); eos (DMLS)

Electron Beam Melting(EBM)

Electron beam MELTS metal powderin powder bed

Arcam (EBM)

Laser Beam FreefromManufacturing (LFM)

Metal powder is sprayed through a nozzle and melted with a laser beam

Optomec (LENS); Aeromet (lasform); POM (DMD); AMBIT ; Efesto (LMD); RMP (LFMT); H&R Technology (PMD MDT)

Electron Beam FreefromManufacturing (EFM)

Metal powder is sprayed through a nozzle and melted with a electronbeam

Sciaky (EBAM) ; Efesto (EBAM)

Terminology


Technology Principle Companies /trade -names

Laser Beam Sintering Heat transferring laser SINTERS Metal powder in powder bed; subsidiary pressurized oven treatment to densify material

Early EOS technology; Trumph;

Tree DimentionalPrinting (3DP)

Binding metal powder by adhesives, subsidiary oven proces to 1) burn out binder and impregnate with bronz or copper or 2) burn out binder and do pressurized treatment to densify part

Exone (BJ) Digital Metal Hoganas (3DP)

LBM-CNC Combining LBM with CNC milling Matsura

Materials


MATERIALS TYPES

Titanium Grade 1 (cp1/2 high purity)Grade 5 (with or without HIP)Grade 23 (with or without HIP)

Stainless Steel 316L17-415-5

Aluminium AlMg10SiAl12SiAlMgSC

Tool Steel X3NiCoMoTi 18-9-5 (maraging)

Hatelloy X NiCr19Fe19NbMo3

Inconel 718625600

CoCr CoCrMo (ASTM F75)CoCrWMo (ISO22674)

Tungsten Pure >99,9%

Tantalum Pure >99,9%

Materials


316L Ti6Al4V Grade 5

UTS

Yield

Elongation

Young’s modulus

Hardness

630-700 MPa

500-590 MPa

45-50 %

170 Gpa

30 J/cm²

1190 Mpa

1100 Mpa

8%

112 Gpa

37 HRC

Thermal expansion (0-100°C)

Thermal conductivity (at 20°C)

Specific heat capacity

Metling point

16.4 µm/m.°C

15 W/m.K

500 J/kg.K

1375-1400 °C

8.6 µm/m.°C

6.7 W/m.K

580 J/kg.K

1660°C

Capabilities


PROPERTY CAPABILITIES

Density 99,5%-100%Depending on Criteria of the application

Dimensions 250-250-400 mm(500-800-500 mm)

Part Accuracy +/-0,1% (min +/-50µm)

Feature Resolution 0,5 mm (min 0,1 mm wall/ min 0,25 mm channel diameter)

Surface Roughness In General Ra 10-15 µmAfter Sandblasting Ra 2-4 µmWith other post techniques up to Ra 0,05 µm

Post-Processing Milling turning, EDM, grinding welding, plating anodizing,…

Potential


Driver Application

Monolithic Construction Reducing the quantity of componentse.g. monolithic burner, 3D dimensional position flexure

Flow Optimization e.g. heat exchangers, laminar manifoldse.g. conformal cooling applications

Miniaturization Very complex high functional parts can fit in very small areae.g. internal cavities with fin structures on the inside of 0,2 mm

Add Functionality Making the geometry more complex to fulfill an additional function will in most cases reduce material and thus cost

Mass reduction Light weight honey comb/lattice structures to reduce weight and optimize strength to weight ratio

First Proto of a MiM-serial ProductionVery small complex products

e.g. Aluminum Housing / Casee.g. fixture/bracket

Design Rules


1) Avoid Downfacings

Design Rules


2) Orientation: Accuracy and Roughness

Design Rules


3) Orientation: Accuracy and Roughness

- X/Y accuracy up to +/-50µm

- Z-direction accuracy up to +/-100µm

- X-Z and Y-Z surfaces have roughness Ra 4-5µm

- X-Y down facing surfaces have roughness Ra 6-7µm

Design Rules


4) Use material friendly design techniques

Design Rules


5) Organic Designs:

- Organic designs are more easy to 3D print then designs with straight edges.

- Never work with 90°angles: tension concentrations causing cracks.

Design Rules


6) Design Checks:

- Down facing surfaces in internal cavities > 45°?

- Channel diameter < Ø 8 mm?

- Sealed cavities?

- Are supports accessible for removal

MT 3D

Pieter Verhaeghestraat 12

8520, Kuurne

Ir. Thomas Bossuyt

T +32 (0)56 37 02 60

M +32 (0)479 55 19 13

www.metaltechnics3D.com

[email protected]


2015-10-28 metal 3dp possibilities

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