voestalpine Additive Manufacturing Centervoestalpine Additive Manufacturing Centerwww.voestalpine.com
OPPORTUNITIES AND CHANCESDIFFERENT APPROACHES
Dr. Eric Klemp
voestalpine Additive Manufacturing Center| |
Agenda
1. Overview voestalpine HPM
2. AM - Value Chain
3. Process Chain / Influences
4. Products
5. Conclusion
3D printing Event - Geleen, NL17.04.20192
voestalpine Additive Manufacturing Center| |
voestalpine AG
3D printing Event - Geleen, NL
Key figures for 2017/18
Employees 51,621
Revenue EUR 12,898 million
EBITDA EUR 1,954 million
EBIT EUR 1,180 million
EBIT margin 9.1 %
Sales by regions Sales by industries
Business year 2017/18 Business year 2017/18
66% European Union
(of which Austria 7%)8% Asia
8% Rest of world
4% South America
14% NAFTA
3% Aerospace
11% Railway systems
34%Automotive
ENERGY 13%
9% Building/ Construction
14%Other
9% Mechanicalengineering
5% White goods/ Consumer goods
MOBILITY: 49%
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voestalpine AG
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Global quality leaderin premium steel strip and cast products, and the
global leading supplier of heavy plate
SectorsAutomotive industry and suppliers, energy,
household appliances, construction industry
Global market leader in turnout technology and a leading partner for
rails, processed wire, seamless tubes and welding
consumables
SectorsRailway systems, energy, automotive industry,
mechanical engineering and steel construction
industries
Global market leaderfor tool steel and a leading partner for high-speed
steel, valve steel, special forged parts and
powdermetallurgical materials
SectorsToolmaking, automotive industry, oil & gas
exploration, aerospace
Global leading supplierof highly refined sections, tubes and precision strip
steel products as well as for ready-to-install system
components made of pressed, stamped and
rollformed parts.
SectorsAutomotive, construction and energy industries,
warehousing technology, mechanical engineering
and steel construction industries
Steel
Metal Engineering
High Performance Metals
Metal Forming
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HIGH PERFORMANCE METALS DIVISION AT A GLANCE
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Global leading special
steel company with a
focus on
technologically
demanding product
segments
Global market leader in tool steel and global
leading supplier in high-
speed steel, valve steel
and other special steels
as well as
powdermetallurgical
materials
“One-stop shop”With additional services
including heat
treatment, coating and
additive manufacturing.
8 production sites in
Europe, North and
South America, and a
sales and service
network with 160
warehouse and
service sites in 45
countries on all five
continents
Supplying customers
worldwide in the
sectors:
» Automotive
» Power generation
» Oil & gas exploration
» Mechanical
engineering
» Consumer goods
» Aircraft manufacture
» and other selected
industry segments
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voestalpine Additive Manufacturing Center| |
Agenda
1. Overview voestalpine HPM
2. AM - Value Chain
3. Process Chain / Influences
4. Products
5. Conclusion
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ADDITIVE MANUFACTURING @ voestalpine HPMOUR APPROACH
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Additive Manufacturing Center
Customer Consulting
Powder development
Powder productionDesign &
engineeringAM-Parts
Heat treatment & post processing
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SOLUTION PROVIDER ALONG THE VALUE CHAIN FOR POWDERS & PARTS
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2013 2019
4x
Staff involved: 5 Staff involved: 20 Staff involved: 30 Staff involved: 50 +
Idea to concept Concept to product / service Market launch/introduction
ADDITIVE MANUFACTURING @ voestalpine HPMAM HISTORY - TIMELINE
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Alloy development Powder productionDesign/Engineering -
Applicationexpertise
AM-Parts productionAM specific post
processing
N
2
N
2
H2
O
H2
OH2
O
H2
O
ADDITIVE MANUFACTURING @ voestalpine HPMEXAMPLES & HIGHLIGHTS ALONG THE VALUE CHAIN
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Multiple locations, markets & technologies
…Powder bed fusion
…Direct metal deposition
…Powder production
Hagfors, S
Kapfenberg, A
Düsseldorf, D
Singapore, SIN
Nantou, TW
Toronto, CAN
Houston, USA
ADDITIVE MANUFACTURINGHIGH PERFORMANCE METALS AM NETWORK
…EOS M290
…EOS M400
voestalpine Additive Manufacturing Center| |
DEVELOPMENT & PRODUCTION OF HIGH QUALITY METAL
POWDERS AT BÖHLER EDELSTAHL & UDDEHOLM
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Atomising rigs at Böhler & Uddeholm
» Production started 2016
» In total a yearly capacity of roughly 200 tons of metal powder will be available for AM
» VIM with max. batch size of 500 kg
» Atomization with inert gas
» Flexible production plant – open for customized solutions (chemistry)
» Atomization of broad range of steel and Ni-Base alloys possible
Facts
Source: voestalpine
voestalpine Additive Manufacturing Center| |
THE CHALLENGE WITH ALL THE AM TECHNOLOGIES» The interaction of material, design, process and equipment is much
stronger than with traditional manufacturing technologies
Part
Performance
Material
Process Equipment
Design
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Agenda
1. Overview voestalpine HPM
2. AM - Value Chain
3. Process Chain / Influences
4. Products
5. Conclusion
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voestalpine Additive Manufacturing Center| |
MATERIAL PROPERTIES
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Source: voestalpine
Density ~95% Density ~99.97%
Technical progress:» Laser technology» Optics» Software» Efforts in R&D
Several years ago Today
Mechanical properties close to bulk material
voestalpine Additive Manufacturing Center| |
POWDER IS POWDER – REALLY?
=
≠
?
» Shape
» Particle sizedistribution
» Hollow structure
» Humidity
» Oxygen content
» Chemistry
» Flowability
Source: voestalpine
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Parameter Development – Proceeding
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Analysis of alloy
PROCESS STAGE 1 - SCREENING
PROCESS STAGE 2 - REPRODUCIBILITY
PROCESS STAGE 3 - MANUFACTURING
Shipping andaccounting
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voestalpine Additive Manufacturing Center| |
» Qualifying new materials for LBM
requires extensive testing and
parameter development
» To manufacture a part via LBM ~200
different build parameters need to be
considered
» A procedure was developed to reduce
parameter development costs and set
a quality standard
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LBM parameter development
Different Parameter Volumes Segments
voestalpine Additive Manufacturing Center| |
» The build process is affected by several influencing factors and process parameters.
» Analysis of the entire manufacturing process was conducted.
» An investigation of all critical process parameters was made
» Handbook and powder handling guide was created.
» Recommendations about the most influencing process parameters during LBM were established.
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Influences LBM
Influencing Factors(temperature, humidity, coating speed, gas flow, …..)
voestalpine Additive Manufacturing Center| |
Agenda
1. Overview voestalpine HPM
2. AM - Value Chain
3. Process Chain / Influences
4. Products
5. Conclusion
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voestalpine Additive Manufacturing Center| |
Applications & benefits through AM
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Plastic injection molding
Aluminumdie-casting
Hot forming / press hardening
Prototype development
Special components
Fluid components
Source: voestalpine
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SUPPORT OPTIMIZATION
» Topology and support
optimizations may allow great
material reduction but… can lead
to massive support and post
processing problems
» Build direction is essential to
minimize support, building time,
distortion and to optimize
platform utilization
21 17.04.2019 3D printing Event - Geleen, NL Source: voestalpine
voestalpine Additive Manufacturing Center| |
MODULATION OF COOLING DENSITY
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» Tailored cooling by
using different channel
density and lattice
density
Source: GoetheLab for Additive manufacturing, voestalpine
High cooling
Medium cooling
Non / low cooling
Activecooling /heating
indirectcooling /heating
InletOutlet
voestalpine Additive Manufacturing Center| |
CONFORMAL COOLING
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APPLICATIONPlastic injection molding tool with conformal cooling
AM ADVANTAGES» Reduced cooling time 20s 6s» Simulation and advanced
channel design* guarantees best performance
» Lightweight design** to reduce cooling losses and reduce printing time
Source: voestalpine
* **
voestalpine Additive Manufacturing Center| |
CONFORMAL COOLING FROM EXPERTS
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Source: voestalpine
Parallel cooling often used when
space-saving is necessary but it is
very challenging to realize due to
» unbalanced mass flow rate
and flow speed
» powder removal
Expert knowledge in simulation
and post processing needed!
voestalpine Additive Manufacturing Center| |
JET ARRAY COOLING DEVICE
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N2N
2
H2OH2
OH2
O
H2O
APPLICATION
Cooling device for flat surface
AM ADVANTAGES
» Quick and homogeneously cooling
» Monolithic design to minimize size
» Combining of air and water
cooling channels
» High efficiency
Source: voestalpine
voestalpine Additive Manufacturing Center| |
Jet Array cooling device
3D printing Event - Geleen, NL
APPLICATION
Cooling device for flat surface
AM ADVANTAGES
» Quick and homogeneously cooling
» Monolithic design to minimize size
» Combining of air and water
cooling channels
» High efficiency
Source: voestalpine
AM first version new version “common rail”
simulationcross-section of “common rail”
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voestalpine Additive Manufacturing Center| |
Initial Design suggestion
Design optimization
Manufacturing
Evaluation & further optimization (if necessary)
flowsimulation
part configuration
thermal simulation
AM-Design ≈ 4 weeks
Simulations ≈ 1 week
Build time ≈ 76 hrs for 2 Jet Arrays
Part weight ≈ 1.6 kg
Design engineering and outlook
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Feeder elbow pipe
conventional cast design
AM design
APPLICATION
Transport pipe for abrasive fluids
AM PART
» High wear resistant material
» Inner flow path optimized
» Wall reinforcement at areas with
high wear
lever
axis
reinforcement
Source: voestalpine
voestalpine Additive Manufacturing Center GmbH| |
» Design and material were changed to
achieve high wear resistance and
good printability
» Elbow pipe is in active service since
18.12.2017
» Conventional part only lasts between
4-6 weeks
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Elbow pipe
Elbow Pipe in Use
voestalpine Additive Manufacturing Center| |
Tools with coating
http://oewf.org/en/portfolio/amadee-18/
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voestalpine Additive Manufacturing Center| |
Technology Showcase - lightweight
Source: voestalpine
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voestalpine Additive Manufacturing Center| |
hood hinge - Essential success factors
» Toolless high flexible manufacture» Investment minimal for small series» update-capable production
» Ultra lightweight design» CAE topology optimization» AM just ultra-lightweight design
» Maximal functional integration» Fragile structure for freedom of
movement» No complex kinematics
» Tool-free high flexible manufacturing
» Ultra lightweight design
» Maximal functional integration
» Sustainability & resource efficiency
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LightHinge+: Weight optimisationAdditive manufacturing only works economically if the highest degree of
functional integration in the component is possible
» Topology analysis without consideration a. of the functional integration b. of the manufacturing conceptbrings the design engineer on a "wrong mechanical track"
Principle "breakaway structure" instead of "kinematics“= Success factor for weight minimization
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Lightweight design – hood hinge
APPLICATION
Automotive hood hinge
AM ADVANTAGES
» Weight reduction of 50%
» optimized structure - strength,
warpage & minimal support
» integrated predetermined
breaking point for pedestrian
protection
3D printing Event - Geleen, NL Source: voestalpine, EDAG17.04.201934
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Topology optimization –hood hinge
Source: voestalpine
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Process optimisation for AM
Source: voestalpine
Optimized Orientation
Additive Manufacturing
Process Simulation
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Functional tests» Degrees of freedom for designers:
they enable the integration of an
active hood function in the flat
design of the front end
» Breakaway fractural structure acts
as an ultra-light, printed kinematics
in interaction with the pyrotechnic
triggered spring elements
» Active bonnet will lift approx. 50
mm in the area of the hinges
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voestalpine Additive Manufacturing Center| |
Agenda
1. Overview voestalpine HPM
2. AM - Value Chain
3. Process Chain / Influences
4. Products
5. Conclusion
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voestalpine Additive Manufacturing Center| |
FinallyApplication and benefits
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design freedom/fast development
Improved life cycle / maintenance
lightweightintegration of
functions/sensors
less time-to-market
porous structures/ ventilation / damping
Graduated materials / wear
resistance
temperature / flow optimization
separation/mixing of fluids
Source: DMRC, voestalpine
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voestalpine Additive Manufacturing Center| | 3D printing Event - Geleen, NL
Don’t try to use AM for parts which are dedicated to
other manufacturing technologies!
AM is only economically if you can
add value to the part!
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voestalpine Additive Manufacturing Center| |
FOR FURTHER INFORMATION PLEASE CONTACT
Dr. Eric Klemp
voestalpine Additive Manufacturing Center GmbH
Hansaallee 321
40549 Düsseldorf
Germany
T.: +49 (211) 522 2331
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