Suorakerrostuksenmateriaalit
J. TuominenTampere University of TechnologyLaboratory of Materials Science
Laser Application Laboratory
Outline• Directed energy deposition (DED) (definition)• DED methods• Feedstock types:
o Powdero Wireo Strip
• Type of metal alloys:o Propertieso Applications
• Summary
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Directed energy deposition (DED)
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• ISO/ASTM 52900:2016 ”Additive manufac-turing – General principles – Terminology”oDED is AM process in which focused thermal
energy (laser, EB, plasma-arc) is used to fusematerials by melting as they are beingdeposited
o The build surface can be an existing part ontowhich material is added (repairing)
Overview of AM processingprinciples for metallic materials
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ISO/ASTM 52900:2016 ”Additive manufacturing – General principles – Terminology”
Directed energydeposition
Powder bed fusion
Directed energy deposition
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• ASTM F3187-16 ”Standard Guide for DirectedEnergy Deposition of Metals”o Applications, DED system set-up, machine operation,
documentation, work practices, system and processmonitoring
DED methods
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Laser: coax-powder Laser: coax-wire (cold, hot),off-axis wire (cold, hot)
MIG/MAG, MIG/MAG pulsed,CMT
EB: coax-wire (xBeam)EB: off-axis wire (Sciaky)
TIG cold-, hot-wire Plasma-arc (powder, wire)
Others:• Additive friction stir welding• Strip cladding (SAW, ESW, laser)• Cold spraying
Standards related to DED feedstock
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• ASTM F3049-14 Standard Guide for Characterizing Pro-perties of Metal Powders Used for Additive Manufac-turing Processes
• AWS: Specification for Filler Metal Standard Sizes,Packaking, and Physical Attributes
• AWS: Welding Consumables – Wire Electrodes, Wiresand Rods for Welding of Aluminum and Aluminum-Alloys
• AWS: Specification for Nickel and Nickel-Alloy BareWelding Electrodes and Rods
• AWS: Specification for Copper and Copper-Alloy BareWelding Rods and Electrodes
• AWS: Specification for Titanium and Titanium-AlloyWelding Electrodes and Rods
• Etc.
Powders
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1. Sulatus2. Puhallus/atomisointi3. Jähmettyminen
• Produced by atomization:o Gases (Ar, He, N2) (spherical)o Plasma (spherical, smooth, high purity,
for reactive metals))o Water (irregular)o Centrifugal (spherical, smooth, for reactive metals)
• Production methods affect:o Shape (flowability, absorption)o Surface texture (moisture?)o Porosity (mechanical properties)o ’satellites’ (flowability)o Size (resolution, surface finish, flowability, efficiency)o Purity (S, P, O) (defects, inclusions, mechanical properties)
o Gas atomized PTA grade typically used (50-150µm)
Wires
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Guest 2014, Canada
Seamless by electrical resistance welding =sähkövastushitsaus,Umpiputkimainen täytelankaPäittäisliitetty täytelankaLimiliitetty täytelanka
• Solid wires (soft & ductile by drawing) (Ø0.8-3.2mm)– Low alloy grades often Cu coated
• Tubular wires (täytelanka) (Ø>1.2mm)– Metal sheath:
• Lubricant coated (graphite, MoS2)
– Internal powders:• Alloying elements (metals, carbides etc.)• Arc stabilizers• Fluxing agents• Slag formers• Shielding gas producers
1. Nauha2. Muotoilurullat (U-muoto)3. Jauhetäyte4. Sulkeminen
Strips
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• Strips for SAW & ESW (w=15–120 mm, t=0.5mm)o Solid (rolling)o Sintered (from powders, Stellites for instance)o Flux-cored
• Strip-wires (w=4.0-4.5mm, t=0.5-0.6mm)o Produced by rolling round wires or cutting from wider bandso To increase deposition rates, better surface qualityo Less penetrationo G3Si1, AlMg4.5Mn, AlSi5
Fronius International GmbH
Materiaalit
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• Low alloy steels (G3Si1,4130, 4140, 300M)• Tool steels (P20, M4, H13, CPM 10V, X42Cr13)• Hadfield-steels (12-19%Mn, 1.1-1.4%C, 0-2.5%Cr)• Maraging steels (low C ultra high strength)• Invar steels (FeNi36)• Stainless steels (316L, 254SMO, 2205, 431, 17-4 PH)• Hardfacing alloys (Stellites, Norem, Nanosteel, Self-fluxing alloys)• Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-Cr NiCr)• Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2)• Copper alloys (CuAl, CuNi, CuSn)• Aluminium alloys (AlSi5 (4043), AlSi10Mg, AlSi12, AlSi7Mg)• Magnesium alloys• Refractory metals (W, Mo, Ta)• MMCs (WC/W2C-NiBSi, VC-tool steel, SiC-Al, synthetic diamonds)• Solid lubricants (MoS2, WS2, CaF2, graphite)• Intermetallics (Cr13Ni5Si2, MoSi2, FeAl, , TiAl, NiTi)• Gradient layers (FGM) (metal matrix composites, monolithes)• High entropy alloys (development of new alloys)
Low alloy steels
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Laser-DED powder: Hybrid (additive + subtractive)manufactured hinge (sarana, nivel) part from 4140
steel (Liou et al. 2007, USA)
Arc-DED wire: Crane hook (RAMLAB,Netherlands), ASTM A391, A973?
11mm
Arc-DED wire: Canal bridge (MX3D, Netherlands) Arc-DED wire: Cantilever beam, ulokepalkki (CranfieldUniversity, UK), topology optimized, 7m, 1500kg
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Arc-DED wire: Mold manufacturing, hybrid (additive + subtractive, ER70S-6 (Akulaet al. 2006, India)
11mm
Hybrid manufactured(additive + subtractive) mildsteel 70S-6 (Song et al.2005, South Korea)
S355: Rm 510-680MPa
Arc-DED wire: 300M UHSS(Skiba et al. 2010)
Low alloy steels
Tool steels
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Laser-DED powder: Graded build-up of laser clad gear teeth (Laser Cladding Venture, NV,Belgium)Wear resistant surface, tough core
• Strength• Fatigue• Wear• Cost
Hot-work tool steel
Tool steels
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Laser-DED powder: Hybrid (additive + subtractive) manufactured bearing seat(laakerin istukka) part from H13 tool steel (Nagel et al. 2010, USA)
EB-DED wire: Build-up and repair oftooling & stamping dies (Sciaky Inc.,
USA)
11mm
Arc-DED wire: Austeniticmartensitic VC tool steel(~850HV1), crack-free (TUT)
Laser-DED powder: CPM 9V (Xue et al.2013, Canada)
Laser-DED powder: CPM 9V cuttingpatterns on rotary cutting die (Xue et
al. 2013, Canada)
Tool steels
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Laser-DED powder: Conformal cooling channels incooling fan mold of H13 (InssTek, South Korea)Complex internal structures
(Griffith 2000)
(kiloponds per square inch = kilopaunaa per neliötuuma)
Maraging steel
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Laser-DED wire: Maraging250 steel test block on
H13
Laser-DED wire: Die casting(painevalu) tool repaired
with Maraging 250
Kottman et al. JOM 67(3) 2015Pangsrivinij, M.Sc. Thesis 2016
Stainless steels
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Laser-DED powder: AISI 431(Smurov 2007, France)
Laser-DED powder: Hybrid, turbiinin pesä,(DMG Mori)
Arc-DED wire: stainless steel (MX3D,Netherlands)
Arc-DED wire: Pelton runnersfor hydropower stations(Andritz Hydro, Switzerland)
Stainless steels
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AISI 308L with GMAW-P (Uziel 2016)
Arc-DED wire: AISI 308L demonstrator part, 85% reduction inmaterial compared with machining (Uziel 2016)
Stainless steels
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Arc-DED wire: Adding features to pressurevessels (Nuclear AMRC, UK)
Arc-DED wire: AISI 304 with CMT (Kapustka 2015,USA)
Arc-DED wire: Blade withCMT, duplex SS 2209(Posch, Fronius Int.GmbH)Instead of casting30 – 60 FNMechanical properities of 2209 (Posch,
Fronius Int. GmbH, AUT)
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Lähde: IMTI National Research Council Canada
§ Complex thermal history (directional heat extraction, repeated melting & rapid solidification, repeated solidstate transformations)§ Reduced grain size due to high solidification rates§ Directionally solidified structures§ Anisotropic mechanical properties
Lähde: IMTI National Research Council Canada
Stainless steels
Stainless steels
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Laser-DED powder: (Rombouts et al. 2012, Belgium)
Lying
Standing
Ni-based superalloys
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Laser-DED powder: Combustion chamberpart (engine casing) IN-718 (TWI Ltd, UK)
Ø300mm, H100mm, t0.8mm2-3 months -> 6 hours
Laser-DED powder: Oil & gas flange In625(TWI Ltd, UK)
Ni-based superalloys
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Arc-DED wire: IN718 (Baufeld 2012)
Arc-DED wire: IN718 (Fronius USA)
Ni-based superalloys
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Laser-DED powder: SIFCO, Ireland
Airfoil (siipiprofiili)
Inconel 625
NRC-CNRC
Laser-DED powder
Laser-DED powder: IN-718 impeller (Xue et al.,2011, Canada)
Laser-DED powder: IN625 mold with coolingchannels (Xue et al., 2011, Canada)
Laser-DED powder: IN-718 honey comb tube(Xue et al., 2011, Canada)
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Lähde: IMTI National Research Council Canada
Microstructure of In625
Ni-based superalloys
Ni-based superalloys
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Numerical analysis of residual stresses in IN718 on IN718 (Mukherjee et al. 2017)
Co-based alloys
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In-situ repair of turbine blades with Stellite 6 (TWI Ltd) Micro-cladding of Stellite (de Val et al. 2014, Spain)
Stellite 21 on AM355 mart. SSAbrasion resistance needed
Ti alloys
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Laser-DED powder: Hip implant (LENS,Optomec) Laser-DED powder:
Femoral component
Manufactured by DMDmethod
Laser-DED powder: (Fraunhofer IWS,Germany)
Ti alloys
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• Laser-DED powder manufacturedand post-machined airliner part
• Ti-6Al-4V
• Length approx. 600 mm
• Improves ’buy-to-fly’ ratio
• Airbus, for instance, spends £250million for conventionallymanufactured Ti componentsevery year -> huge savingpotential
Buy-to-fly ratio = the ratio of the amount of materialpurchased to the amount of material found in thefinal component (lower the better)
Large stair-stepping effect
Aeromet Corp.
Ti alloys
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A large 3D printed titanium part for J-20 or J-31 stealth fighter (China)
A 5 m long Ti central wing spar (siipisalko) forComac C-919 passenger plane (NPU, China)
Large titanium part for mainstructural component in aircraft,1730x250x230mm (Beihang,China)
Ti alloys
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Laser-DED powder: Fatigue strength of Ti-6Al-4V (Prabhu et al. 2015)Presence of unmelted particles affects fatigue lifeRepair condition means that deposited parts are joined to wrought part
Laser-DED powder: Bell helicopterExhaust duct Ti-6Al- 4V (LENS)
EB-DED: Ti6Al4V screw (Sciaky Inc.,USA)
EB-DED wire:Rear upper spars
for Airbus wing(Sciaky Inc.)
Ti alloys
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Ti-6Al-4V
Laser-DED wire:Kottman et al. JOM 67(3) 2015Pangsrivinij, M.Sc. Thesis 2016
Laser-DED wire: University West,Sweden
Laser-DED powder: Suspension mountingbracket, jousen kiinnitysteline Red Bull F1,Ti-6Al- 4V (LENS)-92% Material loss
Laser-DED powder: vetoakselin osa,LENS Laser-DED powder:Valves for racing motorcycle, Ti-6Al- 4V
(LENS)
Ti alloys
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Ard-DED wire: Ti6Al4V flap rib = siiventukikaari (Cranfield University)
Weight as design 1.43kgBillet weight 53kg
Weight as deposited with plate 9kg
Arc-DED wire: Ti alloy landing gear rib =laskutelineen runko (Cranfield University)
Weight as design 21kgBillet weight 240kg
Weight as deposited 24kg
Ti alloys
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’Eliminating 50-75% of thecosts when fabricating titaniumcomponents with arc-DED’
’1000 titanium parts in Boeing787 that can be printed’
’200-lb. needed for 20-lb. partby subtractive manufacturing,30-lb. needed by AM’
Norsk Titanium AS, plasma-arc
Ti6Al4V control arm demonstrator, hot-wire TIG,(EWI, Uziel 2016)
EB-DED wire: Ballast tank forsubmarine =
painelastivesisäiliö (SciakyInc.)
Ti alloys
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Arc-DED wire: Ti6Al4V tensile & fatiguestrength (Cranfield University)
Ti alloys
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Arc-DED wire: Ti6Al4V, high-pressure cold-rolling (Cranfield University)Isotropic mechanical properties + diminished residual stresses
Al alloys
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Arc-DED wire: Stiffened Al panels(Cranfield University) Arc-DED wire: Wing rib = siipikaari
(Cranfield University)
150 layers 40 mm3/s
Hypoeutectic AlSi5(4043) by robot-guidedCMT process, 50 HV0.05
Ra 3.0µmArc-DED wire: tukiseinä/laipio (Cranfield
University)
Al alloys
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Arc-DED wire: Tensile performances of Al alloys (Martina 2015,Cranfield University)
Porosity problemin Al alloys
Rolling helps toremove porosity
Cu alloys
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Arc-DED wire: Brass (Posch, Fronius Int.GmbH, Austria)
Arc-DED wire: Brass sculpture (MX3D, Netherlands)
Laser-DED powder: Drawing die (vetomatriisi) with cooling channels,CuAl10Fe1 (aluminium bronze) (Freisse et al., 2015, Germany)
Mg alloys
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Laser-DED powder: Elektron™ MAP 43 Mg (T. Palmer, PennState, USA)
Refractory metals
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Arc-DED wire: (Williams 2016, Cranfield Unversity, UK)
Intermetallics
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Laser-DED powder. TiAl (Fraunhofer ILT,Germany)
Laser-DED powder:TiAl (Fraunhofer IWS,Germany)
Multi-material
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Laser-DED powder: Nickel/Copper, hybrid (additive +subtractive) (Kerschbaumer et al., 2004)
Arc-DED wire: Steel/Bronze (CuSi3)(Cranfield University)
FGM
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Laser-DED powder: Graded stainless steel 316L / Stellite 6 (Smurov 2007)
Laser-DED powder: In690/TiC FGM (Wilson et al., 2012)Laser-DED powder: NiBSi/WC,NiBSi/CrC FGM, cutting-edge of circularknife (Theiler et al., BIAS Bremen)
FGM
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Laser-DED powder: Graded structure (Smurov 2007)
Laser-DED powder: 304L/Invar (Hofmann et al., 2014)
Yhteenveto• Suorakerrostuksessa lähtöaineet voivat olla jauheen lisäksi
myös lankoja ja nauhoja• Useita materiaalivaihtoehtoja: teräkset, Ni-pohjaiset super-seokset, alumiini, titaani jne.• Myös monimateriaalit, gradienttirakenteet, metallimatriisi-
komposiitit• Hauraat ja kovat materiaalit haasteellisimpia• Kiderakenteet suuntautuneesti jähmettyneitä -> anisotroop-
piset mekaaniset ominaisuudet• Mekaaniset ominaisuudet heikkenee, jos
prosessiparametreistä tai lisäaineen laadusta johtuvia virhei-tä
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KIITOS!