Metal AM Vol 3 No 3

o METAL

o V AM

in this issue

HONEYWELL AEROSPACE DESIGN FOR AM: CASE STUDIES METAL POWDER RECYCLING

Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 1 Published by Inovar Communications Ltd www.metal-am.com | contents page | news | events | advertisers’ index | contact | Publisher & Editorial Offices Inovar Communications Ltd 11 Park Plaza METAL Battlefield Enterprise Park Shrewsbury SY1 3AF, United Kingdom Tel: +44 (0)1743 211991 Fax: +44 (0)1743 469909 ADDITIVE Email: [email protected] www.metal-am.com MANUFACTURING Managing Director, Features Editor Nick Williams Tel: +44 (0)1743 211993 Email: [email protected]

Publishing Director, News Editor Paul Whittaker Tel: +44 (0)1743 211992 Email: [email protected]

Assistant Editor Emily-Jo Hopson Tel: +44 (0)1743 211994 Email: [email protected] Designing the value into Production Hugo Ribeiro, Production Manager Additive Manufacturing Tel: +44 (0)1743 211991 Email: [email protected] The knowledge that an engineer has to possess in order to Advertising successfully produce parts by AM differs fundamentally from Jon Craxford, Advertising Sales Director conventional manufacturing processes. For those new to AM, Tel: +44 (0)207 1939 749 Fax: +44 (0)1743 469909 the complexities of the Design for Additive Manufacturing (DfAM) Email: [email protected] methodology can be particularly daunting.

Subscriptions Metal Additive Manufacturing is published on a Today, there is growing recognition amongst end-users that simply Making your quarterly basis as either a free digital publication putting a part designed for conventional manufacturing through or via a paid print subscription. The annual print an AM machine is doomed to failure. The skills and knowledge subscription charge for four issues is £95.00 required to create a part specifically for AM rely on the designer for Additive Manufacturing including shipping. Rates in € and US$ are embracing a completely new mind set that draws on a wide range DREAMS available on application. of previously unconsidered factors. Accuracy of contents for metal AM Whilst every effort has been made to ensure the Case studies are one way that those who are further ahead on accuracy of the information in this publication, the DfAM journey can share their experience and knowledge with the publisher accepts no responsibility for those who are new to the technology. In this issue of Metal AM errors or omissions or for any consequences arising there from. Inovar Communications Ltd magazine we feature two very different application-focused cannot be held responsible for views or claims reports, both of which offer invaluable insight into how companies expressed by contributors or advertisers, which have successfully leveraged DfAM to transform existing are not necessarily those of the publisher. applications.

Advertisements Although all advertising material is expected Using AM for these applications has brought major benefits, from to conform to ethical standards, inclusion in performance improvements to weight reduction and, in one case, FLY this publication does not constitute a guarantee a dramatic reduction of the total number of components in a With Praxair powders, the sky isn’t the limit or endorsement of the quality or value of product sub-assembly from a hundred to one. Look to Praxair Surface Technologies for the metal such product or of the claims made by its manufacturer. powders, know-how, resources and supply to turn If your company is starting out on the AM journey and you your AM dreams into reality. Reproduction, storage and usage plan to visit the formnext exhibition in Frankfurt, Germany Single photocopies of articles may be made (November 14-17), please drop by our booth (3.0 G65). We’d be for personal use in accordance with national very interested to learn about your metal AM experiences. • Approved aerospace grade copyright laws. All rights reserved. Except as

outlined above, no part of this publication may • Large lot sizes and R&D volumes be reproduced, modified or extracted in any form Nick Williams or by any means without prior permission of the Managing Director • Stock availability and custom offerings publisher and copyright owner. Metal Additive Manufacturing

Printed by IT’S TIME TO DREAM BIG. Cambrian Printers, Aberystwyth, UK ISSN 2057-3014 (print edition) ISSN 2055-7183 (digital edition) praxairsurfacetechnologies.com/am Cover image Vol. 3. No. 3 Autumn 2017 An F125IN turbofan engine This magazine is also available for free manufactured by Honeywell Aerospace download from www.metal-am.com (Courtesy Honeywell) © 2017 Inovar Communications Ltd Contact us to find out how we are making more possible: 1-317-240-2650 or [email protected]

2 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Metal Additive Manufacturing | Autumn 2017 1 © Copyright 2017 Praxair S.T. Technology, Inc. All rights reserved. MetalAM June2017.pdf 1 6/5/17 7:26 PM

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In this case study, Terry Wohlers and Professor Olaf Diegel, both of Wohlers Associates, reveal Contents how industrial mining machine manufacturer Atlas Copco has used DfAM to increase the value 5 Industry News of a hydraulic manifold.

81 Honeywell: Driving AM application 109 Design for AM: Transforming RF and supply chain development in the antennas through intelligent optimisation aerospace industry AM presents the opportunity to completely rethink With dedicated AM facilities in five countries, a product’s design, transforming its functionality Honeywell Aerospace is at the forefront of the and reducing manufacturing complexity. In the development of new commercial aerospace following article, Optisys LLC reveals how, through applications for AM, along with the supply chain intelligent design optimisation, the company has needed to implement series production. Dr Dhruv used Additive Manufacturing to develop the next Bhate visited Honeywell’s Phoenix facility and generation of RF antenna systems for aerospace met with Donald Godfrey, an Engineering Fellow and defence. at Honeywell and the person most credited with directing the company’s progress in AM. 115 AMPM2017: Understanding the impact of powder reuse in metal Additive 93 RapidTech + FabCon 3D: Innovations Manufacturing in binder-based AM and advances in An issue of significant current interest to conformal cooling the Additive Manufacturing world, which can From June 20-22, 2017, the German city of potentially impact both the quality and cost- Erfurt became a centre of gravity for AM, hosting effectiveness of built parts, is whether there the annual RapidTech conference and FabCon is a limit on the number of times that metal 3D exhibition. Dr Georg Schlieper reports on a powders can be cycled around an AM process. number of trends in metal AM process technology Dr David Whittaker reviews three presentations and applications, including binder-based AM on the topic from AMPM2017, the fourth technologies and innovations in toolmaking. annual Additive Manufacturing with Powder Metallurgy Conference, held in Las Vegas, USA, 103 Design for AM: Increasing part value June 13-15, 2017. through intelligent optimisation Paying the right amount of attention to Design 127 Events guide for Additive Manufacturing (DfAM) can make the difference between economic success and failure. 128 Advertisers’ index

industry news

Digital Metal begins commercial program,” explained Don Godfrey, Engineering Fellow – Additive production of its high precision binder Manufacturing, Honeywell Aerospace. jet metal AM system “We believe this will also be critical to applications in other key areas of the broader aerospace industry.” Digital Metal®, Sweden, a Höganäs Ralf Carlström, General Manager, Digital Metal has also stated that Group company, has begun Digital Metal, stated, “Our heritage, it will provide all ancillary equipment commercial production of its high- knowledge and experience in required with each machine, as well precision binder jet metal Additive metal powders, combined with the as introductory and ongoing training Manufacturing system which it development and evolution of our and support. states can produce smaller and cutting-edge printer technology, has more intricate components than any enabled us to succeed where others Digital Metal adds titanium option previous technology. The DM P2500 have failed. With the DM P2500 we are In addition to stainless steels 316L has a 2500 cm3 print volume and bringing to market a tried and tested and 17-4PH, Digital Metal has also Sparking a new era manufactures parts in 42 µm layers 3D metal printer.” extended its material range to include at 100 cm3/h, without the need for Honeywell Aerospace and Digital titanium Ti6Al4V. Titanium is widely in design and manufacturing any support structures. This makes it Metal are said to be exploring a used in the Additive Manufacturing possible to manufacture small objects number of joint AM projects which industry as it combines high strength, in high quantities - up to 50,000 parts will merge Honeywell’s expertise in high hardness and ductility with Through innovation, collaboration and consultation, GE Additive has per print run - and in a wide variety of aerospace engineering with Digital high corrosion resistance. The use shapes, geometries and internal and Metal’s AM technologies. “The binder of titanium can offer a 45% weight built a network of people and businesses that are advancing additive external finishes. The system delivers jetting technology Digital Metal uses reduction compared to conventional manufacturing. Not just for us, but for everyone. We’ve taken our additive a resolution of 35 µm and an average to print small metal parts has the steels. Digital Metal’s Ti6Al4V is said experience and made it even stronger, bringing together machine and surface roughness of Ra 6 µm before potential for various applications to meet ISO 22068 standard. material providers as well as design experts to help you incorporate additional finishing processes are within the Honeywell Aerospace www.digitalmetal.tech applied. additive technology into your operations. Together, we’re helping guide Digital Metal has been using manufacturing in a bold new direction. this proprietary binder jet metal AM technology in-house for four years Let us help you find new ways to grow your business at ge.com/additive. to produce bespoke and precision small-scale components. To date, the company states that it has produced approximately 200,000 pieces for customers in several industries, including aerospace, luxury goods, dental tools and industrial equipment manufacturing. Sintering takes place after the production process and is adaptable for a variety of materials. Powder removed before sintering can also be reused for subsequent jobs, making it one of the most sustainable AM technologies available today. This results in high yield and low scrap rates, meaning downtime is kept to a minimum and there is no powder degeneration. Digital Metal DM P2500 (Courtesy Digital Metal)

BASF establishes Additive Manufacturing company, launches Ultrafuse 316LX for fused filament fabrication of metal parts

BASF SE, Ludwigshafen, Germany, structures with interdisciplinary teams has announced the formation of a new and quick decision-making processes. SMALL IS THE company, BASF 3D Printing Solutions Combining the customer-focused 3D BASF’s Ultrafuse 316LX is suited GmbH, to focus on establishing and printing activities in one location at a to a broad range of applications for expanding the company’s business dedicated business is an important functional prototyping and small with materials, system solutions, success factor.” series production (Courtesy BASF) components and services in the field of Additive Manufacturing. This Ultrafuse 316LX vacuum results in the finished metal NEW BIG wholly-owned subsidiary of BASF BASF has also introduced Ultrafuse part. The whole process is said to New Business GmbH will be head- 316LX for use in fused filament be faster and less expensive than IN ADDITIVE MANUFACTURING quartered in Heidelberg, Germany, at fabrication (FFF) systems for the offered by existing SLM systems. the site of InnovationLab GmbH. production of metal parts. Ultrafuse Ultrafuse 316LX is available in 1.75 BASF 3D Printing Solutions will 316LX is metal-polymer composite and 2.85 mm diameter filament. work closely with researchers and filament with a non-slip surface According to BASF, no changes to application engineers from BASF and allowing its application in any bowden the FFF hardware are required to Imagine design that defies the rules. Accuracy down to single micro- external partners, such as universi- or direct drive extruder. Its high flex- process the material. Currently only a metres. Minimum material waste. Fast track to market. ties and potential customers, in order ibility is said to allow it to be funnelled 316L stainless steel option exists, but Digital Metal® is a unique 3D metal printing technology that delivers to develop the right solutions for a through complex idler pulleys as well BASF states that other metal options formerly unseen levels of resolution and surface quality. Proven by wide array of requirements. as guide roller filament transportation will be developed. more than 200,000 high-quality components produced, it has become “The field of 3D printing for systems. The filament is said to be suited a world-class benchmark standard. industrial applications is highly Once formed, the parts undergo to a broad range of applications for Digital Metal® offers advanced industrial 3D-printers along with all dynamic and still emerging,” stated a standard debinding and sintering functional prototyping and small the support you need to set up your own production. You can also use Volker Hammes, Managing Director process introduced to the Metal series production. BASF lists various our printing services to prototype or mass produce components. at BASF New Business and future Injection Moulding (MIM) market by applications including watches, Want to see how small parts can give your business a big boost? Managing Director of BASF 3D BASF in the 1980s. Catalytic debinding decorative parts and medical Printing Solutions. “This means removes the polymer from the part equipment. CHECK OUT ALL THE BENEFITS OF DIGITAL METAL ON there is a need for agile, start up-like and sintering in pure hydrogen or a www.basf.com DIGITALMETAL.TECH

long-term growth trajectory as an DM P2500 SLM Solutions receives €43 million independent German company,” order for fifty machines Bögershausen continued. “The order also underlines the high suitability of SLM’s machines for the industrial SLM Solutions, Lübeck, Germany, is to the company, the order is an production of parts in high quality.” reported to have signed its largest important step in promoting further SLM 280 machines represent ever single order contract for fifty growth in Asia and underscores the the fastest selling series currently machines from its SLM 280 series, strong global demand for additive produced by SLM Solutions. In amounting to €43 million. The production facilities suitable for addition to offering users the ability systems will be sold via a sales industrial applications. to customise machine parameters, partner in China. Previously, the The fifty machines will be sold SLM 280 machines offer a high level largest single order received from a up over the period 2017-2020. of productivity through the parallel customer was for ten machines from According to SLM Solutions, it is one use of up to two lasers, each with the SLM 500 series in June 2017, also of the largest orders ever placed a maximum 700 W output. The www.pyramid.se in China. in China in the area of Additive machine performance enables users “We are delighted to have won the Manufacturing. to optimise production costs per largest single contract ever in the “This contract shows that we component manufactured while still history of SLM Solu tions,” commented are absolutely right in focusing on allowing full scope for geometrical Uwe Bögershausen, board member at developing long-term customer design. SLM Solutions Group AG. According relationships and underpins our www.slm-solutions.com DIGITALMETAL.TECH DIGITAL METAL ® IS A HÖGANÄS GROUP COMPANY

AP&C unveils state-of-the-art Make the most powder manufacturing facility in Canada

Arcam AB, Mölndal, Sweden, has announced that its Additive of additive Manufacturing powder manufacturing subsidiary, AP&C, officially opened Powder a new facility in Saint-Eustache, Quebec, Canada. The new manufacturing plant will employ more than one hundred new employees by the end of the year, making it manufacturing. one of the largest employers in the region and marking a significant growth for AP&C, which has quadrupled in size over the last two years. Autodesk Netfabb® helps you quickly With a present total production capacity of 750 tons and planned production capacity of 1,250 tons at full capacity, get from 3D model to successfully the new plant is poised to meet the growing demand for titanium powders in terms of quality and capacity. “The printed parts. Combined with need for high end titanium powder is driven by the fast ® Autodesk PowerMill you get a growth and adoption of Additive Manufacturing,” stated Magnus René, Arcam CEO. “Arcam, AP&C and GE Additive powerful hybrid solution are determined to serve the industry through cost-effi- for additive and cient solutions, thus converting traditional manufacturing into Additive Manufacturing. A requisite is to offer highest subtractive parts. quality powder for production at competitive cost and in sufficient volumes.” A subsidiary of the Swedish firm Arcam AB, a GE Addi- tive company, AP&C has invested a total of $31 million CAD in this highly-automated plant, aided by financial SCIENCE! contributions from Canada Economic Development, Montréal International, Investissement Quebec and the NO FICTION Quebec Ministry of Economy, Science and Innovation. “Our new facility represents a new and inspiring phase for Arcam and GE Additive and a major step for AP&C at a We are expanding our portfolio to include SEE WHAT’S NEW time when we strive to respond to the growing demand for powder for additive manufacturing Additive Manufacturing”, stated Alain Dupont, President with the brand BÖHLER AMPO: of AP&C. “We are very pleased that the factory was High quality powder and printing know how delivered on time and on budget, thanks to the dedicated from the material expert. efforts of our team who led the development project. We are also especially thankful to our investors and partners without whom this accomplishment could not have been possible.” DIN 2.4668 (capable to meet the chemistry of API and AMS) www.arcam.com | www.advancedpowders.com

DIN 1.4542 / 17-4PH (capable to meet chemistry of AMS)

DIN 1.2709 / MS1 / ~ Marage 300

www.autodesk.com/make

BÖHLER Edelstahl GmbH & Co KG, Mariazeller Straße 25, A-8605 Kapfenberg Phone +43-3862-200, Fax +43-3862-207576 E-Mail: [email protected], www.bohler-edelstahl.com formnext | Hall 3.0, Stand F70 AP&C’s new facility will produce titanium powder November 14-17 | Frankfurt, Germany (Courtesy GE)

Voestalpine expands its metal AM expanding capacity at its subsidiaries Renishaw reports record 2017 Böhler Edelstahl GmbH & Co KG, activities to Asia and North America Austria, and Uddeholms AB, Sweden. Renishaw plc, Gloucestershire, Adjusted operating profit for the Following the installation of UK, has announced its preliminary metrology division was £115.9 million Voestalpine AG, Linz, Austria, has “In line with our global service state-of-the-art atomisation lines results for the year ended June 30, (previous year: £90 million). During expanded its metal Additive Manufac- strategy, we are successively estab- for powder production at the two 2017. According to the report, the this period, the company launched its turing activities into Asia and North lishing metal Additive Manufacturing sites in 2016, a total of €20 million company achieved a record revenue RenAM 500M Additive Manufacturing America. The company has reportedly services close to our customers. The is currently being invested in similar of £536.8 million, with an underlying system and opened two new AM invested a total of €50 million into the focus is on applying different Additive systems. Voestalpine reported that it growth of 14%. solutions centres in Germany and the Opening of new AM experience centre opening of a new metal AM research Manufacturing processes to best is currently developing new high- The company saw a 25% increase USA. in Germany (Courtesy Renishaw) centre in Singapore, the construction meet their individual requirements,” strength, corrosion resistant powder in adjusted profits to £109.1 Renishaw’s healthcare segment of a new AM technology institute in stated Franz Rotter, Member of the types for increasingly sophisticated million before tax, compared to saw an overall revenue of £33.4 Renishaw reported that it will Taiwan and a production plant in Voestalpine AG Management Board applications. £87.5 million in the previous year. million, up 18% from £28.4 million continue to invest for the long term Canada. and Head of the High Performance “Voestalpine, with its comprehen- Capital expenditure was £42.6 in 2016. Investment into research and is expanding its global marketing This expansion follows the Metals Division. sive knowledge in manufacturing million, of which £24.2 million and development continued, with and distribution infrastructure, successful launch of the group’s Voestalpine’s Taiwan-based metal powder and in the design, was spent on property and £18.4 total engineering costs reaching £9.2 along with increasing manufacturing Additive Manufacturing Centre in Technology Institute Asia, set to open development and production of million on plant and equipment. million compared to £7.9 million in capacity and research and develop- Düsseldorf, Germany, in September in August 2017, will be the group’s ready-to-install components, is a Renishaw’s metrology business, 2016. The company’s medical dental ment activities. During the past year, 2016. While the Düsseldorf third research centre for metal AM. global pioneer in 3D printing,” stated incorporating the company’s product line experienced good growth the company completed construction team specialises in the Additive Meanwhile, construction is underway Wolfgang Eder, Voestalpine CEO. “We Additive Manufacturing product line, with a continued focus on the sale of on its new US headquarters in Manufacturing of small, lightweight, on the group’s first NAFTA-based want to consistently push ahead with reported revenues of £503.4 million, Additive Manufacturing technologies Chicago, USA, as well as its new finely-structured parts and tools, production plant for high-tech Additive our activities in this area by setting compared to £398.9 million in the and equipment into the healthcare facilities in Detroit, USA, and Voestalpine’s Additive Manufacturing Manufacturing in Toronto, Canada. To up new research and development previous year. Growth continued market. However, despite good expanded and refurbished its facilities Centre Singapore is focused on the keep up with the increasing demand centres in non-European growth in all sectors, with the Far East growth, the business reported an in Spain, Sweden, Hungary, Germany manufacture and repair of objects for high-quality metal powders for markets.” achieving the highest level of sales adjusted operating loss of £7.2 million and France. weighing up to 600 kg. AM, Voestalpine is also investing and www.voestalpine.com at £237.9 million, up 28%. and has yet to move into profit. www.renishaw.com

www.kymerainternational.com Can you make ‚‚ Well, we already have. metal 3D printing aﬀ ordable for all

Global Leaders in Aluminium ? creator.orlaser.com and Copper powders

H.C. Starck announces new metal powder programme for AM

H.C. Starck Surface Technology and For optimal results, H.C. Starck Ceramic Powders GmbH, Laufenburg reports that its gas atomised metal and Goslar, Germany, is introducing Additive Manufacturing powders a new range of gas atomised metal are fully dense, have an excellent powders. Titled AMPERPRINT®, flowability, a spherical shape and the new range will be designed high reproducibility. They will be specifically for metal Additive available in a wide range of particle Manufacturing. size distributions covering the full The AMPERPRINT range of range of AM processes, including but powders will include nickel, cobalt not limited to Selective Laser Melting AMPERPRINT powders from H.C. and iron based powders of all major (SLM), Electron Beam Melting (EBM) Starck (Courtesy H.C. Starck) standard compositions, as well as and Laser Metal Deposition (LMD). customised solutions. According to Shashi Shukla, CEO of H.C. Starck ously growing AM market. To fulfil H.C. Starck, its high-end technology Surface Technology and Ceramic customer requirements, H.C. Starck concept will enable production to be Powders GmbH, stated that the intro- has also launched a new website ramped up efficiently while keeping duction of the AMPERPRINT concept dedicated to AM. physical and chemical powder is a further milestone to strengthen www.hcstarck.com properties consistent. H.C. Starck’s position in the continu- www.amperprint.com

The site in Melbourne will house Titomic aims to commercialise rapid a TKF system with a 40.5 m3 build titanium AM process area, reportedly making it the largest Additive Manufacturing machine in Titomic Ltd, Melbourne, Australia, been used as a coating technology the world. “The facility we are building is commercialising a process for the but we are turning it into an Additive at the moment will have a metal 3D Additive Manufacturing of large scale Manufacturing process, so instead printer that’s 9 m x 3 m x 1.5 m, so titanium parts which it claims will be of just coating a surface we actually we are talking about Additive Manu- Transform your business thirty times faster than other metal build a part.” facturing on a scale that no one can Additive Manufacturing processes. A new facility is scheduled to comprehend at this stage,” concluded The new technology, which it calls open in December 2017, with trials Lang. with industrial 3D printing Titomic Kinetic Fusion (TKF), was beginning in the first quarter of 2018. www.titomic.com jointly developed by the Common- wealth Scientific and Industrial Digitization is rapidly impacting the manufacturing world. Research Organisation (CSIRO) and Force Industries. Make the decisive step towards an advanced and agile production The TKF process applies titanium with industrial 3D printing – including connected part and and titanium alloy powders onto a scaffold surface to rapidly produce data flow. EOS provides a comprehensive solution and service titanium or titanium/composite portfolio, and is your trusted partner for implementing 3D printing products and parts. Due to the nature of the process, powder particles do into the production environment. not need to be of a uniform micron size, as is required in alternative AM techniques. Titomic states that the Visit us at cost of this powder is approximately formnext, Frankfurt / Germany a fifth to a tenth of the cost of traditional AM powders, resulting in 14. – 17. November 2017 components up to 50% cheaper. The TKF process applies titanium and titanium alloy powders onto a scaffold Hall. 3.1 / Booth: G 50 Jeffrey Lang, Titomic’s CEO and surface to rapidly produce titanium or titanium/composite products and parts CTO, told The Australian, “This has (Courtesy Titomic) www.eos.info

A primary application for 20MnCr5 GKN adds innovative new metal powder will be in aftermarket sales for the for high strength AM applications automotive industry. The material is highly suitable for the manufacture GKN plc has introduced a new case been successfully reduced through of spare parts on-demand. GKN hardening steel powder optimised for process parameter optimisation. will also offer hybrid production, metal Additive Manufacturing applica- The case hardening process used on combining AM with different tions. According to the company, 20MnCr5 was also developed with a manufacturing techniques to achieve the new 20MnCr5 powder offers focus on standard requirements for optimum results. A key advantage of high strength and ductility as well surface hardness and case-depth 20MnCr5 is its ability to be combined as excellent wear resistance. GKN profile. with all weldable materials, making hopes that the material will enable it Thanks to its increased core it possible to offer spare parts in low to explore new markets, especially for strength and wear resistance, GKN volumes at reduced costs. spare parts in the automotive sector. believes that the availability of “New materials developed by Extensive testing and develop- 20MnCr5 for Additive Manufacturing GKN are challenging established ment has been carried out to will benefit a range of components, paradigms about material optimise AM process parameters for including gears, camshafts, universal performance and robustness. Our maximum density and productivity joints and link applications. Following cutting-edge materials and innova- and minimum surface roughness. completion of the first small batch tive manufacturing processes enable Supported by microstructural analysis of one hundred gear wheels for us to offer our customers around the Powering the sky and mechanical testing, GKN’s a leading gear box supplier, the world valuable, effective solutions researchers state that they have company reports that it has received to extreme product challenges,” We are your innovative partner from prototyping achieved a density of 99.9% in finished a number of enquiries regarding the explained Guido Degen SVP Busi- parts made from 20MnCr5. While high material’s AM capabilities and now ness Development & Advanced to large scale production residual stress can be a challenge, has several collaborative projects in Technology. the company states that this too has development. www.gkn.com

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Tekna and WeAre Group ExOne reports growth in AM collaborate to produce metal machine sales and expands powders for AM in France material options Tekna Plasma Systems, Canada, and WeAre Group, The ExOne Company, North Huntingdon, Pennsylvania, AddUp FlexCare System France, have announced plans to begin manu- USA, has released its financial results for the first half facturing high-quality metal powders for Additive ended June 30, 2017. The period has seen Additive Manufacturing applications in the aeronautics and Manufacturing machine sales 22% higher than the first Protection for tomorrow. space industries. Powder production will begin within half of 2016, with revenue of $8.5 million, up from $7 Today. the existing industrial facilities of Tekna Plasma Europe, million in the same period of 2016. Total first half sales Tekna’s French subsidiary. were reported at $21.7 million, an increase of 7% on the WeAre Group, formed by French companies Chatal, $20.2 million in the first half of 2016. E.S.P.A.C.E., Comefor, Bouy, Ferella and Prismadd, stated ExOne’s gross profit for the first half 2017 was that the agreement will enable its companies to secure reported at $3.6 million, down 33% from the $5.4 million a powder supply for their metal AM activities. Tekna reported for the first half 2016. R&D expense was $4.3 manufactures turnkey plasma systems used to produce million in the first half 2017 compared with $3.8 million a range of metal powders. In addition to the plasma in the first half 2016, with the increase primarily occur- systems, the company also produces metal powders ring in the second quarter. Adjusted EBITDA was an $8.6 including Ti64, tungsten carbide powder, tantalum powder million loss in the first half of 2017, compared with a $5.0 and molybdenum powder. Tekna stated that it hopes to million loss in last year’s first half. leverage the partnership with WeAre Group to consolidate Following these results, ExOne revised its 2017 its position in the aerospace and space markets. revenue outlook. “We are revising our 2017 revenue www.tekna.com outlook modestly, to a range of 20% to 25% growth. www.weare-aerospace.com Our guidance is based on our backlog and anticipated growth in the second half, particularly in the fourth quarter,” stated Jim McCarley, ExOne CEO. “In the third quarter, we expect the Exerial™ beta machine sales will unfavourably impact earnings and we will continue to make investments in organisational and R&D activities. However, we remain convinced that these costs will prove to be good investments and we remain on track to reach positive Adjusted EBITDA by the end of the year. Additionally, we expect a total cash balance in excess of $20 million at year end.”

ExOne adds 17-4PH material for binder jet AM ExOne also announced that it has made available 17-4PH stainless steel (SAE Type 630 / UNS S17400) for metal Additive Manufacturing at its North Huntingdon production service centre. 17-4PH is a chromium-nickel- copper precipitation hardening stainless steel used for applications requiring high strength and a moderate level Flexible, modular and mobile, this compact “Plug & Play” cell system with of corrosion resistance. controlled atmosphere provides must-have protection for your additive The properties offered by 17-4PH are desirable for manufacturing plant and all of your operators. a wide range of applications in a variety of industries, including aerospace, automotive, defence and medical equipment. Manufacturers who supply components in 17-4PH will now have the opportunity to benefit from Exclusively available the advantages of AM using ExOne’s binder jetting technology. at The new addition will complement the other o n 2 0 1 7 AM-capable stainless steel alloys currently available at t i Frankfurt, Germany, 14-17 November 2017

the production service centre, which include bronze- www.addupsolutions.com u n i c a [email protected]

infiltrated 420 stainless steel, bronze-infiltrated 316 o m AddUp - 5 Rue Bleue p C stainless steel and 316 stainless steel highly sintered. Zone Industrielle de Ladoux d U www.exone.com A

63118 Cébazat - France © +33 (0)473 152 500

deposition, the laser generates a weld Airbus and Arconic install first Trumpf adds Fraunhofer’s extreme pool on the surface of a component metal AM part on series production high-speed laser deposition welding and fuses the metal powder, coaxially added simultaneously, to create the commercial aircraft process required shape. The powder then fuses with the surface, gradually Airbus and Arconic Inc. have installed tion aircraft. While metal additively Trumpf, headquartered in Ditzingen, turers can also integrate the EHLA forming a protective coating. a metal additively manufactured manufactured cabin brackets and Germany, reports that it plans method into their existing systems. By contrast, in the EHLA method, titanium bracket on a series produc- bleed pipes are already flying on to incorporate the new Extreme “For EHLA, we can draw on similar the laser strikes the powdery filler tion aircraft. The bracket, which is Airbus’s A320neo and A350 XWB High-Speed Laser Deposition techniques to those we’ve been material above the weld pool, heating being produced at Arconic’s Additive test aircraft, this reportedly marks Welding (EHLA) method, developed using for Laser Deposition Welding,” the material nearly to its melting Manufacturing facility in Austin, Texas, the first installation of a titanium by Fraunhofer Institute for Laser explained Antonio Candel-Ruiz, an point while it is still on its way to USA, is installed on the Airbus A350 additively manufactured bracket The bracket is produced at Arconic’s Technology (ILT), into a number of expert in laser surface methods at the component. Consequently, the XWB, the company’s newest widebody on a commercial aircraft for series AM facility in Austin, Texas its Additive Manufacturing systems. Trumpf in Ditzingen. “The Fraunhofer particles melt faster in the weld pool. commercial aircraft. While aeroplane production. According to the company, EHLA is Institute for Laser Technology This makes it possible to use energy makers have been using Additive Jeremy Halford, President of significantly faster than conventional developed and patented EHLA with much more efficiently. Manufacturing for some time, until Arconic Titanium and Engineered This AM titanium bracket is the Laser Deposition Welding. the primary aim of executing coating Whereas normal laser deposition recently this has primarily been for Products, commented, “Arconic latest product of Airbus and Arconic’s Depending on component processes very quickly with low welding can coat only 10-40 cm2 per components inside the cabin. Equip- is proud to partner with Airbus to ongoing partnership, which was size, Trumpf stated that it has layer thicknesses for rotationally minute, the EHLA method achieves ping airframes with metal AM parts is advance aerospace Additive Manufac- founded in December 2016 with various laser machines which symmetric components.” rates of over 250 cm2 per minute. In a newer field. turing. Our comprehensive capabili- the signing of three agreements are candidates for EHLA. The “For large-area coating tasks, addition, much thinner coatings with In addition, the bracket’s installa- ties, from materials science leader- for Arconic to produce titanium and company’s TruLaser Cell 3000 is lasers have until now lacked the layer thicknesses of 10-300 µm are tion on a series production commer- ship to qualification expertise, helped nickel additively manufactured parts suitable for small and medium-sized necessary speed,” stated Candel- now possible. What is more, EHLA cial aeroplane, as opposed to a test make this achievement possible. We for commercial aircraft, including the components, while the machines in Ruiz. In addition, the minimum layer permits a much finer laser focus, aeroplane, marks a significant step look forward to continuing to advance A320 platform and A350 XWB. the TruLaser Cell 7000 Series are thickness achievable using conven- rendering the process considerably forward in the qualification of more the art of the possible in additive for www.arconic.com suitable for large ones. Apart from tional Laser Deposition Welding is more energy-efficient. complex metal AM parts for produc- aerospace.” www.airbus.com these turnkey systems, manufac- around 500 µm. In conventional laser www.trumpf.com

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GE Additive seeks to certify Carpenter Technology new AM production partners reports financial results

GE Additive has announced that it is actively selecting Carpenter Technology Corporation, Pennsylvania, USA, Come build with us companies to become certified additive production centres has announced its financial results for the fourth quarter It’s time to rethink what’s possible in AM for its customers. The company has stated that it is and fiscal year ended June 30, 2017. Net sales for the working to certify several companies by the end of 2017, fourth quarter 2017 were reported at $507.7 million, said creating a network of additive production capabilities to be the highest achieved in two years. Fiscal year 2017 across many industries and regions. The announcement net sales were $1,797.6 million, down from $1,813.4 follows a similar agreement in June 2017, where a MoU million in 2016. was signed with Oerlikon, Switzerland, making Oerlikon a Carpenter’s Performance Engineered Product division, GE Additive preferred (non-exclusive) manufacturer. the segment of the company that includes the Dynamet “We are not currently in the business of making additive titanium business and the Carpenter Powder Products parts for other companies,” stated Mohammad Ehteshami, business, achieved net sales in fiscal 2017 of $366.6 Vice President and General Manager for GE Additive. “We million, up from $358.7 million in 2016. Operating income want to accelerate Additive Manufacturing by providing for this division was $8.5 million, compared to a $5.5 machines, materials and engineering consultancy services million loss in the previous year. to them. However, we do recognise that there is a huge “Overall, fiscal year 2017 was a successful one as we demand for additive parts, so we feel that setting up these continued to build upon our foundation for long-term certified production centres will allow us to meet the sustainable growth through our progress in becoming growing demand for additive components.” a complete solutions provider, as well as our expansion Each certified production partner will operate additive in core growth areas including titanium powder and machines from Concept Laser and Arcam, use material Additive Manufacturing,” stated Tony Thene, Carpenter’s from AP&C and benefit from orthopaedic best practices President and CEO. developed at DTI. The centres will be held to the highest www.cartech.com quality standards and will receive guidance and advice from GE’s additive design and manufacturing experts – enabling them to deliver world-class additive parts and service, the company stated. www.geadditive.com

Toolcraft selects Simufact to simulate metal AM process

Toolcraft, Hamburg, Germany, has selected Simufact, Georgensgmünd, Germany, to provide metal Additive Manufacturing process simulation software with the aim of optimising its manufacturing techniques. AM processes will now be simulated prior to beginning the build process in order to move from trial-and-error to a more predictive production process. Additive Manufacturing “We have tested Simufact Additive extensively and saw that the solution is going to help us in our daily practice,” stated Christoph Hauck, Managing Director of Toolcraft. “Our clients expect us to examine the feasibility of 3D At Oerlikon, our advantage is clear: we’re integrating and scaling the entire additive printing orders in the early project phase – the simulation manufacturing (AM) value chain to handle your project from point A to Z. of the manufacturing process is the key to this.” We offer comprehensive AM solutions including: Simufact Additive calculates distortions and residual stresses within components, shows the risk of aborted ▪ Metal Powders build jobs and enables users to minimise the number of physical attempts required to achieve a successful build. ▪ Rapid Prototyping The software also covers post-processing simulations Series Production ▪ including heat treatment, support removal and Hot Isostatic Pressing. So far, the technology has been used Ultimately, if you can imagine it, we can build it. primarily in the aerospace and automotive sectors. www.simufact.com | www.toolcraft.de www.oerlikon.com/am

for Additive Manufacturing. It gives New plasma atomisation process for the company significant control over MIM cut powders from PyroGenesis powder sizes produced and offers higher powder production rates at PyroGenesis Additive, a division of considered an undesirable by-product lower cost. “MIM cut powders can PyroGenesis Canada Inc., Montreal, of the company’s standard plasma now be produced in very large quanti- Canada, reports that it has developed atomisation process, which produces ties with little-to-no waste,” he stated, a new plasma-based process to powders in the 15-106 µm range. “thereby growing with and enabling produce metal powders which will Peter Pascali, President and CEO of those requiring ultra-fine powder and enable MIM cut powder production PyroGenesis, stated, “Several months meeting their strategic growth needs. at higher volumes. According to the ago, the company was approached We believe this breakthrough is, if company, the new process may have a by a number of companies who were not more significant, then at least greater impact on the powder produc- interested in MIM cut titanium powder, as significant as our original plasma tion market than its original plasma whereby it became apparent to us atomisation technology,” he added. atomisation technology, developed that the appetite for this ultra-fine “We believe we have not even scraped in 2001. The company stated that powder was significant. As a result, the surface of what this new process whilst ‘MIM cut’ is a particularly small we decided to make adjustments to can do with regard to production rates metal powder size, traditionally used our plasma atomisation technology in and powder quality.” for Metal Injection Moulding (MIM), order to try and shift the particle size Pascali added that PyroGenesis and usually features particle sizes distribution towards the low end of the Additive now produces MIM cut between 5-20 µm, it has in recent spectrum and produce powders in the titanium powder Grade 5, the grade years become increasingly used in range required.” currently requested for use in Binder binder jet AM systems. According to Pascali, the new Jet AM. The new process also has the PyroGenesis has previously plasma atomisation process has the potential to produce MIM cut titanium produced powders for Electron Beam ability to produce extremely narrow powder at Grade 23, the highest grade Melting and Laser Sintering, while size distributions which can easily be titanium powder. MIM cut has until recently been shifted to any particle size required www.pyrogenesis.com

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both active and passive cooling – for Volkswagen pick-up fitted example with a channelled airflow with additively manufactured to cool batteries and brake systems. In addition, functions linked to heat front-end structure management, passive safety and fluids storage have been integrated Altair, APWorks, CSI Entwicklung- Organic design for load-bearing in the organic, load-driven design of stechnik, EOS GmbH, Gerg and structures the front-end module (Fig. 1). Heraeus have used the front-end In view of the growing trend towards structure of a classic VW Caddy electrification in the automotive Combined expertise along the pick-up to demonstrate the full sector, heat management as well as process chain potential of industrial Additive the reduction of design space and With these goals in mind, the Manufacturing in the automotive overall weight were crucial factors experts at CSI Entwicklungstechnik industry. when designing the front-end section. began designing, developing and The final structure is very light, Moreover, structural requirements building the front-end structure. stable and at the same time features relating to vehicle safety, performance The company develops high-quality a high degree of functional integra- and comfort needed to be addressed. modules for vehicle bodies, interiors tion. In this joint development project Accordingly, parts of the additively and exteriors for both manufacturers known as 3i-Print, the companies manufactured front are load-bearing and suppliers in the automotive involved covered every step of the structures that include details for sector. development process, from design, simulation, optimisation and manufacturing to post-production of the part. From conceptual design to final vehicle, the project was completed in only nine months.

The value of Additive Manufacturing for the automotive industry Driving innovation and impacting decisive development processes, metal AM will play an integral role in large-scale manufacturing over the next few years. The technology is already being deployed in a wide range of industries and the constant evolution of production and design techniques using AM will make the technology even more cost-effective and efficient in the future. As such, the use of industrial metal AM will continue to grow, particularly in the automotive industry. The true value proposition of Additive Manufacturing in automotive engineering can only be realised with considerations extending far beyond structural mechanics and lightweight construction. This functional integration – implementing as many technical features as possible with as few components as possible, with the resulting added value – is an additional key advantage that makes the use of AM lucrative for the automotive industry. With the Caddy concept, the 3i-Print project aims to demonstrate Fig. 1 The front-end structure of this VW Caddy has been completely rede- future technological possibilities. signed using Additive Manufacturing

Learn more and visit us at Scalmalloy®, developed by APWorks, to manufacture the components. formnext APWorks provided support for the manufacturing process by Hall 3.1 | Booth F 70 developing the ideal parameter sets for the EOS M 400 system. Thanks November 14 - 17, 2017 to the combined use of AM and this Frankfurt, Germany innovative material, the project is said to successfully demonstrate the possibilities of functional integration that traditional manufacturing methods are unable to offer (Fig. 3).

The 3i-PRINT project, a forum for innovative prototype concepts Initiated by CSI Entwicklung- stechnik, the 3i-Print project acts Fig. 2 A number of components prior to removal from the build plate as an agile engineering platform for research and development enabling innovative prototype Gerg is a leading supplier of of the components for AM. APWorks concepts. The idea is based on the innovative solutions in the area of contributed its knowledge of file use of new development tools and prototyping and small-scale series preparation and handled the actual methods, including industrial AM. for the automotive and aerospace Additive Manufacturing of the The project’s goal is to demonstrate industries. In this project Gerg was structural elements (Fig. 2). As a and fully exploit the potential of responsible for connecting the subsidiary of Airbus, the company state-of-the-art manufacturing Picture: csi entwicklungstechnik additively manufactured components is very familiar with state-of-the-art methods. The 3i-Print project is an and the creation of the final frame. manufacturing processes and enables open platform for collaboration that With its focus on the development various industries to implement best quickly enables the implementation and broad application of simula- practice concepts from the aerospace of new ideas. tion technology to synthesise and sector. Stefan Herrmann, responsible optimise designs and processes, When producing the front end, for light weight design within the Altair’s software solutions were used APWorks relied on a system devel- body in white team at CSI, stated, to design, optimise, simulate and oped by EOS, a leading technology “We are proud to present the Caddy develop the structure. supplier of the industrial AM of both with an exemplary new additively After the successful simulation metals and polymers. Metal powder manufactured front-end structure. and design of the concept, APWorks specialist Heraeus supplied and quali- The new structure and the contrast took care of the final dimensioning fied the high-strength aluminium alloy between old and new impressively demonstrates the potential that 3D printing and functional integration offer, particularly for the automotive industry.” Herrmann continued, “I would Individualize. Integrate. Innovate. also like to emphasise the agile, time-efficient route from the initial idea to the fully converted vehicle, The innovative 3i-PRINT project by csi entwicklungstechnik, APWORKS, Altair, EOS, Heraeus and Gerg shows how which was completed within only nine months. Each of the partici- to leverage the potential of additive manufacturing by applying modern design tools and methods to produce pating companies is a leader in its function-integrated, load-bearing structures for the automotive industry. field. The outstanding collaboration and combined expertise has made the 3i-Print project a resounding The design of the well integrated, organic-inspired front end structure was created with HyperWorks. It features success.” elements of aggregates, active and passive thermal management of electric vehicles and fulfills all structural Among other events, the Caddy requirements regarding vehicle safety, structural mechanics, performance and comfort. can be viewed at formnext 2017 in Frankfurt, Germany, November 14-17, 2017. Fig. 3 Detail showing the complexity of the AM structure www.3i-print.com

to the development of continuous ment at CFK GmbH, a leading AM Indutherm focuses research efforts on process chains for the laser-based AM NanoSteel launches new tool steel for service provider whose expertise lightweighting and steel alloys for AM of complex, varied and highly func- metal Additive Manufacturing NanoSteel says was instrumental tional products using innovative steel in developing the die from concept Powder production and classification the project, Indutherm is focused on materials. In its role, Indutherm is NanoSteel, Rhode Island, USA, has from D2 and M2 tool steels. “We tried to finished part. “For us, the most technology company Indutherm, Walz- developing an explosion-proof powder primarily concerned with the develop- announced the launch of its first tool nearly every combination of material important attributes of NanoSteel’s bachtal, Germany, has reported that atomising system for aluminium ment and testing of plant and process steel developed for the laser powder and conventional CNC machining BLDRmetal L-40 are that it is easily is involved in a number of research alloy powders. While the company’s technology for powder atomisation bed fusion Additive Manufacturing process to create our dual-thread implemented and creates crack-free projects relating to lightweighting and existing systems are suitable for a that meets most of the requirements process. BLDRmetal™ L-40 is a die sets, none of which could cut or high hardness components, which innovative steel alloys for laser-based wide range of alloys (based on Cu, Fe, imposed on alloys and their applica- case-hardening steel powder that grind the complicated dual-thread sets it apart from the many other tool metal AM. The lightweighting of parts Co, Ni, Pd, etc), highly reactive metals tions. An additional aim of Indutherm’s provides high hardness and ductility geometry,” stated Mark Doll, steels we have tested,” commented in automotive and aerospace applica- and alloys impose new requirements research is to increase the output of (case hardness >70HRC, 10%+ core President and CEO of Perfect Lock Dr-Ing Christoph Over, CEO of CFK. tions offers significant opportunities; on the design of spraying systems. metal powders suitable for use with elongation) and is said to print easily Bolt America Inc., a manufacturer of Harald Lemke, Vice President and however, according to Indutherm, the According to Indutherm, the key to laser-based AM systems and to avoid on standard commercial equipment. self-loosening resistant dual-thread General Manager of NanoSteel Engi- availability of suitable metal powders developing a new, safer gas atomisa- satellite formation. The research The alloy reportedly provides superior fasteners. “The NanoSteel solution neered Powders, stated, “Launching for laser-based AM can mean that tion plant is to anticipate the behav- includes the melting, atomisation and performance to M300 maraging steel delivers exactly what we are looking BLDRmetal L-40 after successfully components which would benefit from iours of new alloys during atomisation characterisation of alloy variants to and offers an alternative to difficult- for, including excellent surface finish, producing the roll thread dies ensures the technology can’t be manufactured and use these assumptions as the establish process parameters. to-print tool steels such as H13. flexibility, as well as strength and the commercial viability of the new in this way. starting point for the new design. At Having recently joined the According to NanoSteel, BLDRmetal hardness for maximum die life. This is alloy for customers investigating the Laser Additive Production of present, a pilot plant is being put into Transatlantic Cluster for Lightweight L-40 is designed to be used for parts a welcomed technological innovation use of AM. We don’t stop at material High-Strength Aluminium Structures operation at the University of Bremen, project, the company states that it including tools, dies, bearings and to the fastener industry. We have design, but create joint solutions (LHASA ZIM) is a network project Germany, allowing initial validation now hopes to form new transatlantic gears. been pleased with our testing and are with our customers, facilitating the aimed at the development and tests and process development. partnerships, gaining access to the NanoSteel demonstrated the new slated to start production this year,” process from material selection and qualification of new aluminium alloy The StahlVarianz project is world’s largest research institutes for tool steel’s capabilities by printing he concluded. prototyping to fully qualified produc- powders for the metal AM of high- sponsored by the German Ministry of lightweighting technologies. a 20 cm roll thread die set, which it NanoSteel developed this high tion parts.” strength components. In its role in Education and Research and relates www.indutherm.de states outperformed dies machined hardness alloy through rapid develop- www.nanosteelco.com

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28 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 29 See You at Industry News | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | Formnext, Germany November 14-17, 2017 | Hall 3, Booth: G31 TCT Asia, Shanghai, China March 1-3, 2018 | Hall: N5, Booth: A8 Desktop Metal partners with Morris Group for distribution in thirty US states Ti Mo Fe 4d54S1 2 2 3d 4S 3d64S2 Desktop Metal, Massachusetts, USA, has selected Morris 95.94 Group, Inc., Connecticut, USA, as a top tier ‘Diamond 47.87 55.85 Partner’ supplier of metal Additive Manufacturing systems in thirty US states. Desktop Metal’s Studio System™ will be the first AM system Morris Group, Cr AI traditionally a CNC machining supplier, has made 5 2 3d 4S 2 1 Experts in available to its customers. Ni 3d 4P “We are very pleased to represent Desktop Metal and 3d84S2 52.00 26.98 Additive Metal excited to introduce this ground-breaking 3D printing technology to metal cutting manufacturers in our 58.69 Manufactruring distribution area,” stated Brad Morris, President and Nb CEO of Morris Group. “Our organisation brings more Cu 4d44S1 than seventy-five years of manufacturing experience, 3d104S1 92.91 knowledge and customer support to the table.” Co 63.55 The Studio System uses Bound Metal Deposition, a 3d74S2 3D Metal Printing proprietary process, to build near net shape parts. The Studio System features swappable media cartridges and 58.93 • Titanium T64 quick release print heads for seamless material changes, and was designed for use with a variety of materials from Make 3D printing easier! • Inconel 718 steels and copper to superalloys such as Inconel. www.desktopmetal.com • Inconel 625 www.morrisgroupinc.com About AMC Powders • Cobalt Chrome AMC Powders is the major spherical titanium powder producer in the world with industrial quantities and the highest quality standards in its advanced process of EIGA and VIGA. • Aluminum AlSi10Mg AMC Powders has successfully developed high purity NiTi memory alloy powder with high sphericity, excellent flowabili- • 17-4 Stainless Steel Sciaky adds Siemens PLM ty, and very few non-metallic inclusions, which is suitable for 3D printing, both in powder feeding process and powder software laying process, and makes it possible for the 3D printing personalized human intervention medical equipment (such as • Maraging Steel MS1 cardiovascular stent, internal fixation of spine) manufacturing. Sciaky, Inc., Chicago, Illinois, USA, has announced that it will adopt Product Lifecycle Management (PLM) Main Powders software technology from Siemens to support its - Titanium Alloy Powders: CPTi, Ti-6Al-4V Electron Beam Additive Manufacturing (EBAM) system. - Nickel Alloy Powders: Inconel718, Inconel625, HX The adoption of Siemens PLM software is expected to - Aluminum Alloy Powders: AlSi10Mg enable Sciaky to offer its current and future customers a solution that integrates with the same technology used - Iron Alloy Powders: 316L, 1.2709, 17-4PH by companies globally, to enhance product development - Other Customized Metal Powders: NiTi, TiAl, ZrTi, decision making and produce better products. NbW, HEA · · · Among the Siemens software which will now be available to Sciaky’s customers is NX™ software, an inte- Printed Parts grated solution for CAD/CAM/CAE, and NX™ Nastran®, a CAE analysis solver technology. Bob Phillips, VP Marketing at Sciaky, commented, “Sciaky is excited to join Siemens PLM Software’s partner community. The strength of our two organisations working together will deliver significant value to our customers.” Sciaky’s EBAM systems can produce parts ranging from 8 in (203 mm) to 19 ft (5.79 m) in length, at gross deposition rates ranging from 7-20 lbs (3.18-9.07 kg) 810 Flightline Boulevard of metal per hour. The company produces components DeLand, FL 32724 Phone: (386) 626.0001 in titanium, tungsten, tantalum, Inconel, nickel alloys, niobium and stainless steels. FOLLOW US ON SOCIAL MEDIA AT AMC Powders Co., Ltd. www.3dmaterialtech.com www.sciaky.com Contact Us www.amc-powder.com [email protected] +86 10 82950618 ext.6606 30 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 31 | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | Industry News

Thales opens metal Additive DMG MORI launches Manufacturing facility in new metal Additive Morocco Manufacturing machine

French aerospace company Thales has opened a new DMG MORI CO., LTD., Nagoya City, Japan, has begun Additive Manufacturing facility in Casablanca, Morocco. taking orders for its new Lasertec 30 SLM metal Additive The ‘Industrial Competence Centre’ will specialise in Manufacturing machine. The system was developed in metal AM and currently houses two Selective Laser collaboration with Germany’s Realizer GmbH, which Melting (SLM) systems. The company reports that it joined the DMG MORI Group in February this year. will use these machines to produce an initial series of According to DMG MORI, the Lasertec 30 SLM can metal AM parts in aluminium and titanium, widely used achieve highly accurate Additive Manufacturing with a in the aerospace sector. In the medium-term, Thales is build volume of 300 × 300 × 300 mm and a layer thick- planning to acquire ten machines. ness of 20-100 µm, enabling users to manufacture small The opening of the centre forms part of the Kingdom workpieces such as impellers and dental crowns. The of Morocco’s Industrial Acceleration Plan 2014 to machine is said to be especially suitable for the produc- 2020, which supports the development of an innovative tion of high-mix, low-volume parts or complex-shaped ecosystem involving Thales and its local suppliers. workpieces. Spread across an area of 1000m², in the Midparc zone The Lasertec 30 SLM is also DMG MORI’s smallest in Casablanca, the facility is expected to employ around AM system to date. Its small footprint was reportedly twenty engineers and technicians in the future. achieved by incorporating fewer movable axes and Thales has a long-standing partnership with Morocco. simplifying overall machine construction. The new The company opened its local office in Rabat in 2006 and machine employs a cartridge-type powder material is active in Morocco in defence, aerospace, transporta- supply and collection system, which is said to make it tion and security, and has forty-five employees in the possible to achieve powder recycling rates of 95%–98%. country. “With an existing aerospace ecosystem of www.dmgmori.co.jp subcontractors, Morocco has everything needed to become Thales’ global centre of expertise in Additive Manufacturing,” stated Pierre Prigent, Thales Country ProX DMP 320 Director in Morocco. “The use of a secure digital platform provides the industrial Competence Centre with the latest innovations in terms of connected industry and smart plants, and will improve the competitiveness of Metal Printer the solutions offered to our customers.” Moulay Hafid Elalamy, Morocco’s Minister of Industry, Investment, Commercial and Digital Economy, added, “Thales is bringing state-of-the-art technology and a high added value profession to Morocco: it is a genuine source of pride for us to deliver this leap forward to the country’s industrial sector. This new project is proof that the Moroccan economy is achieving a diametric shift in its industrial sector, which is driving the creation of highly specialised jobs in the country.” www.thalesgroup.com Robust, repeatable large volume manufacturing The Ntron SIL-02 Oxygen Analyser with low total cost of ownership is speciﬁcally designed for OEMs to address the need for a low cost SIL2 oxygen analyser for inertisation High throughput, high repeatability metal 3D printer that in Additive Manufacturing. Accurate generates high quality parts from the most challenging alloys. from 1ppm to 25%, it is the perfect addition to your safety critical Integrated software, material and printer solution with expert process control applications. application support.

Thales has opened a new Additive Manufacturing facility EXCELLENCE THROUGH DIVERSITY www.ntron.com Discover the Difference in Casablanca, Morocco (Courtesy Thales Group) www.3dsystems.com 32 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 33

PSI celebrates thirty years in AM components feature in new Ariane 6 gas atomisation technologies Vinci thrust chambers Metals Additive In 2017, Phoenix Scientific Industries Ltd (PSI), Hailsham, The latest generation of the Ariane in the Vinci engine, which the East Sussex, UK, celebrates its thirty year anniversary. space rocket launcher, scheduled to engine’s designers report improve Manufacturing The company is best known for its activities in gas enter service in 2020, will reportedly cost and time efficiency. “These atomisation equipment for the production of metal offer an increased payload carrying two methods have substantial for Aerospace powders and, in particular, close-coupled atomisation for capacity and the flexibility to perform advantages compared to cast or very fine powder manufacture. a wide range of missions with high forged products, as components PSI was founded in 1987 with the goal of developing reliability. Production has now involving complex structures can & Autosport gas atomised metal powders for the then-emerging Hot begun on the rocket’s Vinci engine be produced in large numbers, Isostatic Pressing (HIP) industry. Since then, the company at ArianeGroup (formerly Airbus without the need for mechanical Vinci thrust chambers for the new has continuously developed its technology in response Safran Launchers) in Ottobrunn, reworking,” stated Denis Ariane 6 (Courtesy DLR) Nickel superalloys including: to the evolving application areas for gas atomised metal Germany. The Vinci engine, which Regenbrecht, who is responsible powders, notably in the Metal Injection Moulding industry CM247LC, Inconel 625, is incorporated in the upper stage for the Ariane programme at economic support is withdrawn. and more recently in metal Additive Manufacturing of Ariane 6, will take over thrust the DLR Space Administration, “European launcher systems face Inconel 718, Titanium alloys, processes. capacity once the rocket has escaped Germany. “The elimination of growing levels of competition The company was founded by Bill and Jan Hopkins and Maraging steel, Stainless steels Earth’s gravitational field using its expensive manufacturing stages and in global markets,” continued backed by Lucius Cary of venture capital company Oxford main stage and solid fuel boosters. simplification of the engine structure Regenbrecht, “which will intensify Technology. It has grown from building small research The engine has been designed to be have cut the costs significantly.” the price pressure in future. Ariane 6 machines for universities to supplying multi-million dollar both energy-efficient and reignitable, Cost-efficiency measures such as is a response to this situation, as its production systems for large corporations. Today, the crucial for ensuring optimal propul- these are said to be imperative to the launch costs will be approximately company has installed systems in twenty one countries on sion in space. production of all space equipment, half of what they were with its seven continents. PSI has a history of devoting much of its Both Powder Metallurgy and which must be economically viable European predecessor, Ariane 5.” resources to R&D, believing that innovation is the key to Additive Manufacturing techniques as competition to provide space- www.arianespace.com success in a world of ever faster technology dissemina- are used to manufacture components faring technologies increases and www.dlr.de tion. To date, the company has been involved in research projects internally, single-client and collaboratively, both in the UK and internationally. A sister company to PSI, Metal Powder and Process Ltd (MPP), was recently formed with the purpose of developing and producing novel powder alloys for demanding applications, placing the company in a strong position to 2017 CAPACITY address world demand for new PM applications requiring high purity spherical metal powders. PSI is also involved 10 × EOS 250×250mm in a number of collaborative research projects addressing the need to develop new advanced metal powders and 2 × EOS 400×400mm innovative production processes, as well as building a Advanced Sieving Systems RHEWUM WA knowledge base on how these powders perform in today’s advanced applications. The Autumn 2017 issue of PIM International features High Performance Screening for Metal Additive Powders AS9100 Rev C an in-depth report on PSI’s thirty-year story and recent Efficiently Removes Fines From Raw Material to 10 Microns & Major Approvals move into metal powder production. For more information on the company and its developments, download your free Recycle Bed Material with Higher Efficiency copy of the digital edition here. www.psiltd.co.uk Contact us today to see how we can improve your additive process! (914)-381-7500 | [email protected] HI-SIFTER BY ELCAN THE PREFERRED SYSTEM 20 Marbledale Road +44 (0)1905 732160 Tuckahoe NY 10707 US www.materialssolutions.co.uk OF AM PROFESSIONALS elcanindustries.com PSI’s production-scale Hermiga system (Courtesy PSI Ltd)

Camber Spine Technologies receives FDA clearance for AM implants SLM Solutions

Camber Spine Technologies, Wayne, pore diameter, strut thickness and presents at formnext 2017: Pennsylvania, USA, has announced trabecular pattern. that it has received 510(k) clear- “Camber Spine is very excited to ance from the US Food and Drug be launching our first in a series of Administration (FDA) to market its spinal implants using […] Additive SPIRA™ Open Matrix ALIF device, Manufacturing. This specialised The SPIRA Open Matrix ALIF implant a unique, interbody fusion implant manufacturing technology allows us consisting of spiral support arches to create these truly unique patented interbody devices to our product SLM 800 and Surface by Design™ technology. structures featuring open arched portfolio create a foundation of This clearance marks Camber’s matrices and proprietary surfaces patented implant solutions that will THE HIGHLIGHT tenth line of spinal implant systems designed to enhance fusion and drive the growth of Camber Spine,” to be released in the US market. promote bone growth. In the coming Pontecorvo added. SPIRA was designed specifi- months we will be launching a series The Camber Spine SPIRA Open cally to increase fusion rates and of five SPIRA spinal interbody cages Matrix ALIF is indicated for use SLM 280 2.0 stabilisation and the spiral support for cervical, lateral and posterior in skeletally mature patients with TREMENDOUS PRODUCTIVITY arches decrease subsidence by load lumbar spine. Extremity implants degenerative disc disease at one sharing over the entire endplate, and custom implants for salvage and or two contiguous levels from while also maximising bone graft complex deformity implants are also L2-S1. SPIRA Open Matrix ALIF is capacity. The Surface by Design under development,” stated Daniel intended to be used with additional SLM 125 technology is a deliberately designed Pontecorvo, CEO of Camber Spine. FDA-cleared supplementary fixation roughened surface that facilitates “We believe that the addition of systems. HIGHEST PRECISION bone growth through an optimised SPIRA and ENZA MIS Integrated www.cambermedtech.com MPM/LPM ALSO FOR MULTILASER 10 years of serial 3D printing in the aviation industry A small part with a big part to play

Hofmann – Ihr Möglichmacher (Hofmann – your ADDITIVE DESIGNER make-it-possible company) uses a 3D printer to manufacture the filling connector for the pilot’s oxygen ELIMINATING SUPPORTS supply in the Eurofighter Typhoon – and has been doing this reliably for more than 10 years now. The additive serial production of complex components has been an integral part of the portfolio of Hofmann – Ihr Möglichmacher for many years. Source: B/E Aerospace Systems PSV This resulted in an elaborate production process and The manufactured filling connector made of stainless ultimately provided the impetus for the development steel (1.4404) for the then B/E Aerospace Systems RELIABLE POWDER SUPPLY (now Rockwell Collins) is a very special success story – of the 3D-printed connector by Hofmann – Ihr Möglichmacher. The company is an aviation industry because the part, which seems rather inconspicuous at first glance, has a decisive role to play in pilot safety. partner, which is certified according to ISO 9100 and The connector is part of the oxygen supply system of which has the DIN 2303 Q2 Q4 BK1 manufacturer’s the pilot, who inhales pure oxygen from a gas bottle. In qualification. the cockpit, where almost every cubic centimetre of We have supplied 1,500 additively-manufactured space must be used, the oxygen is piped through the connectors so far – and each one has proved to be component around a critical geometric location. The 100% functional. Your ‘make-it-possible’ company has system goes into action when the acceleration reaches thus shown that serial production in 3D printing is 6g and above, in order to counter the possible effects possible, even in the case of the most complex of a lack of oxygenated blood in the brain. In these components. situations, the component must withstand enormous forces, even an internal pressure of 200 bar in extreme cases. Visit us at booth E70 in hall 3.0 According to the specifications, the component may shatter at pressures of 400 bar and more, but tests have shown that the 3D-printed connector still functioned at 900 bar – a material strength that has never been attained through conventional manufacturing methods. Earlier connectors consisted of five parts that were SLM Solutions Group AG welded together. Source: Eurofighter Roggenhorster Straße 9c | D-23556 Lübeck Fon +49 451 16082-0

36 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 slm-solutions.comVol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 37 usmp revisedpdf ::

Industry News | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | U.S. Metal Powders, Inc. First metal AM spare parts produced VBN Components at Mercedes-Benz Trucks supplies wear AMPAL | POUDRES HERMILLON resistant AM Mercedes-Benz Trucks, Stuttgart, of parts to be input and reproduced Germany, has produced and success- using the same universal platform, materials to water- fully tested its first metal additively making their production cost-efficient powered drilling manufactured spare part. The part, even at low quantities. a thermostat cover, will now enter “Mercedes-Benz Trucks is project service on trucks and Unimog models reasserting its pioneering role among from older series. The manufacture of global commercial vehicle manufac- The EIT RawMaterials consortium, the company’s first successful metal turers,” stated Andreas Deuschle, Berlin, Germany, has financed AM replacement part follows the Head of Marketing & Operations a collaboration between production of a number of polymer AM in Customer Services & Parts at Swedish-based companies VBN components. Mercedes-Benz Trucks. “We ensure Components and LKAB Wassara Mercedes-Benz Trucks began the same functionality, reliability, to use VBN’s unique wear developing its metal Additive Manufac- durability and cost-effectiveness resistant materials for the Additive turing process with the production of with 3D metal parts as we do with Manufacturing of water-powered rarely-ordered aluminium parts. Using conventionally produced parts.” drilling equipment. The aim of the AM, the company was able to achieve This means that even for classic project is to facilitate more rapid parts with almost 100% density, models, high-quality replacement product development for LKAB greater purity than conventional parts could soon be available Wassara. die-cast aluminium parts, very high worldwide. The new thermostat cover, VBN’s range of wear resistant strength and thermal resistance for example, is only used in truck and metal AM materials, titled ® – making the process particularly suit- Unimog models whose production Vibenite , consists of Vibenite 150,

able for small batches of mechanically ceased around fifteen years ago. This a multipurpose material with a and thermally stressed components. part can now be delivered affordably hardness range of approximately With the addition of metal AM to any country on request, in the 55-63 HRC, Vibenite 280, a mate- technology, Mercedes-Benz Trucks’ required numbers and at consistent rial well suited to cutting applica-

ability to quickly meet orders for quality. tions with a hardness range from replacement parts will be greatly The availability of low-volume approximately 63-70 HRC, and enhanced. In the past, the production production processes also has the Vibenite 350, a stainless material of metal replacement parts has been potential to eliminate the need for with high hardness and high dependent on the availability of the high-cost warehousing and high- chromium content. type of tool used in their original volume transport of large batches According to VBN, the Advanced Engineered Aluminum Powders manufacture, making the cost of of ‘back-up’ replacement parts for collaboration with LKAB Wassara obtaining replacement parts for older discontinued models, further reducing has so far produced part of a models prohibitively high, especially part costs and delivery times for both thin walled DTH (Down-the-Hole) Shaping the Future Together in small batches. The use of AM has company and customers. Hammer using metal Additive the potential to allow the geometry www.mercedes-benz.com Manufacturing, with further United tates etal owders, Inc has been a global leader in the production testing necessary to verify the tool’s properties. If necessary, and distribution of metal powders since ogether with our partners and the design will be optimised, subsidiary companies, and OUD IO, we are helping to shape material-wise and geometrically, before further development. the future of the additive manufacturing industry “Our expertise in material properties, combined with the flexibility of 3D Printing, allows Dedicated esearch, eading dge echnology, lobal roduction ustomiation us to easily adjust the production process according to our clients’ luminum alloy powders pecialist distributor of carbonyl iron needs,” stated Martin Nilsson, odular and spherical aluminum powders and stainless steel powders CEO of VBN Components. “We combine the excellence of LKAB luminum based premi powders Wassara with our own know-how to develop new methods within water-powered drilling.” Mercedes-Benz Trucks’ first metal AM spare part (Courtesy Daimler AG) www.vbncomponents.se

VAC-U-MAX introduces Elcan celebrates 25 years compressed-air powered and reports new method for vacuum system metal powder recycling

VAC-U-MAX, located in Belleville, New Jersey, USA, has Elcan Industries, Tuckahoe, New York, USA, is announced the latest addition to its industrial vacuum celebrating 25 years in metal powder classification. cleaning range for combustible dusts. The new MDL15 Since its founding, the company has expanded from High quality Air-Vac features the exclusive VAC-U-MAX Venturi a small warehouse in New Rochelle, New York, to its power unit, reported to offer the lowest compressed-air current Tuckahoe facility, which comprises state of consumption on the market today. the art test labs, toll processing and complete sales The MDL15 features a 68 litre collection drum and, support. Spherical Powder with no electrical components or moving parts, is said The company recently reported that it has developed to be ideal for high volume recovery of fine powders and a new method for recycling powders for AM which combustible dusts. The system features manual blow- uses the company’s Hi-Sifter sieve technology. The back filter cleaning with static-conductive PTFE pre-filter system is aimed at reducing the time it takes to recycle and secondary cartridge filter, and static-conductive powders for Additive Manufacturing. The equipment casters. Dust, debris, and fine powders are collected in is completely stainless steel and is reportedly the off-the-shelf static-conductive polybags, eliminating the only equipment on the market capable of achieving common issue of a ‘mushroom cloud’ that comes with efficiencies of 98+% in a single pass. drum dumping. Elcan offers its recycling equipment for sale as well The MDL15 is equipped with a static-conductive as offering companies the opportunity to send powders compressed-air hose, ATEX-certified vacuum hose and to its Tuckahoe facility for sieving. This could allow complete cleaning tool kit assembly for floors, walls, companies to regain value from powders which are in machinery and overhead cleaning. storage or awaiting lengthy recycling. www.vac-u-max.com www.elcanindustries.com

CalRAM receives Nadcap accreditation for metal AM

CalRAM, California, USA, has been awarded Nadcap accreditation for Additive Manufacturing by the Perfor- mance Review Institute (PRI). According to CalRAM, this is the first-time a company has received dual accredita- COMPLEX tion for Laser Powder Bed Fusion and Electron Beam Powder Bed Fusion. PARTS WANTED As well as possessing Nadcap accreditation, CalRAM Metal Laser Melting at toolcraft is AS9100 certified. Shane Collins, CalRAM’s Director of Our spherical Ti-6Al-4V titanium alloy powder’s properties Additive Manufacturing Programs, commented, “Four months after stating our intent to pursue accreditation, to receive this critical milestone in pursuing AM excellence make it the material of choice for Additive Manufacturing TOOLCRAFT – YOUR PARTNER is a phenomenal feat, particularly noting this has been FOR TOTAL SOLUTIONS completed on the very first attempt.” Sergio Hernandez, Director of Quality Assurance IN METAL LASER MELTING Powder Characteristics Powder size cuts available for the initiative, added, “This accreditation is a critical ++ Proven in high-end markets such as aerospace and Spherical Shape -25/5µm strategic element for CalRAM to reinforce our high motor sports. ++ For even the most complex geometries. standards of excellence in the AM community”. ++ From super alloys of all kinds, including high-strength High flowability -45/15µm Nadcap is a global co-operative accreditation program Scalmalloy®. ++ No tooling, time saving and energy High density -53/20µm for aerospace engineering, defence and related efficient. ++ Now also with multi-laser equipment for industries. Accreditation is industry-managed and enhanced productivity. Extra low oxygen level -105/45µm brings together technical experts from both industry and government to establish requirements for accreditation, More details and brochure: Controlled chemistry -250/90µm www.toolcraft.de/en/metal-laser-melting accredit suppliers and define operational programme requirements. calraminc.com Contact us for more information

Additive Industries DP Technology launches ESPRIT® expands team Additive Suite for process simplification Renishaw Solutions Centres...

DP Technology, Montpellier, The ESPRIT Additive app for France, has launched the ESPRIT® powder bed fusion systems will lowering the barriers to Additive Additive Suite, designed to simplify operate as a versatile printer driver the full Additive Manufacturing to support the full process of Addi- Manufacturing process, from CAD model to final tive Manufacturing, from orienting part. According to DP Technology, the part and creating supports to the suite features programming, optimising the build, slicing and optimisation and simulation for nesting and generating a job file. Dr Mark Beard (Courtesy Additive direct metal deposition, powder “This decade has been character- Industries) bed and subtractive manufacturing. ised by the widespread, mainstream Additive Industries, Eindhoven, the It is expected to be available to use of 5-axis machining processes, UK Netherlands, has announced that Dr customers beginning in mid-2018 but we are about to enter the Stuttgart Mark Beard has joined the rapidly and will reportedly deliver machine- decade of additive: within ten years, expanding Additive Manufacturing optimised job files and complete we anticipate that ten percent of machine maker and software devel- control of the Additive Manufac- machines will have additive capabili- oper. The former Technical Director turing process. ties,” stated Chuck Mathews, Chief Shanghai at 3T RPD, a leading UK provider For hybrid machine tools — CNC Technology Officer and Executive Vice of metal Additive Manufacturing machines with additive capabilities President at DP Technology. services, Beard will head the growing — the ESPRIT Additive app for direct “We are redefining the meaning Pune Process & Application Development metal deposition will offer inte- of ‘full-spectrum’ with the ESPRIT Toronto team at Additive Industries. grated programming and simulation Additive Suite, which provides a new Chicago “With over ten years of experience for multi-tasking, multi-function, workflow and new process for a new in Additive Manufacturing Mark will multi-channel additive and subtrac- class of machines, both additive and play an important role in execution of tive machine tools and integrate hybrid.” with the ESPRIT CAM system. www.espritadditive.com Visit our stand at: our ambition to become a top three Dallas formnext OEM of industrial metal Additive Manufacturing systems,” stated Daan Hall 3.1, stand E68 Kersten, CEO of Additive Industries. “In his position he will contribute 3D Metalforge receives ISO accreditation significantly to the success of the business cases of our customers in for maritime, oil & gas and energy demanding markets like automotive, aerospace, medical implants and high Metal Additive Manufacturing savings. The certification is also a tech equipment parts.” company 3D Metalforge, Singapore, recognition of 3D Metalforge’s ability Beard holds a Master degree in has been awarded ISO 9001:2015 to build stakeholder trust by deliv- Mechanical Engineering and a PhD in certification by DNV GL, a global ering products and services that meet Material Science from the University accredited third party certification customer, statutory and regulatory of Exeter, UK. “I am very happy body focused on the maritime, oil & requirements. about joining such a dynamic and gas and energy industries. Matthew Waterhouse, 3D progressive company. I look forward The accreditation recognises 3D Metalforge CEO, commented, “We Renishaw Solutions Centres - your pathway to innovative AM products to being part of all the future exciting Metalforge for its understanding of understand that quality standards developments they have planned,” the industry’s requirements and its as well as consistent and sustain- Renishaw Solutions Centres provide a secure development environment in which you can build your knowledge and confidence added Beard. consistent and sustainable business able business practices, are top using AM technology. Additive Industries produces the approach. According to DNV GL, priorities for most of our world-class MetalFAB1, reported to be the first the ISO9001 standard emphasises customers. Through our strong Equipped with the latest AM, machining and metrology systems staffed with knowledgeable engineers, a Solutions Centre integrated metal Additive Manufac- risk-based thinking and promotes partnership approach, 3D Metalforge offers you a fast and accessible way to rapidly deploy this exciting technology in your business. turing machine that, in addition to the adoption of a process-oriented hopes that our ISO9001:2015 certifica- Renishaw will support you throughout your investigation and business case development process, helping you to optimise your its core 3D print process, adds heat approach. tion will provide added confidence design, build your confidence in the process, and gain the evidence you need to make investment decisions. treatment, automated build plate With ISO9001 certification, 3D to our customers and stakeholders handling and storage in the industrial Metalforge stated that it will be able as we collaborate to jointly navigate grade production system. The to enhance business sustainability new opportunities and challenges in For more information visit www.renishaw.com/solutionscentres MetalFAB1 uses a powder bed fusion and customer satisfaction, as the the world of metal Additive Manufac- AM process with multiple lasers. associated reduction in errors offers turing.” www.additiveindustries.com benefits in terms of cost and waste www.3dmetalforge.com Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E [email protected] www.renishaw.com 42 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 43

EOS launches stainless steel 17-4PH powder

EOS GmbH has announced the which are reported to be parts of launch of its StainlessSteel 17-4PH the extensive quality management IndustryLine metal powder for use system used at EOS for systems, Additively manufactured prototype in its metal Additive Manufacturing powdered materials and processes. (apart from the internal springs), systems. The material consists of “We were impressed by both the produced with the EOS StainlessSteel an iron-based alloy powder and quantity and quality of the data that 17-4 PH (Source: Exactech) a specially developed process EOS provided for its IndustryLine parameter for manufacturing on the process and material,” stated EOS M 290 metal system. Zachary Bryan, PhD, test developer IndustryLine, EOS provides reliable The StainlessSteel 17-4PH and metallurgist at the US-based and statistically proven data for the IndustryLine powder is said to be customer Exactech. “We have most important material properties a high-strength, easily curable, manufactured various instruments of finished parts,” stated Dr Tobias highly corrosion- and acid-resistant based on EOS StainlessSteel 17-4PH Abeln, Chief Technical Officer at EOS. material, which is therefore ideal for IndustryLine and achieved the “This significantly raises quality manufacturing surgical and ortho- desired material properties. Exactech standards in Additive Manufacturing. paedic instruments. Parts can be is planning to use this material for The customer can use the data 1:1 to additionally processed, micro-blasted the small-scale manufacturing of qualify the technology for large-scale and polished directly after the Additive medical instruments and intends to production and therefore minimise Manufacturing process or after heat do so in collaboration with EOS.” the time required as well as cut treatment. “Planning security and reliability the cost of in-house material and The quality of each batch of the are top priorities for customers who process qualification,” concluded metal powder delivered is guaranteed are engaged in serial manufacturing. Abeln. by quality assurance processes, For its StainlessSteel 17-4PH www.eos.info

Visit us at formnext: hall 3.0 - E50 We build atomizing equipment for close-coupled and free fall gas atomization of Titanium • Inconel • Tool Steel •Aluminum and more

Toll material processing Industrial Additive Technologies Powder • Castings • Refining of reactive and refractory metals using cold crucible, TRUMPF offers both key technologies for metal additive manufacturing: Laser ceramic and graphite furnaces Metal Fusion (LMF) and Laser Metal Deposition (LMD). Both processes meet the characteristics and quality required in various applications. Industrial solutions for the entire process by TRUMPF, based on the following keys to success: robust machines, intelligent digitalization and clever services. Arcast Inc. www.arcastinc.com www.trumpf.com/s/additivemanufacturing [email protected]

Italian project to focus on Chinese surgeons use industrial integration of titanium AM to replace metal AM cervical vertebrae

A new project is being established in the Lombardy Surgeons at a hospital region of Italy to focus on the integration of metal Additive in Shanghai, China, have Manufacturing technology within industry. The Metal completed what is claimed to Additive for Lombardy (MADE4LO) project will consider the be the world’s first cervical entire value chain, from equipment supply to the finished vertebrae replacement operation product, creating a new model for an AM factory. with additively manufactured The project will last thirty months and has received a titanium bones, reports the total investment of €6.6 million. There are eleven partners People’s Daily Online. in the project, including two universities (Politecnico di The 28-year-old patient was (Photo: Thepaper.cn) ONLY PLAY WITH THE BEST Milano and Università di Pavia), three large industrial diagnosed with chondrosar- companies (Tenova, BLM, and GF Machining Solutions) and coma, a rare type of bone cancer six SMEs (TTM Laser, 3D-NT, GFM, Fubri, Co. Stamp, and that attacks cartilage. A tumour was found on her neck, Officine Meccaniche G. Lafranconi). encroaching on six of the seven bones of the cervical A pilot line is to be established at the Politecnico di vertebra. Doctors at Shanghai Changzheng Hospital PYROGENESIS ADDITIVE Milano with three demonstrator AM systems for different decided to remove all six bones and replace them with classes of applications. A heat treatment furnace will be additively manufactured alternatives. installed at Tenova’s Pomini factory. Integrated systems, The team, led by specialist spinal surgeon Xiao Jianru, demonstrating additive and subtractive finishing, will be chose titanium alloy and used AM technology to produce PLASMA ATOMIZED provided by GF and a metal powder atomiser will be at CSM patient specific customised bone replacements. in Castel Romano. The project will create a network of R&D http://en.people.cn METAL POWDERS accessible to SMEs in the region. www.regione.lombardia.it

EU-funded project launched for development of Al alloy SPHERICAL for structural aircraft parts Longer lifetime with tools or wear parts in Vibenite®. An EU-funded project, AlForAMA, is underway to develop PURE an aluminium alloy for aircraft structural parts manufactured using metal Additive Manufacturing technology. rness The main goal of the project is to develop an innovative DENSE high strength aluminium alloy suitable for laser powder bed systems, with improved weldability and increased mechanical and corrosion resistance in comparison to the HIGH FLOWABILITY cast grades of Al alloys currently employed. According to the project brief, the alloy’s development will focus primarily on tailoring its chemical composition to improve the processability and/or mechanical responses of well-established commercial aluminium

alloys, and on defining the processing of the raw powder

material. Raw materials produced in a powder form will

be obtained by an atomisation process or by a mixing procedure of different starting powders. After SLM processing, a suitable heat treatment will be defined for VISIT US AT BIOMEDICAL • ADDITIVE MANUFACTURING ienite ienite ienite the new alloy by considering its specific microstructural tiness AEROSPACE • THERMAL SPRAY characteristics. FORMNEXT METAL INJECTION MOLDING The AlForAMA project is being coordinated by Lortek in Ordizia, Spain with the participation of the Madrid Institute BOOTH 3.0 G33 for Advanced Studies of Materials (IMDEA Materials) and NOVEMBER 14-17, 2017 the University of Leuven (KU Leuven) in Belgium. CONTACT US www.vbncomponents.com Frankfurt am Main www.cordis.europa.eu Germany T. +1 514 937 0002 • F. +1 514 937 5757 [email protected] • PYROGENESIS.COM 46 Metal Additive Manufacturing | Autumn 2017 TSX-V: PYR •© OTCQB:2017 Inovar Communications PYRNF Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 47

Norsk and Spirit to manufacture Create the unexpected. structural titanium AM components for commercial aerospace industry With outstanding 3D-Printing

Norsk Titanium AS, Norway, and high-quality parts for our customers. Spirit AeroSystems, Kansas, USA, Reducing our material cost and our solutions from BASF. have entered into a commercial environmental impact is a win-win for agreement to additively manufacture Spirit, our customers and the commu- structural titanium components for nities where we do business.” the commercial aerospace industry. Spirit and Norsk have been Norsk Titanium’s proprietary plasma collaborating to develop this arc Rapid Plasma Deposition™ technology for the aerospace industry (RPD™) technology will be used since 2008. The companies stated that Spirit builds thousands of titanium to build parts to near-net shape, they have identified parts which can be parts for customers around the globe with the aim of decreasing waste produced by RPD beginning immedi- and energy consumption and thus ately, thus warranting the extension FAA-approved 3D-printed structural reducing production costs. and solidification of the partnership titanium provider and Spirit is the Spirit currently builds thousands of into a commercial agreement. “As the ideal tier-one aerostructures partner titanium parts for customers around Spirit and Norsk Titanium relationship to leverage this pioneering capability.” the globe and expects that at least approaches its 10th year, we reflect on Spirit AeroSystems is one of the 30% of them could be candidates for the value of this partnership and the largest manufacturers of fabricated the RPD process. Tom Gentile, Spirit’s significant milestones achieved during parts for the aerospace industry. The President and CEO, stated, “We are the transition from R&D to produc- company recently announced plans to pleased to enter into this innovative tion,” commented Warren Boley, expand its fabrication business. commercial agreement with Norsk CEO of Norsk Titanium. “We recently www.norsktitanium.com Titanium to fabricate compliant and announced becoming the world’s first www.spiritaero.com

Specialized in AM @MTI @MTI_ltd Metal Materials @AM-Online

Metal Powders Category Ÿ Cobalt-Chrome Alloys Ÿ Titanium & Titanium Alloys Ÿ Nickel-based Alloys Ÿ Tool Steels & Stainless Steels & Iron Ÿ Aluminum & Magnesium Alloys Ÿ Customized Alloys

Qualified for Processes Ÿ SLM Ÿ EBM Visit us at formnext, booth 3.1-F20 Ÿ DED We offer you engineering solutions and the broadest product Since MTI foundation, we devote portfolio of materials for 3D-Printing in the chemical industry. our enthusiasm to Metal Additive Visit us at: Manufacturing community. Do you want to create the unexpected? Ÿ Tel : +86-(0)20-31040619 Frankfurt, Germany Feel free to contact us: 14 - 17 Nov. 2017 Ÿ Email : [email protected] Booth: 3.0-G24 Ÿ Web : www.mt-innov.com [email protected]

standardised elements dictated by 3D Systems teams with Airbus Defence the limitations of the manufacturing Tamper-proof software for Additive and Space to produce metal AM process, such as rectangular Manufacturing files receives patent satellite RF filter cavities and waveguide cross-sections with perpendicular bends. Using Grow Software Ltd, London, UK, has are combined to create an additive manufacturing processes such as received a US patent for its secure design file containing all of the 3D Systems’ Leuven division, and validation of this part follows a milling and spark eroding, these software for Additive Manufacturing information needed to manufacture Belgium, has partnered with Airbus trend of increasing metal AM use shapes have traditionally been files. According to the company, its the part. This design file is encrypted Defence and Space in Stevenage, UK, in the aerospace industry, with the achieved by machining each RF filter patented software provides a method prior to transfer to the manufacturing A model viewed in Grow’s AM software to deliver what it states is the first technology rapidly making steps from in two halves, which are then bolted for the secure and consistent manu- location. Once received, the build (Courtesy Grow Software Ltd) flightworthy metal additively manu- prototyping to production parts and together. This increases weight, facture of AM designs, in a controlled location is authorised and model factured radio frequency (RF) filter assemblies ready for flight. adds an assembly step to production manner, at a remote location. and build instructions transmitted on manufacturing events and access for a telecommunications satellite. The major goal of this project was time and requires additional quality During the development and directly to the Additive Manufacturing all information necessary to perform According to 3D Systems, the use to increase the performance, produc- assessment. transfer of digital design files for machine being used, without allowing Quality Assurance on their final of metal Additive Manufacturing tion efficiency and customisation In designing the part for AM, distributed Additive Manufacturing, users access to the design file. product. allowed the companies to achieve a capabilities for RF filters on modern 3D Systems and Airbus Defence valuable product data can be According to Grow, this will allow Grow Software Ltd was initially weight reduction of 50% compared to telecommunications satellites, and and Space were able to explore vulnerable to security concerns and products to be manufactured exactly developed at Autodesk subsidiary traditionally manufactured RF filters. to produce a part which would pass complex geometries at no additional accidental alterations. The security to their designers’ requirements Within Labs, and its early distributed Metal RF or waveguide filters have the rigorous testing imposed by manufacturing cost. The new RF filter of product design data is especially and could minimise the need for manufacturing software was been in use since the introduction Airbus Defence and Space. Sending a design features an internal structure important in the aerospace and quality assessment. Using Grow’s integrated with EOS and Arcam. The of space communication systems satellite into geo-stationary orbit can based on a series of depressed defence industries, while medical software, no third party will have the company believes that the impact of nearly fifty years ago. RF filters act as cost as much as $20,000 per kilogram super-ellipsoidal cavities. According devices are particularly sensitive to opportunity to access any product its latest technology on the Additive ‘wave guides’ by allowing frequencies of its weight; therefore, every new to 3D Systems, this unique internal the small parameter adjustments geometries or intervene with the Manufacturing industry will be from selected channels to pass satellite part designed must also be structure enables the part to channel which could be made accidentally original design at any stage. In significant, as corporations begin to through and rejecting frequencies as light as possible. and reject RF currents of different during file loading. addition, users will be able to verify recognise and address the challenges from signals outside those channels. 3D Systems developed the new RF wavelengths with the minimum Using Grow’s software, a 3D model and trace authorisations by tracking of secure distributed manufacturing. High-capacity telecommunication filter for production in its ProX® DMP energy loss possible. and its machine process instructions each build, receive automated reports www.grow.am satellites can sometimes carry as 320, a laser powder bed AM system In some cases, the difference many as 500 RF filters incorporating which it refers to as a Direct Metal in surface topology between metal more than 600 waveguides, many of Printer. As well as achieving a 50% additively manufactured and which are custom-designed to handle weight reduction, the company was traditionally manufactured parts may specific frequencies. able to consolidate the filter from two be a concern. While the microscopic 3D Systems’ metal additively parts into one, improve its function- topology of machined parts usually manufactured RF filter was developed ality by incorporating an internal includes sharp peaks and troughs, with funding from the European Space structure not possible to manufacture the spherical powders used in metal Agency as part of its project on the via traditional means, reduce produc- AM result in a smoother, ‘waved’ ‘Modelling and design of optimised tion time and lower production costs topology, as opposed to steep transi- waveguide components utilising for customised designs. tions. However, after X-ray CT scan- NEW 3D manufacturing techniques.’ RF filters have traditionally ning by Airbus Defence and Space, News of the successful testing been designed using libraries of the metal AM RF filter was reported EN 9100 certification to have a good general surface quality for its purpose, with the advantages of its internal structure outweighing any potential disadvantages posed by its surface topology. During testing to mimic the conditions an RF filter would face during launch and in orbit, including vibra- tion, shock, temperature extremes and vacuum conditions, Airbus Defence and Space reported that all test samples exceeded requirements, with the best performance coming • Nickel & Cobalt base superalloys, steels, other specialty alloys • Selective laser melting, electron beam melting, laser metal deposition from an RF filter which was silver- • Customized particle size plated via an electrolytic process after • VIM gas atomization process manufacturing. Contact The first flight worthy metal AM radio frequency filter for a telecommunications www.3dsystems.com [email protected] satellite, shown with coin for size comparison (inset) (Courtesy 3D Systems) www.airbus.com www.aubert-duval.com - www.erasteel.com

Materialise receives first US clearance for metal AM maxillofacial implants

Materialise, Leuven, Belgium, has said to help achieve better aesthetic received US clearance for its additively results and minimise surgery time manufactured titanium maxillofacial for patients. TRUMATCH has reported implants. The surgical implants will positive results in European and be distributed to the US market by Australian markets since its introduc- DePuy Synthes, Westchester, Penn- tion in 2016. sylvania, USA. TRUMATCH® titanium “As the first of our extensive AM implants enable surgeons to selection of implants to receive The first AM titanium maxillofacial provide patient-personalised solu- clearance for the US markets, the implants to receive clearance for the tions for orthognathic surgery, also decision is a real milestone for our US market (Courtesy Materialise) known as corrective jaw surgery, as medical department,” stated Brigitte well as for facial reconstruction. They de Vet, Vice President of Materialise surgery and allow me to perform are produced using Materialise’s Medical. “Thanks to our partnership procedures more accurately, saving design software, clinical engineering with DePuy Synthes, our devices will time in the OR and improving patient and metal Additive Manufacturing be able to provide better healthcare outcomes.” Visit us at: production facilities and, according to for as many patients as possible.” “Moreover, they offer new treat- Metal Additive Materialise, are the first AM titanium Dr Thomas Schouman, who uses ment possibilities, allowing me to FORMNEXT maxillofacial implants to receive TRUMATCH maxillofacial implants as perform more complex surgeries Manufacturing 2017 clearance for the US market. CMF surgeon at Groupe Hospitalier or multiple procedures in a single Booth 3.1-E30 By enabling the production of Pitié Salpêtrière, France, commented, intervention whereas without the patient-specific virtual surgical “For seven years now I’ve experienced implants several interventions would planning, AM surgical guides and the benefits of 3D printed implants be necessary.” implants, Materialise’s system is first hand – they simplify maxillofacial www.materialise.com

citim is a service provider specialized in Ad- ditive Manufacturing for prototypes and production parts. Materials Furthermore, all services are brought together in one place covering the whole pro- • Aluminium (AlSi7Mg, AlSi10Mg, AlSi9Cu3, duction chain: part design, printing process, AlSi12CuNiMg) CNC machining and post processing. citim • Aluminium - Scalmalloy® has its own development capacities for new materials and parameter optimization. • Cobalt Chrome (CoCr) The service bureau is a leading supplier for • Copper Alloy (CuNi2SiCr) metal AM components with production facili- • Inconel (IN625, IN718) ties in Europe and North America. • Stainless Steel (316L, 17-4, 1.4859) Now get the benefit from our experience and • Titanium (TiAl6V4) our know-how, worldwide and over numerous business segments. • Tool Steel (1.2709)

For more information visit our website www.citim.de/en and www.citim-am.com

citim GmbH citim AM, LLC Steinfeldstrasse 7 1590 N Roberts Rd NW | Suite 113 39179 Barleben | Germany Kennesaw | GA 30144 | USA Phone: +49 (0) 39203-5106-0 Phone: +1 770-575-2899 E-mail: [email protected] E-mail: [email protected]

AM-MODULE NEXT GEN Höganäs appoints Fredrik Emilson as President and CEO following departure of 5-AXIS SOLUTION WE GUIDE LASERS WITH PRECISION VACUUM FURNACES DESIGNED Melker Jernberg FOR HEAT TREATMENT POST

ADDITIVE MANUFACTURING Höganäs AB, Sweden, has appointed Fredrik Emilson as its new President and CEO following an announcement in July that its current CEO, Melker Jernberg, will be leaving STRESS RELIEVING, SOLUTION TREATMENT & the company to join Volvo Group. Emilson joined Höganäs in 2010 and has been responsible for the company’s AGEING of ALLOYS PRONE TO OXIDATION business in Asia since 2012 and prior to that held the Nickel, Titanium, Cobalt-Chrome-Molybdenum, Tungsten same position in Europe. Prior to joining Höganäs he held the positions of CEO at Pergo Europe and CEO at EDIC TOM RON M A U OT E AU L A I A T V I Trelleborg Waterproofing. E C “With Fredrik Emilson, Höganäs will have a CEO with S a broad knowledge of the company’s customer base, products and organisation,” stated Staffan Bohman, Chairman of the Höganäs Board of Directors. “He has a documented ability to deliver healthy growth and good results and is a strong leader.” VACUUM & CONTROLLED ATMOSPHERE TREATMENTS “Fredrik is a highly qualified person to continue the for MATERIALS PRODUCED BY 3D PRINTING implementation of the different initiatives that have been started during the past couple of years, such as ways of working, strategy and organisation, as well as to develop • Specifically tailored to alloys prone to oxidation, the company’s strong offering and customer relations.” It was announced in July 2017 that Jernberg would • Perfect homogeneity thanks to our resistor’s patented be leaving Höganäs to assume the position of President design, at Volvo Construction Equipment as well as becoming a • Clean treatment: molybdenum heating core and metal member of the Volvo Group Executive Board. insulation, www.hoganas.com • Atmosphere control during treatment (optional), • Productivity increased thanks to an accelerated PROCESS CONTROL – FAST & PRECISE neutral gas cooling. ARC Group Worldwide

WITH AM-MODULE NEXT GEN anda t d S rds Contact : +33 4 76 49 65 60 ie n if o rt rm e announces Drew Kelley as e C [email protected] AMS 2750 s For working fields from 250 mm x 250 mm to 500 mm x 500 mm new interim CEO AMS 2769 with 100 % overlap thanks to parallelization for higher productivity On-Axis process monitoring with zoom function ARC Group Worldwide, Inc, Deland, Florida, USA, a key More compact and highly integrated design global provider of Additive Manufacturing solutions through its 3D Material Technologies (3DMT) subsidiary, Direct fiber connection has announced the appointment of Drew M Kelley to Max. laser power 3 kW Interim Chief Executive Officer and Board Member. Kelley replaces Jason T Young, who is leaving his position with the company and the board to pursue other interests. Kelley has served as ARC’s CFO since October 2013. Visit us on FORMNEXT 2017. Prior to joining the company, he was an investment banker and equity research analyst. “I appreciate the Hall 3.0, Stand B88. confidence the Board has placed in me and look forward to working with the entire ARC organisation as we establish and implement initiatives designed to improve operational efficiency, increase financial profitability and create a stronger balance sheet,” Kelley stated.

www.arcgroupworldwide.com - RCS GRENOBLE 478 969 173 N° Siret 000 44 Pictures Credit : Fotolia ECM TECHNOLOGIES WWW.ECM-FURNACES.COM Headquarters: Subsidiary China: Subsidiary USA: www.3dmaterialtech.com RAYLASE GmbH RAYLASE Laser Technology (Shenzhen) Co. RAYLASE Laser Technology Inc. Wessling, Germany Shenzhen, China Newburyport, MA, USA Q +49 8153 88 98-0 Q +86 755 28 24-8533 Q +1 978 255-1672  [email protected] Metal Additive Manufacturing [email protected] | Autumn 2017  [email protected]© 2017 Inovar Communications Ltd Vol. www.raylase.com3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 55 | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | Industry News

Singapore’s A*STAR launches EPMA launches AM Motion A new Industrial Additive collaboration survey Manufacturing Facility GLOBAL The European Powder Metallurgy Association (EPMA) has launched a survey related to the collaboration needs Singapore’s Agency for Science, Technology and of its members as part of the AM-motion H2020 project, LEADER Research (A*STAR) has launched its Tech Access Initia- launched November 2016. tive and new Industrial Additive Manufacturing Facility The overall objective of the AM-Motion CSA is to (IAMF), reports OpenGov Asia Singapore. Both launches contribute to a rapid market uptake of AM technologies IN METAL are part of the Singapore Government’s drive to partner across Europe by connecting and upscaling existing initia- local companies to upgrade their technical capabilities tives and efforts, improving the conditions for large-scale, under the Research, Innovation and Enterprise 2020 cross-regional demonstration and market deployment, AM (RIE 2020) plan, which aims to advance the country’s and by involving a large number of key stakeholders, technological capabilities in the domains of advanced particularly from industry. According to the EPMA, the engineering and manufacturing. survey is aimed at better assessing the needs of the The new facility is aimed at helping SMEs to take industry, with a particular emphasis on collaboration, in advantage of Additive Manufacturing technologies with order to address them through its activities – such as a the support of A*STAR’s equipment, user training and series of ‘Match-Making Sessions’ scheduled for 2018. technical advice. Under the Tech Access Initiative, the In the framework of the AM Motion project, workshops organisation’s Singapore Institute of Manufacturing will also be held with the objective of bringing together Technology (SIMTech) will make available nineteen types key stakeholders to identify barriers to AM business Sintavia is the global leader for Independent of AM equipment including inspection tools, robotised development on both the technological and non- Metal AM for precision industries, including 3D scanners and high-pressure cold sprays. Through technological side, and search for possible and feasible Aerospace & Defense, Oil & Natural Gas, the IAMF, it is hoped that Singapore’s SMEs will be able solutions on selected value chains. Automotive, and Ground Power Generation. to identify opportunities to leverage AM processes to www.epma.com improve their offerings and experiment with possible applications, without the high-cost investment of By leveraging Design for Additive Manufacturing acquiring AM equipment upfront. while offering elite powder analysis, post- The Singapore Government has reportedly identified processing, and mechanical testing on-site, Additive Manufacturing as one of several technologies Sintavia offers unprecedented manufacturing which must be embraced to reinforce the competitive- 90% of your services to these important industries. ness of the country’s manufacturing industry. Under the RIE2020, the government has committed to invest potential is still hidden $ 3.2 billion in R&D and innovation, and to support SMEs in overcoming barriers to advanced manufacturing techniques, between 2016-2020. In a speech given at the launch of the Tech Access Initiative and opening of the IAMF, Dr Koh Poh Koon, Singapore’s Senior Minister of State, Ministry of Trade and National Development, stated, “Our manufacturing sector has successfully gone through major shifts, from High Speed 3D Printing a labour-intensive sector in the 1960s to one that is SLM | Concept | Arcam | EOS innovation-driven and productive today.” Metallurgical Services “Moving forward, technological trends such as Powder Analysis digitalisation, robotics and automation, and Additive Manufacturing are transforming not just shop floor Metrology & Design operations and supply chains, but also business CT Scanning models. Against this backdrop, the Committee on the Mechanical Testing Future Economy has recommended that we continue HIP Services to sustain a globally competitive manufacturing sector as an anchor for our economy. The government is committed to partnering our companies to upgrade their Uncover your AM possibilities now! technological capabilities to ensure that they succeed in Ampower is your independent consulting partner for a successful the new manufacturing paradigm.” implementation of industrial Additive Manufacturing. www.a-star.edu.sg

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New particle size measurement technique uses air permeability for greater precision If it´s thinkable, Micromeritics Instrument older methods. The specific surface Corporation’s Particulate Systems area is then easily converted by the Division, Norcoss, Georgia, USA, has instrument to an equivalent spherical announced a new instrument for particle diameter using geometric Subsieve AutoSizer (Courtesy we make it buildable. the more precise estimation of the and density considerations. Micromeritics Instrument Corp.) average particle size of powders. For over fifty years, the refractory The new instrument uses an air metals, ceramics, lighting, other Leading gases and technologies permeability technique previously phosphors and pharmaceutical and for outgoing powder material for additive manufacturing. popularised by the Fisher Sub-Sieve industries have relied on air perme- specifications. The new instrument Sizer, which is no longer available. ability measurements to estimate the thus offers a fast and easily-obtained The Subsieve AutoSizer (SAS) particle size of their materials. Some estimate of particle size in order to measures the specific surface area of these methods offer very imprecise meet those specifications. of a powder by passing air through a results, leading to a large degree Several international standard packed powder bed and determining of rework and confusion in those test methods have been developed the pressure of the transmitted air industries. Because of its accurate for use with the SAS, including by means of calibrated and traceable and precise measurement of pressure ASTM Standard Test Methods B330 digital pressure transducers (also by means of pressure transducers, for metals. ISO Standard 10070, a used for setting the packing force the SAS reportedly provides much general standard test method for this and input pressure) instead of the greater precision than traditional type of particle size measurement, is water-filled manometer standpipe methods, allowing for appropriate currently being revised for use with (or bubble-rate pressure estimate, in particle size specifications to be set the SAS. the case of input pressure) used in for both process and quality control www.micromeritics.com

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Linde – ideas become solutions. Visit us at formnext 14–17 November 2017 Hall 3.0, booth E.91 Frankfurt, Germany [email protected] AMA113 PMRAdPATHS.indd 1 4/10/15 4:44 PM www.linde-gas.com/am 58 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 59

German researchers receive Simulating Manufacturing funding boost for metal AM heart stents Simufact Additive The Bavarian Research Foundation (Bayerische Forschun- gsstiftung), Germany, has pledged €220,000 toward a research project into the development of heart stents helps you produce using metal Additive Manufacturing. Led by Germany’s OTH Regensburg, University Hospital Regensburg and Metal AM parts FIT Production GmbH, the project is part of ongoing global efforts to combat cardiovascular diseases which, according to the World Health Organisation, are the most t me t frequent cause of death worldwide. A stent is a wire mesh tube which is inserted into a coronary artery to widen it, allowing better blood flow and preventing cardiac failure. The operation is usually carried out when an artery has been narrowed by a build-up of plaque (cholesterol deposits). However, the insertion of a stent into a blood vessel can cause injury by ‘stretching’ the arterial walls. In addition, most traditionally manufactured stents come in a range of ‘off the shelf’ sizes, which may not correctly fit every patient’s needs. When an ill-fitting stent moves in an artery, it may become blocked, requiring surgical intervention to either reopen or bypass. The NewGen-Stent project is developing metal additively manufactured stents with a cylindrical geometric structure which are capable of targeted expansion to allow controlled fit and vessel widening, thereby minimising the risk of cardiovascular injury. www.fit.technology | www.forschungsstiftung.de

O.R. Laser tailors metal AM ptimie and imuate A systems to universities and procee uicy and preciey SMEs Determine and reduce ﬁ nal part distortion Germany’s Industry Federation of Mechanical Engineers Minimize residual stress (VDMA) recently interviewed Uri Resnik, CEO of O.R. Optimize build-up orientation and support structures Lasertechnologie GmbH, Dieburg, Germany. In the Condition the part after heat treatment, base plate/ interview he explained the company’s current target users support structure removal, and Hot Isostatic Pressing (HIP) and applications. Resnik stated that O.R. Laser is currently Recalculate pre-deformed part geometry aiming its AM systems at small to medium-sized businesses (SMEs) and universities, having set itself a price cap of €100,000 per system. “To [SMEs and universities], the prices of today’s powder bed systems pose a high initial hurdle,” he stated. “Three years ago, we decided to close this gap… Pricewise,

our system is tailored to small and medium-sized Meet Simufact businesses and universities.” at Hexagon Stand F27 in This comparatively low pricing was made possible by Hall 3 O.R. Laser having its own laser and software develop- additivemoreinfo ment facilities, he stated. “We develop and realise laser 4. - 7. . 207 simufact.com/additive systems, mechanics and software in-house. This allows us Franfrt am Main flexibility when working with our customers’ demands.” www.or-laser.com | www.vdma.org

Ames team wins award for development of titanium powder manufacturing process OPEN FOR INDUSTRY Iver Anderson, Senior Metallurgist Injection Moulding for aerospace, at the US Department of Energy’s medical and industrial parts. Ames Laboratory, and his team have In addition to Anderson, the award been announced as winners of a 2017 is shared by Andy Heidloff and Joel Excellence in Technology Transfer Reiken, formerly of Ames Laboratory Award from the Federal Laboratory and now of Praxair Surface Tech- Consortium (FLC) Mid-Continent nologies, Inc.; and David Byrd, Ross Region. The FLC recognised the Anderson and Emma White of Ames Global Strategy development of a ‘hot-shot’ pour tube Laboratory. “Our team is very proud Schematic of titanium Close-Coupled that, when adapted into a high- to accept this FLC award,” stated Gas Atomisation set-up utilising the ESTABLISHMENT OF efficiency nozzle, can produce titanium Anderson. “It helps us keep pushing ‘hot shot’ composite pour tube powder by a method that is said to be Ames Laboratory’s processing U.S. OFFICE approximately ten times more efficient science forward to these ultimate Farsoon Americas @ Austin, Texas than traditional powder-making technology transitions involving our that were responsible for this unique Demo + Integration Center methods. people.” titanium atomisation process.” Call today (512) 387-7224 Titanium powder produced using In a letter of support for Ames In congratulating Anderson and his and schedule a visit! the hot-shot pour tube is said to have Laboratory in the FLC competition, team of scientists on the award, Ames enabled a dramatic shift in manufac- Dean Hackett, Vice President of Laboratory Director Adam Schwartz turing away from traditional titanium Praxair Surface Technologies, Inc., said the award demonstrates Ames casting/forging methods to net-shape said, “Ames Laboratory is uniquely Laboratory’s commitment to the forming. This successful manufac- equipped and staffed with talented Department of Energy’s mission turing technique led to the formation researchers who work as a team to of transferring technologies to the of a multi-award winning start-up develop breakthrough technologies in marketplace for the benefit of the company, Iowa Powder Atomization the production of atomised powders. American taxpayer. “We are very proud Technologies, which was purchased in Praxair Surface Technologies has to join Iver and his team in celebrating 2014 by Praxair Surface Technologies. chosen to commercialise the titanium this technological success,” said In 2015, Praxair began international atomisation technology from Ames Schwartz, “And we’ll look forward to sales of spherical titanium powder and also to hire two of the three many anticipated future successes.” for Additive Manufacturing and Metal investigators (Heidloff and Reiken) www.ameslab.gov Farsoon Laser Melting Systems Cummins partners with ORNL on repairs using metal Additive Manufacturing Removable Partial Denture (RPD) Material: CoCrMo Diesel engine maker Cummins, Using the new method of repair, System: FS121M Inc., Columbus, Indiana, USA, is the research team ‘scoops out’ the collaborating with Oak Ridge National worn section and uses a Direct Metal Laboratory, Oak Ridge, Tennessee, Deposition (DMD®) machine by DM3D USA, to develop a method and Technology, Auburn Hills, Michigan, material to repair the cylinder heads USA, to deposit a high-nickel- Cummins diesel engines are used in on heavy-duty engines by Additive containing alloy over the damaged many heavy-duty truck makes globally AMERICAS Manufacturing. area. This material offers a number (Courtesy ORNL) Farsoon Americas Cummins diesel engines are used of properties which help to avoid Add: 21 Cypress BLVD, Suite 1110 Round Rock, Tx 78665 in many heavy-duty truck makes glob- cracking of the repaired cylinder head longer, and turning it into increased Tel: (512) 387-7224 ally. According to the manufacturer, and increase its thermal efficiency efficiency,” explains Nikhil Doiphode, Email: [email protected] the cylinder heads on these engines The goal of the new repair process Parts R&D Engineer at Cummins. typically wear out after a million miles is to save energy at the same time “While these are not brand-new CHINA/ASIA on the road. Ordinarily, these cast as extending the life and increasing engines, we’re striving to make them FS271M FS121M Farsoon Technologies iron parts would have to be replaced the strength of the engine. “We’re better than new.” The FS271M’s dynamic beam focus and adjustable spot The FS121M’s small beam focus enables the Add: No.181 Linyu Road, Changsha National with new castings; a costly process in decreasing the engine’s thermal www.cumminsengines.com size work together to produce parts with improved production of parts with enhanced detail and surface nish while open parameters and intuitive support nish. Combined with a compact build area, High-Tech Industrial Zone, Hunan, China 410205 terms of time, energy and money. conductivity, which holds heat in www.ornl.gov generation software provides the user with unparalleled the FS121M is the best choice for dental, Tel: +86.731.8386.0368 control. jewelry, and exotic alloys. Email: [email protected]

FAME award presented to Retsch introduces new generation Professor Ian Gibson Camsizer X2 for high-res metal powder characterisation Professor Ian Gibson, Deakin Univer- technologies in the world. This was a sity, Geelong, Victoria, Australia, has technology that used a steel/polymer Retsch Technology, Haan, Germany, than 2 minutes, including aspect become the first Australian-based blend to create a ‘green’ part using has released a new dynamic image ratio, roundness and symmetry. This academic to receive an international Selective Laser Sintering. The 3D analysis system for high-resolution makes it possible to quickly and lifetime achievement award recog- printed part was then transferred Professor Ian Gibson (left) received metal particle size and shape reliably evaluate fresh powders, as nising his contribution to Additive to a furnace where the polymer was the international FAME Award analysis. The Camsizer X2 offers well as recycled material which often The new Camsizer X2 (Courtesy Manufacturing. The International burnt away and replaced with bronze users comprehensive particle size contains a certain percentage of Retsch) Freeform and Additive Manufacturing to create a composite metal part that The other project is related to and shape analysis in the lower undesired particles. Excellence (FAME) Award is given could then be used as a tool insert.” Direct Energy Deposition using Deakin micron range and can be used to During the system’s dynamic annually and every year recognises More recently, Gibson’s work on University’s LENS MR-7 machine. He characterise metal powders used image analysis process, a sample particles outside the main size one outstanding researcher in the metal AM at Deakin University has explains, “This process allows us to for Powder Metallurgy, Additive of metal powder is dispersed to be distribution are reliably detected, field. Gibson received the award at the developed in two primary areas. “We control the material and energy flow Manufacturing and Metal Injection analysed in an air jet. Two high-speed even if their percentage of the total Annual International Solid Freeform have generated a lot of traction in to create functionally gradient parts. Moulding. cameras then capture clear and sample is less than 0.01%, making Fabrication Symposium in Austin, research into post-processing of These functional properties can be in As even the smallest quantity of distortion-free shadow projections this technology superior to other Texas, USA. metal powder bed parts,” he stated. terms of mechanical variations, like oversized particles or dust can have of every single particle, enabling the methods such as sieve analysis and Gibson’s research has included a “This is using our SLM process to localised strength and porosity or in a negative impact on the manu- system to carry out an automatic laser diffraction. number of metal-focused projects. create parts that are then studied for terms of blending different metals facturing process, it is important evaluation of more than 300 images Retsch will present its Camsizer Speaking to Metal AM, he explained, machinability, as well as analysing together for even greater variations that the quality control process per second in real time. X2 on Booth #85 at Euro PM2017 “I started working in metals about the requirements for heat treatment. throughout a 3D printed metal part. must ensure that size irregularities The Camsizer X2’s ability to Congress and Exhibition, Milan, Italy, twenty years ago when I was a This is an area that is of great interest This is in its early stages, but the in powder samples are reliably analyse millions of individual October 1-4, 2017, and Booth 3.0-E90 lecturer at Hong Kong University, to industrial users of this technology knowledge gained in this research detected. According to Retsch, the particles in real time ensures a high at formnext, Frankfurt, Germany, where my group had purchased to provide the knowledge to create could be far reaching.” new Camsizer X2 records all relevant degree of statistical certainty and November 14-17, 2017. one of the first Rapidsteel tooling effective end-use parts.” www.deakin.edu.au size and shape parameters in less reproducibility. According to Retsch, www.retsch.com

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西安欧中材料科技有限公司 Call for papers issued for Sino-Euro Materials Technologies of Xi’an Co.,Ltd. AMPM2018

The Metal Powder Industries Federation (MPIF) has Specialized in Powder issued a Call for Papers for its AMPM2018 conference. The event will be co-located with POWDERMET2018, the International Conference on Powder Metallurgy and Particulate Materials, taking place June 17-20, 2018, in San Antonio, Texas, USA. The three-day conference will feature a number of talks from worldwide industry experts presenting the latest technological developments in the field. All abstracts must be submitted to AMPM’s submissions portal by November 3, 2017. The submission of full manuscripts is optional; however, all submitted manuscripts will be considered for the Best AMPM2018 Dreamteam Paper Award. Authors are advised to contact Debby For EaSy and rEliaBlE Production oF mEtal PoWdErS Stab ([email protected]) for further information. www.ampm2018.org

Australia to host First SMT SS-PREP Powder Asia-Pacific International Conference on AM · CP Titanium The 1st Asia-Pacific International Conference on · Ti-6Al-4V Grade 5 & 23 Additive Manufacturing (APICAM 2017) is set to take place in Melbourne, Australia, at RMIT University, · BT20(TA15) December 4-6, 2017. The conference is believed to be the first of its kind to be held in the Asia-Pacific · In718,EP741NP,Hastelloy region and aims to provide an opportunity for industry professionals and thinkers to come together, share · Co-Cr-W,Co-Cr-Mo knowledge and engage in the networking vital to the Au, Ag, Cu, Sn, furthering of the Additive Manufacturing industry. Ni, Fe, Co, Pd... · Specialty steel 17-4PH, AF1410 According to Materials Australia, the conference organisers, the programme will include presentations from some of the leading minds in AM on pressing issues facing the industry and the ways in which these BluE PoWEr atomisation Plants Powder characterization challenges can be navigated. AM for the automotive, biomedical, defence and aerospace industries will be and BluE PoWEr air classifier · Spherical · Satellite-free covered by experts from each respective field. the Blue Power au series atomisation plants for the Blue Power air classifier ac 1000 for the sepa– As well as a number of expert presentations, · Non-hollow · High Flow Rate APICAM 2017 will include workshops designed to help efficient metal powder production, even in small ration of metal powders into fine and coarse attendees sharpen their skills and understanding of batches. For particle sizes from 10-200 µm and powder fractions especially also in the range < 25 µm, AM. In addition, the programme has been designed for a wide spectrum of alloys. where conventional sieving operations fail. to allow for ample networking time, so that important low cleaning efforts with little metal loss and cross contamination. High process stability. www.c-semt.com knowledge-transfer can take place and partnerships can be created that will enrich the industry. Easy and reliable handling. [email protected] The conference is to be chaired by Jian-Feng Nie [email protected] of Monash University, Yvonne Durandet of Swinburne University, Ma Qian of RMIT University and Andrey Tel:+86 29 86261802 Molotnikov, also from Monash University. The conference will also include contributed presentations and posters, and an award will be given for the best student presentation during the conference. www.apicam2017.com Brettener Straße 32 · 75045 Walzbachtal · Germany Phone +49 7203 9218-0 · E-mail: [email protected] 66 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 67 www.blue-power.de 14.-17.11.2017, Frankfurt, Germany A4 CUT A4 SAFE AREA SAFE AREA CUT A4

The organisers of formnext powered by tct 2017 have You … reported a 50% increase in the number of companies set to exhibit at the event compared to the previous year. Taking place November 14-17, 2017, Frankfurt am Main, COMPLEX GEOMETRY want fine particles to be  Germany, this will be the third of formnext’s annual 3D Cooling Channels Additive Manufacturing industry events. Thanks to its Internal Features removed – not only limited? Build Volume: strong international presence, variety of global market HOLLOW leaders and density of innovations from areas along the (D)250mm x (W)250mm x (H)185m want your own powder –  entire additive process chain, it is considered one of the (D)250mm x (W)250mm x (H)300m * VARIABLE DENSITY most important AM events globally. Gas Venting not an ordinary composition? With 393 exhibitors having registered two months Gas Assist (* Option) before the trade fair opens its doors, formnext’s exhibition POROUS floor space has almost doubled – from 15,500 2m in 2016 NANOVAL – Specialist 2 to around 27,000 m this year. Sascha F Wenzler, Vice LAYER MACHINING for Specialty Powders President for formnext at Mesago Messe Frankfurt GmbH, High Aspect Features stated, “With this extremely impressive growth, formnext Reduce EDM Processing underscores its status as the leading international NO EDM conference and exhibition for Additive Manufacturing and the next generation of intelligent production solutions. In PROFILE MACHINING a highly dynamic market, formnext has its finger right on High Accuracy the industry’s pulse and provides the solutions required to Precision Finished Parts meet current and future challenges.” Emphasising formnext’s global presence, the organisers stated that around 49.6% of exhibitors at the TIME SAVING event will be from outside Germany, with the majority of international visitors being from China (14.7%), the USA One Process Manufacture Reduced Lead Times BLEED (10.2%), France and Great Britain (each with 9.6%), Spain BLEED (7.1%), and the Netherlands, Austria, and Russia (each TIME with 6.1%). In addition to equipment, software and material suppliers, the event will include a focus on measurement We … technology and post-processing. formnext 2017 will also showcase some of the most sophisticated technology in various other industry sectors. “We are proud of the fact The LUMEX Avance-25 is the world's first hybrid powder bed fusion machine. The combination of additive technology and Matsuura's 80 years of offer outstanding flowability, no that we have been able to expand into more specialised subtractive high speed milling technology into one seamless process, fines due to air classification! fields along the process chain,” added Wenzler. enables the production of complex, high accuracy moulds and parts.

formnext.com Further adding to Matsuura's expertise in the Hybrid metal AM field, produce the composition this technology is now also available in the large format LUMEX Avance-60 machine. you want, you can include:

Ag, Al, Au, B, Ba, Bi, C, Ce, Co, Cr, Cu, Fe, Ga, Gd, Hf, In, Ir, La, Li, Mg, Mn, Mo, Nb, Nd, Ni, P, Pb, Pd, Pt, Re, Rh, Ru, Sb, Sc, Se, Si, Build Volume: Sm, Sn, Ta, Te, Ti, V, W, Y, (D)600mm x (W)600mm x (H)500m Zn, Zr More information at www.lumex-matsuura.com Nanoval GmbH & Co. KG Phone: +49 30 3 22 90 22-0 Kienhorststrasse 61 – 65 [email protected] D-13403 Berlin www.nanoval.de MATSUURA Europe GmbH MATSUURA Machinery Ltd The organisers have reported a 50% increase in the MATSUURA Machinery GmbH Gee Road Whitwick Business Park number of companies set to exhibit at formnext Berta-Cramer-Ring 21 D-65205 Coalville Leicestershire Weisbaden-Delkenheim GERMANY LE67 4NH ENGLAND Tel: +49 (0) 6122 78 03 - 0 Tel: +44 (0) 1530 511400 Fax: +49 (0) 6122 78 03 -33 Fax: +44 (0) 1530 511440 Email: [email protected] Email: [email protected] 68 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol.Website: 3 No. www.matsuura.de 3 © 2017 Inovar CommunicationsWebsite: Ltd www.matsuura.co.uk Metal Additive Manufacturing | AutumnHall 2017 3.0 - Stand69 F80

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IT IS our MPP Ltd Australian team successfully test-fires ImagInaTIon PM Solutions by Design metal AM rocket engine

A team of designers from that inspires us to turn the Australia’s Amaero Engineering and seemingly impossible into reality. Monash University have designed, manufactured and successfully test-fired a metal additivelyMPP Ltd manufactures manufactured rocket bothengine. largeThe and small lots, MPP Ltd - your Partner in ProjectX engine is built from high- delivering powders in metal powder processing strength nickel based superalloy Hasteloy X on an EOSquantities M280 system as low as 5kg Ÿ Powders tailored to your and has a design thrustthrough of 4 kN to multi-tonnage requirements (1000 lb). orders. Having successfully manufac- The ProjectX engine is built from tured the world’s first AM jet engine, high-strength nickel based superalloy Ÿ Clean, spherical powders Amaero reportedly challenged PhD Hasteloy X on an EOS M280 system Engineering students at Monash to (Courtesy NextAero) Ÿ Flexible - R&D to design an engine which made full production use of the geometric complexity enabled by Additive Manufacturing. efficiency at ground level. As they Ÿ Optimised for AM Graham Bell, Project Lead, stated, climb the flame spreads out reducing “We were able to focus on the thrust. The aerospike design main- features that boost the engine’s tains its efficiency but is very hard performance, including the nozzle to build using traditional technology. geometry and the embedded Using Additive Manufacturing we can cooling network. These are create complex designs, print them, normally balanced against the need test them, tweak them and reprint to consider how on earth someone them in days instead of months.” is going to manufacture such a The PhD students involved in complex piece of equipment. Not so the project have now created a with Additive Manufacturing.” company, NextAero, to take their The resulting rocket engine is a concept to the global aerospace complex multi-chamber aerospike industry. The development of the design. According to Martin Jurg, aerospike rocket was supported by an engineer with Amaero, this Monash University, Amaero Engi- geometry offers some unique neering and Woodside Energy through advantages compared to more the Woodside Innovation Centre at Please contact us to discuss your conventional designs. “Traditional Monash. requirements for customised bell-shaped rockets, as seen on www.amaero.com.au powder development for both the Space Shuttle, work at peak www.monash.edu R&D and large scale production www.metalpowderprocess.co.uk Application of MPP Powders

Ÿ Automotive Ÿ Aerospace Ÿ Energy Storage Ÿ Energy Generation Ÿ Medical To make dreams come true, we trust in our imagination and creativity, which inspire us to seek new solutions and processes. In this way, by committing today to such innovative Metal Powder & Process Limited technologies as additive manufacturing – 3D printing with metals – we are paving the Chaucer Business Park - Dittons Road way to the future. Polegate - East Sussex - BN26 6JF - UK Together, we are taking the future into our own hands. Tel: +44 (0)1323 404 844 [email protected] ProjectX engine during a test fire. The shock-cell structure in the rocket plume www.metalpowderprocess.co.uk is visible (Courtesy NextAero) voestalpine High Performance Metals GmbH www.voestalpine.com/highperformancemetals/en 70 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 71

World’s first class-approved metal AM ship propeller nears completion

Rotterdam Additive Manufacturing as a propeller, it can take weeks or Lab (RAMLAB) in the Netherlands months to order and deliver, costing has produced a full-scale prototype companies millions of dollars in lost of the world’s first class-approved time. It can also be quite costly for metal additively manufactured companies to keep large stockpiles THE WORLD’S LEADING PROVIDER OF HEAT TREATMENT ship’s propeller. The propeller is of parts in warehouses around the being developed by a consortium world. Using faster fabrication options AND SPECIALIST THERMAL PROCESSING SERVICES of companies including Damen such as the metal AM of large ship Shipyards Group, RAMLAB, Promarin, components and finishing the pieces Autodesk and Bureau Veritas. using traditional CNC milling and WAAMpeller prototype during produc- The 1,350 mm diameter, 400 kg grinding methods, replacement parts Optimise material properties of 3D printed metal parts tion (Courtesy Damen) triple-bladed propeller - named could be produced within a matter of with a comprehensive service model: WAAMpeller - is based on a Promarin days, saving time and money without design used on Damen’s Stan Tug sacrificing precision or performance. double-curved, geometric shape with 1606. It is produced in a Nickel One of the first steps the develop- some tricky overhanging sections,” • Heat treatment Aluminium Bronze alloy using wire ment team took was to carry out Custers explains. arc Additive Manufacturing with extensive testing of the material “We have to make sure that • Hot isostatic pressing (HIP) industrial robotic arms, followed properties of the printed material to the material properties meet the by CNC milling at Autodesk’s ensure compliance to Bureau Veritas needs of the application,” states • Part removal from build plate Advanced Manufacturing Facility in standards. “This involved printing two Wei Ya, Postdoctoral Researcher Birmingham, UK. straightforward walls of material then from the University of Twente at • Quality testing and inspection This first prototype WAAMpeller using a milling machine to produce RAMLAB. “Material toughness, for will be used for display purposes, samples for lab testing of tensile example – ensuring that the propeller and planning for a second example and static strengths,” stated Kees is able to absorb significant impact is already underway. The consortium Custers, Project Engineer in Damen’s without damage. But we have also

Photo credit: MBFZ Toolcraft GmbH reported that it would begin produc- R&D department. been working towards optimising tion of a second class-approved Another key challenge was in the production strategy for 3D metal propeller prototype late in October redesigning the propeller for AM. deposition. This includes bead shape 2017, with the aim of installing it on a “The challenge has been to translate and width, as well as how fast we can working tug by the end of the year. a 3D CAD file on a computer into a deposit the printed material.” Currently, if a vessel comes into physical product. This is made more www.ramlab.com port needing a replacement part such complex because this propeller is a www.damen.com

Visit us at STAND 3.0-A78 History of sintering and key players identified in new publication

A new publication from Professor bles and precious metal jewellery. In Randall M German, titled ‘Sintering modern times, humans apply sintering Science: A Historical Perspective’, to the production of precise engi- is now available in both print and neering components, such as automo- digital formats. This monograph is tive transmission gears and artificial an overview on how sintering science knees. Indeed, sintered structures are evolved, identifying the key actors found in most every aspect of modern and the progress that leveraged from life, including cellular telephones, jet This historical platform provides a advances in atomic theory, materials engines and laptop computers. base for looking into the future where testing and microstructure quantifica- The scientific understanding of research on nanoscale particles tion. It documents who did what and sintering is a relatively recent develop- and Additive Manufacturing are when critical pieces of the puzzle fell ment. Quantitative ideas on particle employing new sintering concepts. into place. bonding emerged between 1945 and ‘Sintering Science: A Historical Sintering is an ancient process, 1955. Those ideas continue to be Perspective’ is available from the used thousands of years ago for the refined, now largely in the form of MPIF in either print or PDF format. www.bodycote.com © Bodycote plc 2017 – Ref: ID188407, Design by ID fabrication of bricks, pottery, cruci- advanced computer simulations. www.mpif.org

four different W components, as well Additive Manufacturing of tungsten as conducting a study to evaluate metal powder the development of W cellular structures for industrial applica- At the 19th Plansee Seminar held A Renishaw AM125 system was tions. in Reutte, Austria, May 29 - June 2, used to study the effectiveness of Table 1 is a summary of the four 2017, Alfred Sidambe and Peter Fox, SLM processing of pure W. The sets of processing parameters used of the School of Engineering, Univer- AM125 system employs a high to manufacture W SLM components sity of Liverpool, UK, presented the powered ytterbium fibre laser with with a layer thickness of 30 μm. results of their investigation into the a wavelength of 1070 nm, has a Processing was carried out in challenges of using Selective Laser maximum laser power of 200 W in an argon atmosphere to prevent Melting (SLM) to produce tungsten continuous wave mode, a maximum oxidation. The 3D laser energy (W) components from pure W powder laser scanning speed of 2000 mm/s density was derived from the 3D (<45 µm). and a laser beam diameter of 43 μm specific energy input, obtained by The authors stated that SLM is at the powder surface, which was combining laser power, laser scan not currently used commercially for used to melt plasma-densified speed, powder layer thickness and the processing of refractory metals, tungsten powder (W45) under an hatch spacing. The authors stated such as W, mainly due to the intrinsic argon atmosphere. The laser beam that the Renishaw AM125 machine problems of processing higher has a Gaussian intensity profile, uses a point exposure scan strategy, melting point materials. Tungsten which the researchers stated has which implies that the laser does has a melting point of 3422°C, as sufficient intensity to melt refractory not remain continuously on when well as a high density (19.2 g/cm3), metals such as tungsten when the incident on powder material. and has traditionally been processed focus offset is set on the central part Therefore, the scan speed was using Powder Metallurgy techniques of the geometry. A commercially derived from the point distance including pressing and sintering, pure titanium substrate was used and the exposure time used in the Hot Isostatic Pressing, etc. However, for the SLM experiments. In addition parameters.

though processing via SLM would be to identifying some of the technical Fig. 1 shows tungsten block Measurement Details S-160412-093 Average of 'Powder, Lot: 3-3, 6/16/2016 12:11:17 PM Sample Name Measurement Date Time PS# ZNI111-02BK, Analysis# 163751' Operator Name tgraham Analysis Date Time 6/16/2016 12:11:17 PM SOP File Name AeroS.cfg Result Source Averaged components (L = 50 mm, W = 10 mm Praxair Surface Technologies Inc R-20160412-055 technically challenging, it would lead issues said to limit the effectiveness Customer Submission Number Sample Number S-160412-093

Analysis to a significant advantage in high- of SLM processing of pure W, the and H = 5 mm) manufactured Particle Name Nickel (AI 0.1) Particle Refractive Index 1.980 Dispersant Name Dry dispersion Dispersant Refractive Index 1.000 Particle Absorption Index 0.100 Laser Obscuration 3.65 % Weighted Residual 0.19 % Scattering Model Mie value manufacturing sectors. researchers succeeded in producing using the AM125 SLM machine. Analysis Model General Purpose Analysis Sensitivity Enhanced

Result

Concentration 0.0147 % Span 0.768 The samples were successfully Uniformity 0.232 Result Units Volume Specific Surface Area 189.5 m²/kg Dv 10 22.6 µm D [3,2] 31.7 µm Dv 50 33.0 µm fabricated without any visible defects D [4,3] 34.3 µm Dv 90 47.9 µm Frequency (compatible) or delamination during the melting 25.0 20.0

process, and a relatively smooth 15.0

10.0 Volume Density(%)

surface was achieved. Fig. 2 shows 5.0

0.0 the SEM images of the top surfaces 0.01 0.10 1.0 10.0 100.0 1,000.0 10,000.0 Size Classes (µm) (left) and side surfaces (right) of [36] S-160412-093 Average of 'Powder, Lot: 3-3, PS# ZNI111-02BK, Analysis# 163751'-6/16/2016 12:11:1 Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In Size (µm) % Volume In 0.0100 0.00 0.0526 0.00 0.276 0.00 1.45 0.00 7.64 0.00 40.1 12.09 211 0.00 1110 0.00 0.0114 0.00 0.0597 0.00 0.314 0.00 1.65 0.00 8.68 0.00 45.6 7.66 240 0.00 1260 0.00 0.0129 0.00 0.0679 0.00 0.357 0.00 1.88 0.00 9.86 0.00 51.8 3.78 272 0.00 1430 0.00 SLM tungsten fabricated using the 0.0147 0.00 0.0771 0.00 0.405 0.00 2.13 0.00 11.2 0.00 58.9 1.30 310 0.00 1630 0.00 0.0167 0.00 0.0876 0.00 0.460 0.00 2.42 0.00 12.7 0.02 66.9 0.24 352 0.00 1850 0.00 0.0189 0.00 0.0995 0.00 0.523 0.00 2.75 0.00 14.5 0.32 76.0 0.01 400 0.00 2100 0.00 0.0215 0.00 0.113 0.00 0.594 0.00 3.12 0.00 16.4 1.51 86.4 0.00 454 0.00 2390 0.00 parameters in Table 1. 0.0244 0.00 0.128 0.00 0.675 0.00 3.55 0.00 18.7 4.11 98.1 0.00 516 0.00 2710 0.00 0.0278 0.00 0.146 0.00 0.767 0.00 4.03 0.00 21.2 8.02 111 0.00 586 0.00 3080 0.00 0.0315 0.00 0.166 0.00 0.872 0.00 4.58 0.00 24.1 12.38 127 0.00 666 0.00 3500 0.0358 0.00 0.188 0.00 0.991 0.00 5.21 0.00 27.4 15.82 144 0.00 756 0.00 0.0407 0.00 0.214 0.00 1.13 0.00 5.92 0.00 31.1 17.08 163 0.00 859 0.00 Optical micrographs confirm Validating Powders,0.0463 0.00 0.243 0.00 1.28 0.00 6.72 0.00 35.3Products15.66 186 0.00 976 0.00 & Feedstock

Software Version: 2.10 Malvern Instruments Ltd - www.malvern.com the density levels (up to 98%) of Page 1 of 1 the tungsten fabricated by SLM, Since 1945, NSL Analytical has helped customers verify the highest standards of Fig. 1 Tungsten components manu- Fig. 2 SEMs of the top surface (left) achieved using the four different materials quality, performance and safety in their products. Customers trust us with factured by SLM (Courtesy Plansee) and side surface (right) of SLM tung- processing parameters, which their most critical materials testing needs. are equivalent to different energy sten (A and B) (Courtesy Plansee) NSL supports innovation by testing powder metal, feedstock, prototype designs densities used in SLM. The manu- and final product in the Additive Manufacturing Industry. 3D volume facture of a porous lattice structure SLM Point Exposure Apparent energy Hatch Space Processing Distance Time Speed also demonstrates the suitability g Material Composition — chemical analysis of major and trace level elements for R&D density (mm) Parameter (μm) (μs) (mm/s) and future potential of using SLM to (J/mm3) and specification conformance produce lighter weight, geometri- g Powder Characterization — flow rate, density, particle size distribution and particle shape A 20 200 100 578 0.115 cally complex W components. g Validate Metal Printed Parts metallurgical analysis, mechanical testing, B 20 200 100 434 0.155 — 19th Plansee Seminar Proceedings microstructure and failure analysis C 29 200 145 399 0.115 th Proceedings of 19 Plansee g Powder Studies — alloy development and powder re-use D 29 200 145 299 0.155 Seminar, 2017, are available to purchase directly from Plansee. Table 1 Summary of four sets of processing parameters used to manufacture four tungsten components by SLM (Courtesy Plansee) www.plansee-seminar.com Trust NSL, contact us at NSL Metallurgical NSL Analytical NSLanalytical.com/industries/ 4535 Renaissance Parkway 4450 Cranwood Parkway additive-manufacturing Cleveland, OH 44128 Cleveland, OH 44128 or call 877.560.3875 216.475.9000 877.560.3875 74 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 75

NSL-Metal-Additives-A4-052617.indd 4 9/8/17 4:17 PM etalDutumnDpdf ::

densification. Samples produced at Selective laser melting of tungsten and 3D Systems (3DS) were characterised tungsten alloys by a higher density (95.8-97.1%TD), regardless of the applied energy density above 200 Jmm-3. Aljaž Iveković, along with research W and W-Ta alloy. This included an For the in-house produced colleagues from Belgium’s in-house SLM machine developed samples with 5 wt.% Ta (W5Ta), the Katholieke Universiteit Leuven by KU Leuven and an industrial densities ranged from 88 to 94.1%TD and 3D Systems, has studied the ProX® DMP 320 at 3D Systems. The with the highest densities obtained at influence of Selective Laser Melting in-house SLM machine is equipped an energy density of 200-250 Jmm-3 (SLM) processing parameters with a 300 W Nd:YAG laser with (Fig. 2a). For the 10 wt.% Ta (W10Ta) on the melting and solidification a wavelength of 1.064 μm and a grade, the densities ranged between behaviour of both tungsten (W) laser beam diameter of 90 μm. The 89.5-97.5%TD, with highest densifi- and W alloys. They presented their machine is also equipped with a cation at 300-400 Jmm-3 (Fig. 2b). A results in a paper at the 19th Plansee preheating module, which enables minor beneficial effect of preheating Seminar, held in Reutte, Austria, preheating of the baseplate up to was observed; however, the increase May 29-June 2, 2017. 400°C. The ProX DMP 320 machine in density was not reproducible. The researchers used a is equipped with a 500 W laser and Therefore, it was concluded that pure W powder and also a W-Ta has a smaller spot size. All experi- no systematic increase in density powder mixture (1, 5, 10 wt.% ments were conducted in a flowing was observed when preheating was Ta). Two complementary Additive Ar atmosphere with resulting oxygen used, similar to the observation Manufacturing systems were used content of 150-200 ppm for the with pure W. The researchers to investigate the effect of different in-house machine and < 50 ppm in attributed the lower density obtained equipment on the processing of the the ProX DMP 320. Samples of 10 in the in-house built machine, in x 10 mm2 and a total height of 10 comparison with the industrial mm were fabricated with varying 3D Systems machine, to the higher processing parameters: laser oxygen level in the chamber of the power, scanning speed, layer thick- in-house equipment. ness, hatch spacing and scanning Regardless of the processing strategy. parameters used and scanning The densities of the samples strategy, cracks were always produced at different energy density observed, which was attributed to inputs are plotted in Fig. 1. With the thermal stresses arising during increasing laser energy input, the rapid solidification or recrystal- measured density of the W samples lisation. In pure W, a clear network increased up to 300 Jmm-3, where a of cracks was formed. With the plateau was reached. A maximum addition of tantalum, the grain size density of 94.4%TD was obtained was significantly reduced, resulting for the materials produced at in a more irregular crack pattern. Fig. 1 Relative density of SLM 475 Jmm-3. Further increase in Baseplate preheating was suggested tungsten as a function of the applied energy density up to 1000 Jmm-3 as a way to prevent crack formation; energy density (Courtesy Plansee) had a minor effect on increasing however, preheating up to 400°C was not sufficient to prevent crack formation in SLM of W or W-Ta. A higher preheating temperature is needed to mitigate thermal stresses during solidification, and lowering the oxygen content is essential to obtain a crack-free high density microstructure in SLM W and W-Ta alloys.

19th Plansee Seminar Proceedings Proceedings of 19th Plansee Seminar, a) b) 2017, are available to purchase directly from Plansee. Fig. 2 Relative density of SLM (a) W5Ta and (b) W10Ta as a function of the applied energy density (Courtesy Plansee) www.plansee-seminar.com

phenomena of W powders during SLM Effect of process parameters on the processing. The balling phenomenon selective laser melting of tungsten is said to occur primarily due to incomplete wetting and spreading of W melt droplets exposed to the laser. In a paper presented at the 19th using a Concept Laser Mlab Cusing The solidification time of molten Plansee Seminar, held in Reutte, R machine . Experiments were tungsten droplets is very short due Austria, May 29-June 2, 2017, conducted at hatch spacings of 15 to the high thermal conductivity of R K Enneti and R Morgan of Global and 30 µm and scan speeds in the tungsten. The solidification time is Tungsten and Powders Group in range 200–1400 mm/s. A constant much shorter than the spreading Towanda, Pennsylvania, USA, and laser power of 90W and a powder time, resulting in molten W droplets S V Atre at the University of Louisville, layer thickness of 30 µm were used. solidifying without completing the Kentucky, USA, reported on a study Rectangular cuboids of 7.8 ± 1.4 mm spreading process. The low power to understand the effect of process x 10.1 ± 0.1 mm x 10.1 ± 0.04 mm used in the study (90W) is also not parameters such as hatch spacing were printed using various process sufficient to completely melt the W and scan speed on the densification parameters and then analysed for powder and reduce the viscosity of of tungsten (W) by SLM. It was found densification. The samples were built the partially melted W droplets. The that the resulting density of SLM on a steel base plate. A maximum low viscosity of W droplets was also tungsten is inversely proportional to density of 75% theoretical was found to inhibit faster spreading of the hatch spacing and scan speed. achieved at an energy density of melt, resulting in low density in the The researchers used a pure 1000 J/mm3. samples. W powder having an average SEM micrographs (Fig. 2) of the The researchers stated that particle size of 30 µm and with W sample processed at a scan speed SLM processing of the W powder at morphology shown in Fig. 1. SLM of 1200 mm/s and a hatch spacing higher laser powers will increase of the W powders was carried out of 15 µm clearly show the balling the temperature, resulting in a lower viscosity melt pool and faster spreading. The faster spreading in turn will assist in increasing the density of the material. They also found that scan speed is the dominant factor in SLM of W, contributing to 75.7% of the variation in densification, while hatch spacing contributed only 7.1%. The high thermal conductivity of W may be the reason for the lack of a significant effect of hatch spacing on densification.

19th Plansee Seminar Proceedings Proceedings of 19th Plansee Seminar, Advanced CAD 2017, are available to purchase directly from Plansee. Fig. 1 Morphology of the tungsten powder used in SLM experiments for advanced manufacturing. (Courtesy Plansee) www.plansee-seminar.com

nTopology Element

Honeywell: Driving AM Frankfurt, Germany, 14 – 17 November 2017 formnext.com application and supply chain development in the aerospace Simply limitless. industry Engineers think like children. There are no limits, only possibilities. Over the past decade Honeywell has been a leader in accelerating the adoption Join us and be inspired at formnext, the international exhibition and of metal Additive Manufacturing in the aerospace industry. With dedicated conference for Additive Manufacturing and the next generation of facilities in five countries, the company is at the forefront of the development of new commercial aerospace applications and the supply chain needed to intelligent industrial production. implement series production. Dr Dhruv Bhate, Associate Professor in the Polytechnic School at Arizona State University, visited Honeywell’s Phoenix Where ideas take shape. facility on behalf of Metal AM magazine and met with Donald Godfrey, an Engineering Fellow at Honeywell and the person most credited with initiating and directing the company’s progress in the field of metal AM.

For over a century, Honeywell Honeywell’s metal Additive the facilities on this complex is tasked Aerospace and its legacy companies Manufacturing programmes and with final assembly of the company’s have been at the forefront of both initiatives are managed out of its propulsion engines for business jets military and civilian aviation. Today, Phoenix complex, which is situated and helicopters, as well as engines they are best known as developers of next to the Phoenix Sky Harbor for the M1 Abrams battle tank and air innovative solutions in a wide range International Airport. The largest of turbine starters. of areas, including aircraft engines, cockpit and cabin electronics, wire- less connectivity services, logistics and more. Honeywell Aerospace is a division of the Honeywell International conglomerate and generates approximately $14 billion in annual revenue, about one-third of Honeywell’s overall revenue. It is headquartered in Phoenix, Arizona, USA, an area in which aerospace and defence manufacturing is a key industry. Honeywell Aerospace consistently ranks among the top employers in Arizona, with its five facilities in the state employing approximately 8,000. The company has played a key role in driving the aerospace and defence manufacturing sector in the region and has also been instrumental in leading the development of the region’s metal Fig. 1 A Honeywell HTF7000 engine in production at Honeywell’s Phoenix facility Additive Manufacturing expertise. (Courtesy Honeywell) @ formnext_expo # formnext 80 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 81 Metal AM at Honeywell | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | Metal AM at Honeywell

niches do not currently align well with Honeywell’s specific needs and applications. With regards to materials, Honeywell has identified Inconel 718 processed by laser-based Powder Bed Fusion as its leading Initial development of prototype DMLS 718 swirler on Reactive metals lab material and process. This year parts with external vendors Airbus flight test bed opens the team generated a complete ‘B-Basis’ for this alloy, following requirements specified in the Metallic Materials Property Design 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 and Standardization (MMPDS) handbook used commonly in the AM pilot aerospace industry. This requires facility the generation of enough statistically valid data that at least 90% of Fig. 3 Honeywell’s Phoenix Additive Manufacturing Technology Centre, opened DMLS 718 Tangential On Opening of first AM lab in First functional the sampled population equals or in 2014 Board Injector on flight test Phoenix and subsequent metal part in bed global sites production exceeds the value of interest - for example strength - with 95% confidence. Generating B-Basis data is an essential requirement for the insertion of these materials into critical production parts. In addition to Inconel 718, Honeywell is currently working on titanium and aluminium Fig. 2 A timeline of Honeywell’s journey in metal Additive Manufacturing over the last decade alloys, stainless steel and a number of proprietary alloys and processes.

Honeywell’s metal Additive being opened in Bengaluru (India), Metal AM technologies and Manufacturing journey Brno (Czech Republic), Mexicali materials A spectrum of value: (Mexico) and Shanghai (China). tooling, production parts Honeywell’s metal Additive In 2016, Honeywell opened a Over the past three years, the team and design optimisation Manufacturing journey began a reactive metal alloy AM facility in at Honeywell has focused on Laser decade ago with several prototype Phoenix (Fig. 4). Converted from Powder Bed Fusion and Electron Like others in the wider AM parts manufactured by external an old flame spray facility, this Beam Melting and is somewhat industry, Honeywell has recognised Fig. 4 The Reactive Metal Alloy Facility in Phoenix, opened in 2016 vendors (Fig. 2). Over the following now supports the production of unique in having real-world experi- the technology’s potential beyond five years, the company continued to AM parts from aluminium and ence across these two technologies prototyping; namely in tooling and evaluate the technology for insertion titanium alloys. By the end of 2017, with four different equipment for production parts. While there is into applications where there was Honeywell is expecting to be in suppliers, namely Arcam, Concept a temptation to address challenges a need for a rapidly manufactured production with Inconel 718 parts Laser, EOS and SLM Solutions. This in production right away, Honeywell metal parts, including for test bed at a new large pilot production has allowed Godfrey and his team to has taken an approach that seeks components. This coincided with facility, also in Phoenix (Fig. 5). The directly observe the relative merits of to enable cost and time savings for significant consolidation in the metal company’s rapid growth in metal the technologies and suppliers first- non-critical applications, while also AM service industry, which had the AM has been complemented by over hand and make informed decisions on developing a pathway for moving risk of impacting the company’s $25 million in procured research production-scale manufacturing. into the production of parts with ability to source metal AM parts. funding, a positive endorsement of Honeywell also makes use of increasing criticality and impact. In 2014, led by the efforts of the progress the company has been indirect metal AM using 3D printed “With regards to production of Engineering Fellow Donald Godfrey, making. sand casting moulds for short-run functional parts, we are currently the company opened its first This expanding range of facilities metal parts that are best suited to selecting components that are not $5 million AM facility in Phoenix, is enabling Honeywell to drive casting but where the timescales and/ life-critical. This is to get ourselves, with a focus on Laser Powder Bed forward the development of new or costs of traditional methods are our customers and the FAA Fusion and Electron Beam Melting AM applications, from concept not justified or feasible. In a wider (Federal Aviation Authority) more technologies from a range of through to pilot scale production. It discussion about metal AM technolo- experience with the technology. different suppliers (Fig. 3). The last is planned that following successful gies, Godfrey stated that while other There is no sense swinging for the three years have been particularly pilot scale production parts will technologies such as Directed Energy fences when there is so much fruit Fig. 5 Honeywell’s new metal AM pilot facility in Phoenix is in the process of productive, with similar facilities transfer to external vendors. Deposition have their merits, their easily picked,” explained Godfrey. being commissioned and will be fully operation by the end of 2017

Fig. 6 Some examples of the metal AM tooling currently in use at Honeywell. Left: Carousel for burner rig; top right: Test Fig. 7 Tubular parts are prime candidates for replacement with metal AM. This Inconel 718 part has completed certifica- rake; bottom right, Clamp bracket. tion at all three levels

Tooling often results in both cost and time Production parts Several tubular components The team at Honeywell has made the reductions of over 90%. Additionally, The use of metal AM for production were also identified for their ability conscious decision to implement a operators on the manufacturing floor parts has significant benefits for to enable part consolidation and, global effort to additively manufacture are able to continuously provide ideas the aerospace industry and is in one case, a reduction from eight production tooling in parallel with to improve production efficiency, arguably where the largest return-on- sheet metal and cast components the production parts. Godfrey stated, by proposing and designing tools investment for the technology lies. For to one metal AM part was achieved “While the time invested to gain that aid in assembly. In addition a new manufacturing technology to (Fig. 7). This part has recently gain acceptance for the production of received approval at all three levels. an engine component for an aircraft, it As previously stated, Honeywell also “The use of metal AM for production must be approved at three levels. The uses indirect metal AM using 3D first level is internal, which involves all printed sand moulds to make metal parts has significant benefits for the the different groups that are impacted castings for rapid, low-volume part aerospace industry and is arguably by the change. It is here where risks production or replacement parts. and benefits are evaluated. These are deployed on Honeywell’s where the largest return-on- The second level of approval comes HTF (turbo fan) and 777X turbine Fig. 8 Two views of another tubular AM part developed by Honeywell investment for the technology lies” from the customer, who has to sign engine programmes. off on the change. Once this is done, the FAA has to certify that all the Design optimisation customer and government approvals to the inspiration for these parts requisite data necessary for the part Several components across different concerned with high rework rates, metal AM is considered a legitimate to print production parts can be coming directly from manufacturing, in question have been collected and programmes have been identified quality issues and associated costs. option in design and manufacturing long, the printing of tooling is very Honeywell also used the opportunity that it meets stipulated criteria. For at Honeywell as candidate parts Additionally, new product groups are discussions. A three-day ‘Design quick and has immediate impact on to evaluate the process’s capability for its first metal AM production part, for production using metal AM. The looking at metal AM to improve the for AM’ course is currently offered financial spreadsheets.” manufacturing lattice structures by Honeywell selected a relatively simple selection of these parts is often performance of their components at the Phoenix facility for Honeywell Some examples of functional building them into the designs, a good and non-critical splash guard used driven by requests from supply chain while reducing weight. employees and plans are in place to tooling already in use at Honeywell example of the technology’s ability in a gearbox. This part was approved groups concerned with long lead Engineers at Honeywell are extend this offering worldwide. are shown in Fig. 6. Manufacturing to add complexity without incurring by all three parties and is currently in times or from quality and supplier actively driving a culture change Formal training is complemented selected tooling with metal AM additional expense. production. management groups that are through the organisation so that by proof-of-concept studies such

problems and opportunities in the areas they work on locally and is thus likely to innovate with regard to using metal AM technology in different ways best suited to their applications. One such example is the remarkable use of metal AM to customise prototype turbochargers, initiated by the Bengaluru site (Fig. 11) by building a custom component on top of a previously built and standard housing. In addition to a global presence in five countries, Honeywell Phoenix is contributing significantly to the local community and has touched Fig. 10 Honeywell’s Shanghai AM facility. An Electro Static Discharge (ESD) small business and academia surface can be seen on the floor in front of the EOS machine in a number of ways. Honeywell has always had a close working relationship with Arizona State University (ASU) and was the largest investor in establishing the university’s $2 million Manufacturing Research and Innovation Hub. This hub contains an Additive Manufacturing facility Fig. 9 A proof-of-concept Inconel 718 engine mount bracket. The original part (top left), topology optimised design which includes two laser-based (bottom left) and manufactured part using Laser Powder Bed Fusion (right). The process achieved a 56% weight metal Powder Bed Fusion machines reduction while maintaining desired strength in addition to a range of polymer technologies. The facility primarily enables students at ASU to gain as the engine mount bracket shown Global presence, local Lessons learned in the exposure to this technology and is in Fig. 9. The original component impact development of the Phoenix also used for early-stage research was designed for casting and was lab have been applied to other by faculty and students across the therefore redesigned using topology While the majority of Honeywell’s facilities. This is perhaps most university. optimisation software. It was then metal AM activities are conducted at true for the safety aspects of this Honeywell also works with manufactured from Inconel 718 its Phoenix facility, significant efforts technology. Honeywell’s laser students from ASU in a number using a laser Powder Bed Fusion are also underway at its four global Powder Bed Fusion reactive alloy of capacities. One example is the machine. The finished component sites in Brno, Bengaluru, Shanghai facility in Phoenix, supporting both capstone project, a team project was shown to have achieved a weight and Mexicali. All these sites have titanium and aluminium alloys, is involving three to six senior reduction of 56% while meeting the similar equipment to that at Phoenix’s the only one of its kind in the state undergraduates who, over a period stated strength requirements. first non-reactive alloys lab and are and has been established with of nine months, are co-advised by A key challenge in implementing contributing to the overall Honeywell stringent safety protocols, including a Honeywell engineer and a faculty metal AM for critical applications, metal AM programme in a number of implementation of Electro Static member at ASU. Projects that have such as the above engine mount differing ways, while also looking to Discharge (ESD) prevention methods been completed include the design bracket, is the need to have multiple improve the company’s supply chain comparable to those used in the of an AM heat exchanger, powder levels of qualification data. This responsiveness. semiconductor industry. These alloy development and combustor starts at the material level, in The Brno lab focuses on trans- include ESD coatings installed on material development. terms of what is commonly called a portation technology development, top of the concrete floor, grounding “Every project has applicability B-Basis in the MMPDS handbook. reflecting Honeywell’s position as stations, ESD grounding straps for to real life-production,” explained The necessary collection a global leader in turbocharger clothing/shoes, personal protective Godfrey, “The projects involve real- of B-Basis data can be time- technology. As such, it has developed equipment (PPE) to protect from world designs within the Honeywell consuming and expensive. At this significant post-processing expertise dust inhalation and ESD mats organisation.” Honeywell has hired time, Honeywell has established and capabilities, including machining (Fig. 10). two ASU students at its Phoenix this dataset for Inconel 718 only and inspection. The Bengaluru site While the primary driver for campus this year alone and has and, as such, this is the lead alloy has made significant strides in tooling establishing a worldwide presence supported research at the university Fig. 11 An innovative feasibility study from Honeywell’s Bengaluru facility, which being considered for structural for transportation systems test rigs, is to have a responsive supply through seed funding and teaming demonstrates a proof-of-concept for rapid customisation of turbocharger applications. among other projects. chain, each site has familiarity with on research proposals. prototypes

Fig. 12 Honeywell’s new vacuum heat treatment system from Ipsen Industries Fig. 13 An operator cleaning an SLM 280 AM machine at Honeywell

Enabling future growth and sieving, a vacuum furnace, a all qualification requirements are met “Ultimately, this means that the opportunities in AM for the state. One manufacturing, lattice modelling Hot Isostatic Press (HIP), machining during the move toward production at way Honeywell manages powder, of the focus areas of the committee and evaluations of in-situ monitoring While Honeywell has already made areas and a quality room, as well scale. This is currently a major thrust certifies machines, qualifies lasers is workforce development at senior solutions for laser powder bed fusion. significant strides in metal AM over as engineering offices and training within Honeywell and the company and many other steps must be high school, community college and The company has also provided the past decade, there is a long rooms. This is on track to be fully is evaluating both existing metal integrated into the supply base one university levels and engineers from funding for research in dissolvable road ahead of exciting opportunities operational by the end of 2017. The AM service companies as well as vendor at a time. Let us not lose focus Honeywell are actively informing supports being driven locally out of and challenges. These broadly fall purpose of the pilot production factory established aerospace manufacturing on the fact that the FAA still considers the direction of the committee with ASU in collaboration with faculty at into three categories: supply chain is to develop processes and get them companies that may only have limited AM a new and novel technology the aim of developing Arizona as a Penn State University. enabling, workforce development and approved internally, by customers and of experience in metal AM. The goal and because of this it will be tightly powerhouse for AM talent. research and development. by the FAA. is the building of a robust supply chain. controlled. This work is going to take Commenting on the development some time. It will be slow and it will Research and development The realisation of a vision of the AM supply chain, Godfrey be meticulous but it will be done Honeywell has obtained over $25 stated, “Honeywell’s approach is to correctly under the watchful eyes of million in federal funding for research While Honeywell’s progress in AM “After successful production has develop Additive Manufacturing to the both internal and external decision in AM since installing its first metal is undoubtedly the result of several been established, Honeywell will point where it is a generally accepted makers,” stated Godfrey. AM facility. Projects have included team members’ efforts, few would manufacturing technology within the an Open Manufacturing programme argue that Godfrey’s vision and drive look to transfer the process to aerospace industry. This means a Workforce funded by the Defense Advanced have been pivotal in ensuring the supply chain will have to be developed At the root of Honeywell’s investment Research Projects Agency (DARPA) company is where it stands today. external vendors by training them on and managed. Today, engine/airframe in ASU is a recognition of the need that combines new alloy development, Godfrey first realised the potential of Honeywell’s specific requirements...” OEMs have taken the approach of for engineers who not only have process monitoring and Integrated AM for functional parts in 2008 and using a vertically integrated supply the mechanical aptitude but the Computational Materials Engineering what started as a solitary project in chain with respect to AM because a know-how to operate and maintain (ICME) software in an effort to Honeywell’s engines business has reliable global supply chain does not AM machines. In addition to its accelerate new material qualification now developed into a multi-year, Supply chain After successful production has currently exist. However, it would be investment in equipment and support and alloy design. multi-million dollar competitive Honeywell’s pilot production been established, Honeywell will look unreasonable for a company to expect of student projects, Honeywell is also Honeywell has also been part of advantage, which is putting Honeywell factory in Phoenix will support to transfer the process to external to vertically integrate all the machining a key member on a recently formed several teams conducting research at the forefront of metal AM. AM production using Inconel 718 vendors by training them on Honey- or assembly for its products. The same Arizona Additive Manufacturing as part of the America Makes Godfrey was recently awarded and stainless steel powders and well’s specific requirements and applies to AM and therefore a supply Committee that seeks to collabo- consortium, working on projects the Honeywell Aerospace Navigator includes a powder room for storage working closely with them to ensure chain must be developed.” ratively address challenges and including metal AM heat exchanger Award in recognition of his initiative

Looking ahead

“As of today, the FAA has given approval for three parts to fly in commercial applications,” Godfrey stated. “Honeywell has a strong Space and Defense Group and there are AM parts being used for these applications. Honeywell already has one part in space on a satellite launched last year. In rolling out the production of AM components, Honeywell has taken the approach to print non-life-critical engine components. These types of components lower the barrier of acceptance from our customers and the FAA. Honeywell will have at Fig. 15 Honeywell staff in Phoenix presenting recent builds least four components qualified by the end of 2017 but there is a high probability it will most likely be six components. The number qualified for flight should be expected, at a minimum, to double every year for the next few years, meaning Fig. 14 At the official launch of ASU’s Innovation Hub, January 2017. From left to right, Kyle Squires (ASU), Malcolm Green that by 2019 we could be looking at (ASU), John Murray (GE-Concept Laser), Ann McKenna (ASU), Rich Barlow (Honeywell), Keng Hsu (ASU, currently at the twenty-four types of components in University of Louisville), Don Godfrey (Honeywell), Joyce Yeung (GE–Concept Laser) (Photo Credit Jessica Hochreiter, Ira A production, increasing to nearly one Fulton Schools of Engineering, ASU) hundred by 2021.”

Author and perseverance in bringing the easy button and it happens, but the structural aerospace components. technology to the engines business truth is that is not how businesses “The key to success with additive Dr Dhruv Bhate and beyond. He has also been granted operate. It is a fallacy to think a technology,” Godfrey stated, “is Dhruv was recently appointed twenty patents, with Honeywell person can say ‘let’s make produc- identifying risks and working as Associate Professor at the generating additional revenue by tion parts with additive’ and everyone with organisations to control and Polytechnic School, Arizona State licensing its technology. gets in line and all the pieces fall into minimise them the best we can as an University. At the time of writing this Fig. 16 A new Quintus HIP system for the final densification of AM parts Godfrey cites several lessons that place,” commented Godfrey. organisation.” report he was Senior Technologist have emerged from his decade of He also cites the importance Godfrey has emerged as much a at Phoenix Analysis & Design experience with metal AM technology. of leaders in the growth of AM as champion of metal AM technology Technologies, Inc. (PADT). itself as he is a successful member of Honeywell’s global AM team. Email: [email protected] “All of us would like to have the ideal He recently co-authored the book www.padtinc.com Additive Manufacturing of Metals: https://poly.engineering.asu.edu situation where we say ‘this is needed’ The Technology, Materials, Design and ‘that has to occur,’ then press an and Production (Springer, 2017). “Machining is a generally accepted Contact easy button and it happens, but the manufacturing process,” said Godfrey. “My goal is to make Additive Adam Kress truth is that is not how businesses Manufacturing a generally accepted Senior Manager, Media Relations operate.” manufacturing process.” Honeywell’s Honeywell Aerospace AM team, and its rapid but deliberate progress in the past three years in Tel: +1 602 365 5034 Chief among these is an appreciation a manufacturing option of choice particular, is evidence of the fact Email: [email protected] for working with what is available. “All within the company. Finally, Godfrey that this goal, as challenging as it https://aerospace.honeywell.com of us would like to have the ideal situ- identifies collaboration with multiple may appear to those familiar with ation where we say ‘this is needed’ organisations as crucial for success the issues the technology has yet to Fig. 17 A vacuum heat treatment furnace for the thermal processing of metal and ‘that has to occur,’ then press an in metal AM, particularly for overcome, is well in sight. AM aerospace components

high precision manufacturing solutions machinery & laser systems RapidTech + FabCon 3D: Innovations in binder-based More lasers. AM and advances in conformal cooling More materials. From June 20-22, 2017, the German city of Erfurt became a centre of gravity for Additive Manufacturing, hosting the annual RapidTech More Sisma. technical conference and its accompanying trade exhibition, FabCon 3D. Dr Georg Schlieper visited the event for Metal Additive Manufacturing magazine and highlights a number of innovative trends in metal Additive Manufacturing process technology and applications, including the latest binder-based Additive Manufacturing technologies and innovations in toolmaking.

This year’s RapidTech + FabCon 3D BASF: printing metal like (PBF) and Binder Jetting. BASF SE, event attracted a record attendance plastics Germany, introduced a polymer fila- of more than 4,800 visitors and ment containing a high concentration over two hundred exhibitors. Now Several innovative AM technologies of 316L metal powder. The filament in its 14th year, the organisers also were presented in the exhibit hall material is based on the company’s reported a 20% increase in exhibitor which will complement, and possibly Catamold® binder system, which numbers over the previous year and compete against, established powder has been used successfully for many an increase in floor space of nearly bed AM processes such as laser and years in the Metal Injection Moulding 25%. The RapidTech conference, held electron beam Powder Bed Fusion (MIM) industry. In cooperation with in English and German with simul- taneous interpretation, featured Come see what’s new at nearly a hundred presentations from Europe and further afield, and covered some of the most important hall 3.0, booth D10 sectors of Additive Manufacturing through a series of parallel Trade Forums. The conference opened with a keynote presentation by Charles ‘Chuck’ Hull, recognised as the inventor of stereolithography and co-founder of 3D Systems, a leading US producer of AM machines. Hull shared the story of his career and spoke about the many frustrations that each inventor has to go through before a product is created that can be manufactured and marketed economically. Today, Hull is 3D Fig. 1 The modern Exhibition and Congress Centre of Erfurt (Courtesy Messe Systems’ Chief Technology Officer. Erfurt)

further degraded by the flame of a natural gas burner so that the final products are completely harmless to the environment. Industrial debinding ovens for this process are available from several manufacturers and in various sizes, either batch type or continuous.

Sintering After the removal of the main binder constituent by catalytic debinding, the parts are sintered at a temperature above 1300°C to create a solid metal structure. The portion of the binder remaining in the component after debinding, the ’backbone binder’, is rapidly evaporated through the open pore network while the parts are heated to sintering temperature. As Fig. 2 The desktop-based metal AM system EVO-lizer (left) and printer head with nozzles (right) (Courtesy Evo-tech) the organic components are removed, the fine powder particles begin to sinter, forming solid material necks at their contact interfaces. This way, the metal powder does not disintegrate Nozzle diameters between 0.2 and Debinding and the part shape is maintained 0.8 mm are available, generating a The next step is the degradation of the throughout the process. layer thickness of 0.1–0.75 mm. The POM binder in an acid environment Sintering, the process by which EVO-lizer can be plugged into any at temperatures around 120°C. The powdered material is transformed 230 V household power plug and the catalytic debinding process uses from a loose arrangement of powder

power consumption is just 250 W. highly concentrated nitric acid (HNO3) particles into a solid material without Needless to say, the price with a concentration of at least 98%. losing the shape of the component, is point for this printer is an order of The acid vapours rapidly decompose accomplished by diffusion processes, magnitude less than the price of a the main binder constituent without i.e. atomic displacement and material Fig. 4 AIM3D’s new AM system along with a ratchet and turbine wheel manufac- PBF-based metal AM system, which damaging the part, thereby creating transport in the solid state. As the tured by the company (Courtesy AIM3D) could lead to a dramatic reduction a network of open porosity in the temperature increases, so does the in cost for certain types of additively part. The part shape and size are part strength, as the internal porosity manufactured metal product. not changed, nor is there any is reduced until the part is almost deformation during the debinding fully dense. EVO-lizer technology or similar for undergo a MIM-style debinding and Fig. 3 Demonstration parts in the Processing the extruded part process, since the temperature for The driving force of sintering is the rapid prototyping or small series sintering cycle to achieve the required green state, manufactured on the BASF’s filament is produced by catalytic debinding is significantly reduction of the free surface energy. production. material properties (Fig. 4). EVO-lizer (Courtesy Evo-tech) working metal powder into a lower than the softening point of the Along with the densification goes a The AIM3D system can handle polymer binder based on polyoxym- binder system. A portion of the binder shrinkage of the part, amounting to commercial polymer granules as ethylene (POM), with a metal powder remains in the part after catalytic roughly 15% linearly. At the end of AIM3D: FDM of MIM well as metal and ceramic, making the Austrian company EVO-tech content of 50–60% by volume. It has debinding so that sufficient strength the sintering process the material feedstock granules it easier for manufacturers to extend GmbH, BASF has developed a Fused a diameter of 1.75 mm and can be is maintained to hold the part is nearly pore-free and the physical their range of materials using the Deposition Modelling (FDM) process printed like a polymer filament. The together and allow safe transporta- properties are similar to those of Another AM innovation was presented wide variety of feedstocks commer- analogous to the printing of polymer result is what is called a green part tion to the sintering furnace. wrought materials. by Germany’s AIM3D GmbH. This cially available. Lieberwirth told Metal filaments and Evo-tech presented a (Fig. 3) requiring further processing. The speed of binder degradation start-up is a spin-off out of Rostock Additive Manufacturing magazine desktop printer for both polymer and The parts created using this method using this method is relatively high, This complete process may sound University. Clemens Lieberwirth, that successful tests have been metal filaments under the brand are reportedly characterised by an as compared to other binder removal rather complex to readers who are AIM3D’s Technical Manager, has carried out with 17-4 PH, 316 and 304 name EVO-lizer (Fig. 2). excellent green strength that allows processes such as solvent or thermal not familiar with MIM, but it is a invented a micro extruder for use as stainless steels, tungsten carbide and The EVO-lizer, with external for the removal of scaffolds and debinding. BASF claims that the well-established industrial process an AM print head which handles MIM ceramic feedstocks. Even copper has dimensions of 860 x 840 x 540 mm, post-processing to be carried out in main binder constituent, POM, can be and many millions of parts are feedstock granules like an injection recently been manufactured. has a build space of 270 x 200 the green state with little effort and completely removed from parts with produced by this technology every moulding machine. Integrated in This system is not restricted to a x 210 mm and is equipped with at low cost in order, for example, up to 5 mm wall thickness in less day. MIM parts manufacturers an AM system, it can manufacture catalytic debinding system and is able two high temperature nozzles for to improve the surface quality or than three hours. The main reaction with catalytic debinding ovens and metal parts by FDM. As with BASF’s to process even feedstocks based melting the filament at up to 330°C. individual dimensions. product is formaldehyde, which is sintering furnaces can easily adopt new filament, these green parts then on water soluble binders, thereby

2 copper pins Conformal Blood-vessel channels

External cooling Internal cooling Internal cooling Ø 6 mm Ø 2.5 mm Ø 3/2.12/1.5 mm

Fig. 5 An XJET machine and demonstration parts made from 316L stainless steel (Courtesy XJET) Fig. 6 Possible cooling concepts for an injection moulding tool insert (Courtesy University of Leoben)

reducing the required investment for During production, the machine’s technology, exert a pricing pressure moulding tools. The time required Surface Temperature binder removal systems. The system build space is heated, thereby evapo- on the established laser beam for the injection moulding cycle at Mold °C will be commercially available starting rating the carrier liquid and creating systems and further extend the range comprises the times required for 194.5 Empty in 2018. firm contacts between the powder of applications of metal AM products. tool closing, injection, holding the 194.5 These developments mark particles. Scaffolding structures can pressure, cooling, tool opening and a significant step towards cost be made of a different material to ejection of the component. To a great 184.8 reduction for metal AM components. the product, making them easier to Advances in AM for extent, productivity is determined by 175.2 However, more research and remove than traditional scaffolds and conformal cooling the required cooling time (i.e. pres- 165.5 engineering development is required supports. The manufactured green applications sure hold time plus remaining cooling 155.8 to prove the integrity and reproduc- parts are then sintered to almost full time). Accelerated cooling is therefore 146.2 ibility of materials produced by this density, with a shrinkage between 5 Since the emergence of metal Addi- a key approach for increasing A B 136.5 technology. Dimensional accuracy and 10% linearly, depending on the tive Manufacturing, the toolmaking productivity. For components with 126.8 and surface quality, critical features material. industry has adopted this technology large differences in wall thickness, 117.2 of all AM processes, need further XJET claims to have achieved for various industrial applications. the installation of tool inserts with 107.5 improvement. Since the technology is unprecedented detail, excellent Many of these have been reported internal cooling channels produced by 97.9 still very young, significant progress dimensional accuracy and surface in this magazine; perhaps the most Additive Manufacturing is particularly 88.2 in this respect can be expected in the quality in parts produced with this well-known being mould inserts advantageous. 78.5 years to come. technology (Fig. 5). Among the metals with internal cooling channels, for Berger compared three different 68.9 available, 316L stainless steel has injection moulding and pressure injection moulding tool insert designs, 59.2 been processed so far. The speed of casting tools. In its Trade Forum on one in the traditional design with two XJET: inkjet printing for manufacture is reported to be similar Tool, Mould and Fixture Making, the copper pins of 6 mm diameter to help 59.2 metal and ceramic powders to that of other AM technologies RapidTech conference covered this remove the heat faster due to the C D thanks to a multitude of nozzles in the topic and the latest broader develop- high thermal conductivity of copper Fig. 7 Surface temperature of the mould insert 3.5 s after the start of the A new AM technology for metals and printer heads. ments in the sheet metal forming of and two inserts with internal cooling moulding cycle (Courtesy University of Leoben) ceramics was promoted by XJET These examples show that automotive components and body channels made by metal AM (Fig. 6). Ltd., Rehovot, Israel. ‘Nano Particle there is still room for substantial parts. The first AM design presented was Jetting’ uses a slurry of sub-micron innovation in metal AM. It is exciting a single conformal cooling channel metal or ceramic powder particles to see the continued development Optimising cooling channel design with a constant diameter of 2.5 mm. without putting the stability of the was reduced at each branch by the in a carrier liquid as raw material, of such technologies and that new Gerald R Berger, of the University Conformal cooling means that one or component at risk. square-root of 2, starting from 3 mm which is supplied in sealed cartridges. and unconventional ideas are being for Mining, Metallurgy and Materials more cooling channels are designed The second AM design was through 2.12 mm to a minimum Printer heads are used to deposit an realised by researchers. This will in Leoben, Austria, presented his to follow the contour at a constant modelled to mimic the structure of diameter of 1.5 mm. This ratio derives extremely thin layer of particles with lead to more competition among research on the optimisation of distance as close underneath the blood vessels, with several branches from the condition of equal volumetric each print cycle. the various alternatives in metal AM cooling channel design in injection surface of the insert as possible, of channels. The channel diameter flow rate through each channel.

potential for weight reduction; as a result of the trend towards weight reduction in car production, body panels have become ever thinner. In order to achieve sufficient strength and stability, automotive companies have developed a process to harden body parts in the forming press, called press hardening. Rapid cooling of steel sheet of a reasonable size from 1000°C to below 200°C requires an extremely efficient cooling system. This can only be achieved with conformal cooling channels, as demonstrated by Roland Malek of Volkswagen Slovakia. Malek reported on the results of manufacturing a demonstrator body Fig. 8 Forming tool design with conformal cooling (left) and the resulting component (right) (Courtesy Fraunhofer IWU) part by press hardening. Two mould inserts were compared, one with conventionally drilled cooling chan- A constant flow of the cooling Development of an automotive Mathias Gebauer of Fraunhofer nels and one with conformal cooling medium and limited pressure component forming tool Institute for Machine Tools and channels made by Laser Beam differences between the channels Although at first sight they may sound Forming Technology (IWU) in Melting. The two solutions are shown were achieved by keeping equal almost the same as the injection Chemnitz, Germany, has developed in Fig. 9. The upper example has length between the branches as far moulding and pressure casting a sheet metal forming tool with the drilled cooling channels and the as possible. applications mentioned above, the conformal cooling channels made by lower one has the conformal cooling The performance of the investi- technical requirements for sheet Additive Manufacturing. The three tool channels. Temperature profiles of gated cooling concepts was studied metal forming are much more elements which make direct contact the formed sheet with conventional in a series of computer models. demanding. While the temperatures with the component, i.e. punch, die cooling (top) and conformal cooling Fig. 7 shows the calculated surface during injection moulding of polymers and downholder, were all equipped (bottom) are also shown. The insert temperature of the mould insert at are usually less than 200°C and with conformal cooling channels with drilled cooling channels was 3.5 s after the start of the moulding temperatures of about 500°C are (Fig. 8). For economic reasons, a not capable of cooling the part fast cycle for the optimised cooling reached during aluminium pressure hybrid solution was chosen whereby enough for complete martensitic concepts. Images A-D compare two casting, sheet metal forming involves only the functional geometry with the hardening. There was a critical area different insert materials, namely temperatures of about 1000°C for cooling channels was made by Laser in the centre where the maximum steel 1.2343 (A, C) and the copper austenitising the steel sheet. This is Beam Melting and the main body temperature was still 335°C, whilst base alloy AMPCO 83 (B, D) with a then rapidly cooled to below 200°C of the tool elements was made by the part manufactured with conformal higher thermal conductivity than in the press to achieve a martensitic conventional technologies. With this cooling had a maximum temperature steel, and two cooling concepts, the hardened structure. Because of innovative tool solution, the cooling of 177°C. conformal (A, B) and blood vessel the high temperatures involved, the time required to cool the component In the discussion following the cooling channels (C, D). The higher requirements for the mould insert from 1000°C to below 200°C and presentation, an objection was raised thermal conductivity of the copper material are much higher than for the create a martensitic structure could that the few tool steels currently alloy resulted in a marked lowering other applications mentioned above. be reduced from ten to three seconds. available for laser Powder Bed Fusion of the surface temperature, but the Automotive components made Here, conformal cooling is crucial wear relatively quickly under the effect of the blood vessel cooling from high strength steels by sheet to remove the heat fast enough to high pressures and temperatures compared to the conformal cooling metal cold forming pose extremely achieve a martensitic steel. they are exposed to during press was even more pronounced. high challenges on the forming hardening and thus cannot guarantee In the discussion that followed process. Alternatively, direct Car body parts by direct press a sufficient lifetime. Malek agreed and the lecture, a listener commented hardening in the forming press offers hardening suggested that it is the responsibility that the blood vessel solution was higher strength and consequently the Today, car body parts are usually cold of AM machine developers to enable practically problematic because option to save weight by reducing the formed from steel sheet in several the production of tool steels with it would be almost impossible to sheet thickness. Furthermore, parts steps on highly automated stamping higher carbon contents. This would clean the channels once they were can undergo martensitic hardening and press lines. The huge stamping contribute to further industrialisation clogged. A practical application in sections where high strength and and forming tools used represent a of Laser Beam Melting and could be would therefore always prefer wear resistance is required and left major cost factor in the production of a major advancement for the tool- Fig. 9 Demonstrator body part tool cooling designs and sheet temperature cooling channels of a uniform with higher ductility in other sections car bodies. Reducing the thickness making industry, growing the demand profiles for parts made with conventional drilled cooling (top) and conformal diameter over a branched version. by cooling less rapidly. of the steel sheet offers significant for AM systems. cooling channels (bottom) (Courtesy Fraunhofer IWU)

■ Undisputed industry- leading report for 22 consecutive years

■ Estimates and forecasts based on years of hard data Fig. 10 Stealth keys on a build plate exhibited at RapidTech, along with the finished design (Courtesy UrbanAlps)

■ Input and analysis

Start-up Award: security processing except separation from from the largest keys coming out of the the support structure. Fig. 10 shows Metal Injection Moulding: group of experts powder bed a batch of stealth keys prior to Learn more about this removal from the build plate of the net-shape process for AM system. According to UrbanAlps, worldwide During the conference, a Start-up complex components Award was given for a particularly the target price for these keys, innovative business idea relating to when produced at high volumes, is New binder- AM. All companies that entered the approximately €30. based AM competition presented their business The jury stated that it was technology plans to an expert jury, with the especially impressed by this providers make winner receiving €3000. concept because it demonstrates no secret of This year, the jury unanimously the feasibility of mass producing the technology selected Alejandro Ojeda, Co-Founder consumer products by metal AM. debt owed to and Managing Director of Urban UrbanAlps is now seeking three MIM in their Alps AG, Zurich, Switzerland, for pilot customers willing to test the processes, whilst the overlap with the development of a new type of innovative key concept in daily some of the longest established high-security key. The Stealth Key is practice in order to eradicate AM companies has long been similar to conventional high-security any teething problems and prove understood. keys, but incorporates two flat side the usefulness of the stealth key The closer one looks, the more it covers to hide the key profile – the concept. appears that these technologies essential information for unlocking are closely interwoven on a a door – so that it cannot be easily Author number of levels. copied, even using the latest 3D scanners. Other geometrical details Dr Georg Schlieper Learn about the latest MIM Order your report today! to prevent copying can be integrated Harscheidweg 89 applications and business devel- in the design at no extra cost. D-45149 Essen, Germany opments in the PIM International The key, manufactured by Laser Tel. +49 201 712098 magazine, free to downdload Powder Bed Fusion, requires no post- Email: [email protected] from www.pim-international.com wohlersassociates.com

Design for Additive CALL FOR PRESENTATIONS Manufacturing: Increasing part value through intelligent optimisation

Paying the right amount of attention to Design for Additive Manufacturing (DfAM) can make the difference between economic success and failure. When considering Additive Manufacturing for production applications, it is important to consider designing, or redesigning, parts that would otherwise June 17–19, 2018 • San Antonio, Texas be produced using conventional manufacturing. In this case study, Terry Wohlers and Professor Olaf Diegel, both of Wohlers Associates, reveal how Focusing on metal additive manufacturing, this conference industrial mining machine manufacturer Atlas Copco has used DfAM to increase the value of a hydraulic manifold. will feature worldwide industry experts presenting the latest technology developments in this fast-growing field.

Atlas Copco, an industrial tool and fluid flows to the proper ports. Valves Support structures as a key PERSPECTIVES FROM: EXHIBITION: equipment manufacturer headquar- and sensors can also be attached consideration tered in Nacka, Sweden, has been to measure pressures. When using • End Users • Trade Show Featuring Leading AMPM exploring DfAM as it considers the conventional manufacturing, the only One of the most important goals of • Toll Providers Suppliers move from traditional manufacturing way to produce connecting channels designing for metal AM is to reduce • Metal Powder Producers to AM to add value to its products and inside the block is to drill holes from the amount of support material used • Equipment Manufacturers production processes. One application the outside of the block and then plug when printing the part. With metal example is a hydraulic manifold used them so that the internal channels AM, support material is used to • R&D from Academia and Consortia on one of its underground drilling rigs remain. anchor the parts to the build plate (Fig. 1). The company is particularly TOPICS WILL COVER: Manuscripts are optional; however, all interested in using AM to substantially submitted manuscripts will be considered reduce the weight of the manifold’s • Materials parts while improving its functionality. • Applications for the Best AMPM2018 Paper Award. Because the manifold is mounted • Technical Barriers at the end of the rig’s extendable • Process Economics boom arm, reducing its weight could • New Developments add substantial value to the rig’s functionality. A project to redesign this manifold for AM was carried

out by Fredrik Andersson, Magnus Stainless steel Karlberg and Sima Valizadeh of Atlas block Copco, together with Lund University Master of Engineering student Henrik Held in conjunction with: Nilsson, who led development. The hydraulic manifold, currently manufactured by CNC machining, Submit abstracts at AMPM2018.org before November 3, 2017 consists of a block of stainless Machined and drilled steel into which a large number of Plugged holes input and output ports and Metal Powder Industries Federation connecting holes are drilled. They channels 105 College Road East • Princeton, New Jersey 08540-6692 U.S.A. form a number of interconnecting Fig. 1 Top, an Atlas Copco underground drilling rig and bottom, the company’s TEL: (609) 452-7700 • FAX: (609) 987-8523 • E-mail: [email protected] channels through which hydraulic original manifold block design

during printing and to transfer heat away from the parts. This approach reduces the possibility of distortion of the parts from the extreme heat. In particular, it is important to avoid support material in any internal features, such as the channels of the manifold, as this can be difficult or impossible to remove. Typically, any feature that is more than a certain angle from vertical, such as 45° (the exact angle varies depending on the material being printed), will require support material. A wall can be used as a feature of the design to avoid support material while also improving the strength and rigidity of the part. The functionality of the manifold was also improved using the DfAM process. On the original design, the positions of the inlet and outlet ports were determined by the easiest direc- Fig. 2 The hydraulic manifold designed for metal AM with support structures tion from which the holes could be attached drilled, rather than where they would be most suitable for use or assembly. Fig. 4 Top and bottom views of the finished optimised stainless steel AM hydraulic manifold On the redesigned version, the outlet ports were moved to the top surface and only the inlet remained at the The process begins with simpli- bottom surface. This greatly reduced fying the original block design by the overall volume required to install eliminating all drilled holes that are the manifold in the machine. Fig. 2 normally blocked by plugs. These shows the redesigned manifold before holes serve no functional purpose support removal, Fig. 3 shows the other than to allow the creation of manifold after support removal and internal channels. The goal is to Fig. 4 shows the completed manifold. produce the simplest representation Atlas Copco’s redesigned manifold of the block manifold with the actual required minimal amounts of channels for transporting hydraulic support material (Fig. 5). Also, the fluid. It can also be useful, at this required support material was in stage, to add fillets to smooth the Fig. 5 The support material required for the optimised manifold design easy-to-access locations, making it flow of fluid, compared to the original relatively straightforward to remove. straight holes. After being redesigned for metal AM, the manifold’s weight dropped from 14.6 kg to 1.3 kg - a weight reduction Reducing material usage of more than 90%. Once the block design has been suitably simplified, the next step is Understanding the thought to remove the excess material of the processes used through a cube to leave only the pipes that form simplified design the manifold channels. Most CAD software products have a shell func- It is important to consider the overall tion that removes everything except thought process employed in the for a shell of specified wall thickness; redesign of this manifold. One way to in this case, the six outer faces of the examine it is through the step-by-step cube were selected to be removed, design of a simple generic manifold leaving only the internal channel Fig. 3 The hydraulic manifold designed for metal AM with support structures made from a 100 mm3 block of steel structure, with a wall thickness of Fig. 6 Simplified block design manifold showing only the required in and out removed (Fig. 6). 2 mm (Fig. 7). channels

the next step would be to examine Alternatives to support the design from the point of view structures of AM optimisation. Note also that if the sole purpose of this exercise A design option worth considering were to achieve maximum weight is to add a thin wall under each of reduction, the design would now the horizontal channels to entirely be complete, because it uses a eliminate the need for support minimum amount of material. material. The idea is that the added wall becomes the support, as well as a permanent feature of the Part orientation on the part. In Fig. 9, the bottom walls build plate are chamfered at 45° to eliminate the need for support material. Oval An important factor to consider Fig. 7 Manifold design before and after the shell operation on the manifold holes in the walls are instead used at this stage of the design is the block design to reduce weight and eliminate the print orientation, as it will affect need for support material inside the Fig. 10 Material was added to the pipes for subsequent tapping of screw most other design decisions. holes. The result is a design in which threads, with a 45° chamfer to eliminate the need for support material When designing for metal AM, support material is only necessary to one should always design around attach the bottom of the part to the the specific orientation in which build plate. the part will be printed. This is The support walls also provide the above which support material is strated in the Atlas Copco manifold because part orientation impacts functional benefit of added rigidity. required, and the angle beyond which example. By reducing its weight, the direction of anisotropy, surface These walls will counteract some of support material is required. making it easier to manufacture and finish, roundness of holes and the forces generated when fastening In this example, the horizontal improving its functionality through support material. In this case, one the pipes to the manifold and thus pipes have been carefully sized to the use of DfAM, the value of the part could make the decision to print help to minimise the risk of damage. include an inner diameter which was substantially increased. the part with the large diameter Compared to alternatives, the eliminates the need for support pipe in the vertical orientation. If it design in Fig. 9 would require material. This is usually 6-8 mm, were printed with the larger pipe minimal work to remove support depending on the AM system being Authors in the horizontal orientation, the larger diameter pipe would become Olaf Diegel and Terry Wohlers Fig. 8 Support material required by the shelled block design in two different filled with support material, which Wohlers Associates, Inc. print orientations would be difficult to reach and Fort Collins require additional post-processing, “A design option worth considering Colorado 80525 increasing the build time and is to add a thin wall under each of USA amount of material used (Fig. 8). When running the design the horizontal channels to entirely www.wohlersassociates.com through software used to generate eliminate the need for support support structures, such as Magics, we can see that support material material.” is generated between all the horizontal pipes. In the orientation at which the larger diameter pipe material. After using wire EDM or used. Material has been added where is horizontal, support material is sawing to remove the part from the pipes will be tapped for screw threads generated inside this pipe. build plate, a quick shot-peening as a post processing operation. A 45° Both print orientations necessi- operation may be sufficient to finish angle for chamfers has been used tate the removal of support material the surfaces. The part may also to eliminate the need for support after printing and both will require Fig. 9 The optimised design on the left requires minimal support material, as require the tapping of screw threads, material. The weight of the original surface treatment to improve can be seen on the right so material can be added to accom- 100 mm3 block manifold design the finish at the points where the modate this (Fig. 10). in steel is 7.1 kg. In contrast, the support material makes contact optimised design weighs only 600 g - with the part. The print orientation Using the shelled version, it is the horizontal channels to include a weight reduction of nearly 92%. at which the large diameter pipe is much easier to visualise the overall an upwards vertical bend. If so, the Conclusion It is important that approaches horizontal would make it difficult to manifold design. This in turn makes easiest option may be to return to DfAM must be taken consciously. remove the support from inside the it easier to determine whether, to and modify the original block With DfAM, it is important to consider The results are only as good as the pipe. The better print orientation, and how, the part’s functionality design, then redo the shell function. a number of design rules and guide- decisions made about the strategies therefore, is with the large pipe could be improved. In this case, one Alternatively, supposing the design lines. Among them are minimum used to minimise the need for post- positioned vertically. improvement might be to modify is as functionally sound as possible, wall thicknesses, hole diameters processing. This is clearly demon-

Design for Additive Manufacturing: Transforming RF antennas through intelligent optimisation

Additive Manufacturing presents the opportunity to completely rethink a World PM2018 product’s design, transforming its functionality and reducing manufacturing complexity. With the right application and the right approach, the results really can live up to industry buzzwords such as ‘disruptive’ and ‘transformational’. Venue: China National Convention Center In the following article, Optisys LLC reveals how, through intelligent design optimisation, the company has used Additive Manufacturing to develop the next Organizing Committee of World PM2018 Exhibition generation of RF antenna systems for aerospace and defence. IRIS Exhibitions Service Co., Ltd ● Tel: 4000778909 ● E-mail: [email protected] Optisys, based in West Jordan, mindset is still pretty widespread. But and costs through parts consolidation Utah, USA, is a specialist producer we formed our company by identifying in a Ka-band monopulse tracking of innovative radio frequency (RF) a niche market where Additive array. Today the company is antenna systems using Additive Manufacturing is the production developing a full line of customisable Manufacturing. By applying the method from the start. We’re solving antenna feeds and other antenna principles of Design for Additive end-use challenges with it.” products and delivered its first Manufacturing (DfAM), the company’s Earlier this year Optisys revealed commercial products to a customer engineering team can take an the savings possible in weight, time this summer (Fig. 2). antenna assembly that has a hundred parts and consolidate them into just one. Optisys’ CEO Clinton Cathey calls the results of this extreme parts consolidation ‘single-piece assemblies.’ The result is a dramatic reduction in size, weight, lead time and cost while boosting RF performance. Fig. 1 shows an aircraft antenna with an AM antenna feed running horizontally through its centre and an AM Ortho Mode Transducer protruding through the rear; these two components were www.worldpm2018.com optimised through DfAM. “There are not many companies like us that are designing products to take full advantage of AM,” stated Cathey. “Designing antennas for Additive Manufacturing requires a new way of thinking about structures. The early adopters of AM made Fig. 1 Extreme parts consolidation of antenna systems enables reduced size, just prototypes and tooling and that weight, lead time and cost while boosting RF performance

An opportunity to fill an industry void

Cathey and COO Rob Smith came together to form Optisys with a like-minded group of colleagues who share a combined sixty years’ experience in the aerospace systems world which includes RF design, satellite communications (SATCOM), mechanical engineering and Additive Manufacturing. “We had the total package for generating full antenna systems and, with our experience in AM, we saw the potential to put everything together to fill a void in this niche market,” states Smith. The team felt that the AM industry as a whole had a weakness in terms of value-added engineering. “We realised we could be the turnkey provider that adds pre- and post- Fig. 3 Optisys designed and manufactured the one-piece, functional assembly antenna shown on the left by optimising processing to meet exact customer a 100-piece design for AM. As shown on the right, high-frequency electromagnetic field simulations are used to analyse specifications,” Smith explained. and optimise AM antenna designs for maximum RF performance Cathey agreed, stating, “There are certainly plenty of companies that know how to do design, that know rectangular waveguides so critical integrate so many pieces together the parts are combined into a single how to additively manufacture, but for channelling the electromagnetic you can have significant tolerance functional one, they realised they there’s a lot of throwing things over energy carrying the data; these are stack-up and be completely off would be able to reduce lead times the wall between them. You end up joined together via brazing, plunge target.” from months to weeks, cut size and with parts that are intended to be EDM and/or multiple bolted joints. Additive Manufacturing, by weight dramatically and improve costs machined, or designed for traditional Such assemblies can be large and contrast, supported the type of to their customers. manufacturing methods, that don’t long with unique shapes creating systems-engineering approach “Of course, we did testing to take full advantage of Additive internal geometric hazards that can that Optisys’ founders envisioned validate our assumptions and took Manufacturing.” interfere with the flow of the very for building their business. By parts to customers to get their The ability to consolidate parts data the antenna is supposed to viewing an antenna assembly as responses and then tested for with AM was what sparked the idea to convey. “Every single joint, seam or an integrated structure in which all answers to their questions. But we form Optisys, stated Smith. “We had a fastener creates the potential for a high degree of intuition that Additive discontinuity that can result in RF Manufacturing would solve many of losses as the signal travels through the problems we’d been fighting in the antenna,” stated Smith. “Even our past experiences with antenna how tight you make the screws can manufacturing” (Fig. 3). add a lot of variability to this insertion loss - if you don’t do it exactly right you can end up with an inadvertent AM overcomes the antenna at each of your seams.” challenges of conventional Tolerances can also be an issue production when a hundred or more parts are joined together, Smith pointed out. The challenges faced by an antenna “When you have the kind of compli- producer when using conventional cated system you get with a tradition- manufacturing technologies are ally manufactured antenna assembly, numerous, adding both time and you have to inspect each piece part money. There is often a huge number independently, then put them all of parts in a conventional design, together and hope it translates to typically a daunting array of a hundred better overall RF performance. The Fig. 4 Complexity that can affect RF: a drawing of a metal antenna system Fig. 2 Examples of additively manufactured metal antenna feeds customised by or more individual metal components tolerances of each part have to be to be manufactured according to traditional methods. The antenna horn is Optisys and produced in its Concept Laser AM machine (Fig. 4). These include the hollow, very, very exact and by the time you represented by the four square holes at left

simulation using Ansys HFSS software to model the high- frequency electromagnetic field inside the air cavity of the proposed array. Smith explained, “Mike and I go back and forth a bit to identify the air-cavity design that best meets our requirements, then I import that file into SolidWorks to figure out the optimum wall thickness for the aluminium walls that I’ll ‘wrap around’ that air cavity in order to create a design that can be additively manufactured as a single metal assembly.” At this point Smith uses his experience and intuition to create the ideal topology of the design, adding Fig. 6 Optisys CEO Clinton Cathey examines a microwave waveguide ‘single- just enough extra material where piece assembly’ manufactured in the company’s Concept Laser machine needed to create an integrated unit which will manufacture consistently. Fig. 5 Optisys makes antenna feeds such as the one in the centre of this segmented antenna. The black reflector shown, He also adds support structures made by a partner company out of composites, completes this lightweight antenna intended to disassemble and fit into for those features that merit them, a soldier’s backpack. This feed (long structure in the middle) includes an AM polariser that is both cost effective and using Autodesk Within and merging lightweight the result using SolidWorks and Magics. “These integrated support structures stabilise the geometry throughout the build, drawing the had already done enough internal reached 5-15 GHz.” As with all Optisys approach to antenna production; heat away so we don’t get stress testing to convince ourselves that we products, the Ka-band array was however, the company stresses that concentrations in shrinkage loca- were onto something,” stated Cathey. evaluated for both bench and outdoor it is critical to design for AM from the tions, and then provide the entire The biggest discovery during RF range performance. Similar start. “This lets us take advantage system with support when it’s in early evaluations, and the one that designs have passed rigorous vibra- of all the best aspects of Additive operation,” stated Smith. “They also delivered the most convincing value tion testing for ‘military ruggedness.’ Manufacturing, while recognising happen to look pretty cool!” proposition to potential customers, Subsequent Optisys designs have its challenges and designing around was that the smaller size of their reached up to 50 GHz in RF capacity. those,” stated Smith. additively manufactured products Rather than start from a pre- Benefits beyond the build greatly shortened the overall distance conceived geometry, Optisys begins Designing for AM that an RF signal had to travel within with the RF requirements desired for The final design is transferred the system, a huge benefit to antenna The Concept Laser metal AM machine the finished product. “Because AM into Concept Laser’s proprietary Fig. 7 Optisys CBO Janos Opra (left) and COO Rob Smith (right) with antenna performance. used by Optisys provides the build promotes parts consolidation, we manufacturing software, which components produced by AM Extreme accuracy is not necessary quality to achieve such results, Smith have the freedom to work towards drives what Concept Laser calls the for, say, a car antenna, which picks up stated. “I’ve been very happy with its the goal of optimum RF output LaserCUSING® process in the AM signals from 360° around the vehicle. fine resolution, nice surface finish and rather than derived requirements machine. The advantages of Additive “Our competitive advantage is the Contact But the directional, microwave the superior ‘human factor’ element such as individual part tolerances,” Manufacturing carry forward, Smith integration of systems engineering, antennae used for most satellite and of working with these machines. We explained Smith. “Your typical Additive pointed out. “By consolidating design and Additive Manufacturing, all Optisys LLC line-of-sight communications, aircraft felt confident that we can meet the Manufacturing service bureau doesn’t parts, you’ve already designed out customised for this niche application,” 6764 Airport Rd and UAVs operate in the 1-100 GHz type of feature resolutions that we have the RF expertise to achieve assembly and rework. You can easily stated Cathey. “We haven’t even West Jordan, UT 84084 frequency band. In those industries, need with them.” these requirements, so passing tweak an existing design with new pushed the RF boundaries as far USA light weight is highly desirable. Aluminium is the material of inspection is a challenge because the features, and components with fewer as they can go yet so metal Additive Tel: +1 801 664 5595 “We found a sweet spot for Additive preference for a build; it stands up critical geometry is internal and can’t parts require less maintenance and Manufacturing will continue to be Email: [email protected] Manufacturing where the technology better than plastics to environmental be measured directly. Using AM, we service over time.” pivotal in getting us there.” www.optisys.tech provides many benefits and is stresses, from ground level to outer can avoid internal geometry issues With a number of patents pending Cathey has some advice for others also economically advantageous,” space, and has essentially the same and deliver the lowest insertion loss and discussions progressing with looking to capitalise on AM technology; stated Cathey. “With our Ka-band properties as a solid piece of the and the highest RF possible for each leading aerospace companies “I highly encourage people to look monopulse tracking array we tested same material. design.” and academic institutions about closely at Additive Manufacturing and RF frequencies to 30 GHz, which is It could be said that the final For the next step in Optisys’ expanding their portfolio of find other niche markets in which much higher than anyone else was AM process is the easiest stage process the group’s RF expert, Mike antenna-product lines, Optisys is to apply it from the very beginning. doing; other companies have only of Optisys’ systems-engineering Hollenbeck, develops a microwave optimistic about business growth. There’s still a lot to be achieved there.”

AMPM2017: Understanding the impact of powder reuse in metal

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An issue of significant current interest to the AM world, which can potentially impact both the quality and cost-effectiveness of built parts, is whether there is a limit on the number of times that metal powders can be cycled around an AM process. In this article, Dr David Whittaker reviews three presentations on the topic from AMPM2017, the fourth annual Additive Manufacturing with Powder Metallurgy Conference, held in Las Vegas, USA, June 13-15, 2017.

Understanding the effects of and then backfilling with the inert content in the chamber drops to metal powder reuse in laser gas. Builds generally start at a low approximately <10 ppm after the first Powder Bed Fusion oxygen content of <1000 ppm, with the few layers. For the main reported possibility of a starting atmosphere study, builds began at <1000 ppm of <100 ppm if required. The oxygen oxygen content. For titanium powder, The first reviewed presentation on this subject was given by Lucy Grainger (Renishaw plc, UK) and further supported by reference to a Hall flow relevant Renishaw White Paper on the subject. The presentation began by underlining that the properties of the powder, and the machine parameters that are used to process it, are closely related. The chemical and physical properties of the powder are therefore Shape/morphology critical. Join us in California for some serious business Only a small proportion of the powder that is laid down in a build 16 Airbus Defense and Space, Boeing, NASA and the Mayo Clinic are among the speakers already confirmed for the first edition 14 process is actually melted into a 12 of Additive Manufacturing Americas, taking place on 6-8 December in Pasadena. They join exhibitors including Stratasys, GKN component, with most being left 10 8 Sinter Metal, 3DEO, Raise 3D, Aleph Objects (LULZBOT) and Wacker (Aceo3D). unmelted and therefore available for 6 reuse. If unmelted powder was to (%) Volume 4 Shouldn’t you be there too? 2 be considered as contaminated and, 0 0.01 0.1 1 10 100 1000 3000 Additive Manufacturing Americas is the business-to-business trade show for the AM / 3D printing industry, free from the therefore, unfit for reuse, then the Particle size (μm) distraction of consumer-oriented technologies. The show covers the entire advanced design and manufacturing ecosystem cost of additively manufactured parts Density/packing Particle size distribution (PSD) from full AM/3D printing systems, software solutions, scanning and imaging equipment to finishing solutions and material would likely be prohibitive for the vast innovations. majority of applications. Renishaw AM systems use an Be a part of it! Visit www.amshow-americas.com today to find out more. inert argon atmosphere, which is Fig. 1 Important physical properties of metal powders for AM include shape/ generated by first creating a vacuum morphology, particle size distribution (PSD), density/packing and flow [1]

of effects due to powder particles placed directly on top of the remaining 2500 Ti6Al4V grade maximum / % Element type Element being either near the weld pool or powder in the silo. It can also be Grade 5 Grade 23 (ELI) being ejected from the weld pool. topped up during a build with virgin or Grade 5 maximum 2000 Oxygen (O) 0.20 0.13 Physical properties which will have used powder, although for this study an effect on the way a metal powder only used powder was added. Nitrogen (N) 0.05 0.05* behaves within the AM system The way that the argon atmosphere 1500 Interstitial Grade 23 maximum Carbon (C) 0.08 0.08 include: is generated is unique to Renishaw systems. Firstly, a vacuum is created Hydrogen (H) 0.0125 0.0125 • Shape; a spherical morphology in the chamber to remove any air 1000 is preferable compared to / ppm Oxygen Aluminium (Al) 5.5-6.75 5.5-6.5 and moisture. The chamber is then angular or spongy Oxygen 20 builds Alloying backfilled with argon, creating an Vanadium (V) 3.5-4.5 3.5-4.5 500 Oxygen 38 builds • Packing/density inert atmosphere for the build with Some specifications state 0.03% • Particle size distribution (PSD) <1000 ppm O2. This process takes Table 1 Ti6Al4V grade specifications for interstitial and alloying elements [1] approximately 10 min and requires 0 • Flow 600 l of argon. 0 5 10 15 20 25 30 35 40 Powder flow is very important After the build, all unmelted mate- No. of builds when dosing from the silo and for rial is directed into overflow bottles, Fig. 4 Oxygen analysis over two separate reuse studies shows a gradual creating consistent layers across using the integrated glove box located increase in concentration [1] the bed and this is directly affected in the door of the build chamber. by shape, density/packing and PSD. Overflow bottles are then sealed If PSD is too wide or bimodal, the ready for removal from the system. smaller particles will sit in the Overflow bottles filled with unmelted the unmelted powder under argon, within the boundary of grade 23 ELI spaces between the larger particles, powder from the build are directly replacement of the sieved powder and well within the grade 5 boundary. increasing packing and inhibiting connected to the sieve, which is kept into the silo located at the top of the Results from the first study showed flow. If the PSD is too narrow, this under an inert argon atmosphere. An machine and repeating of the cycle all of the powder was within ELI could lead to insufficient packing argon-filled overflow bottle catches Fig. 4 shows the oxygen content limits for oxygen over 20 builds. and pores in the melted part (Fig. 1). the powder as it is sieved and is then results from this and an earlier study, In studies 1 and 2, it was observed In the study, powder flow was used to replace the powder directly starting from a slightly lower oxygen that, when starting with <1000 ppm measured using the Hall funnel back into the silo. level of 800 ppm and comprising oxygen in the chamber, oxygen method. The basis of the experimental twenty builds. Compared to the first pick-up over 20 build cycles was The reported study focused solely study was to start with a single batch on the reuse/recycling of a titanium of virgin powder to fill the silo, to use alloy, Ti6Al4V, which is specified in the same AM250 system throughout, “This was an extreme analysis of two main grades; 23, also known as to carry out routine builds reusing Fig. 2 The Renishaw AM250 system [1] ELI or extra low interstitial, and 5. the powder until there was not powder reuse, as usually the silo would Maximum allowable levels of some enough left to build to the full test be topped up regularly with virgin elements are highlighted in Table 1. sample height, to not add any virgin it is important to have a low oxygen might cause the powders to become In the Renishaw AM250 machine or other powder to the batch at any powder, essentially refreshing the (and nitrogen) atmosphere due to out of specification in terms of these (Fig. 2) used for the reported trials, point, to build standard test samples used powder” the material’s propensity to absorb elements. the powder silo is located at the top to analyse both powder and tensile these gases. The question therefore In terms of physical characteris- of the machine. The advantages of properties over the period of reuse arises as to whether, if reused tics, the powder can be affected in this arrangement are that sieved and to sieve unmelted powder to many times, the cumulative effect a variety of ways, with the majority powder from a previous build can be remove oversized material from each study, the oxygen levels from the 320-360 ppm. In a third study with build before replacing into the silo. second study were generally higher, zero oxygen in the chamber, there In total, thirty-eight AM builds were but the oxygen pick-up rate was was still an oxygen pick-up of around carried out over a period of three similar. A few of the builds crept out 230 ppm (Table 2). It seems likely 1 3 4 2 Remove build plate months. of the ELI maximum range (builds 15, that the source of this oxygen was

This was an extreme analysis of 25, 26, 27 and 33), but all others were H2O from moisture in the powder powder reuse, as usually the silo would be topped up regularly with virgin powder, essentially refreshing Starting atmosphere Δ oxygen pick up after the used powder; this study looked O2 level 20 builds at the most extreme case of never Study 1 < 1000 ppm 365 ppm refreshing the used powder. After the 5 Repeat silo had been filled with virgin metal Study 2 < 1000 ppm 321 ppm powder, the following stages (Fig. 3) Study 3 < 30 ppm 238 ppm Fig. 3 A reuse cycle: 1) build, 2) remove build plate, 3) sieve unmelted powder, 4) replace sieved powder into silo at the contributed to a reuse cycle: AM build, top of the machine [1] removal of the build plate, sieving of Table 2 Oxygen pick-up in the three studies [1]

600 or chamber; this issue is currently 1200 under investigation at Renishaw. Grade 5 and 23 maximum Nitrogen levels (Fig. 5) also showed a 500 1100 gradual increase, staying well within the 500 ppm maximum specification 400 1000 and coming above the 300 ppm Alternative grade 23 maximum maximum specification within the 300 900 last few builds.

PSD was measured using a wet / MPa UTS Nitrogen / ppm Nitrogen 200 800 Nitrogen 20 builds laser diffraction method. Very little UTS Machined surface Nitrogen 38 builds change was observed in the particle 100 size distribution of the powder 700 UTS as built surface (Fig. 6). The difference between 0 the 1st virgin and 38th build powder 600 0 5 10 15 20 25 30 35 40 samples was most significant in 0 5 10 15 20 25 30 35 40 the D10 value, where a very small No. of builds Build change of +1.30 μm was recorded. Fig. 5 Nitrogen analysis over two separate reuse studies shows a gradual D50 and D90 values increased by increase in concentration [1] Fig. 8 Ultimate tensile strength values for the ‘as built’ and machined tensile bars from builds 1, 12, 18, 24, 31 and 38 +1.0 μm and + 0.4 μm respectively. showing an example of each type of pulled bar [1] There was a general tightening in PSD over the reuse cycles, with 60 smaller particles being slowly removed - probably by sintering to Ultimate Tensile Strength (UTS) to dispose of unmelted Ti6Al4V after Investigation of the effects 50 larger particles. This resulted in values did not change significantly. it has been cycled around the AM250 of recycling 316L powder on an increase in the Hall flow of the An increase in 100 MPa from virgin system a limited number of times. 40 consistency and properties powder. The virgin powder required to build 38 can be attributed to the This does, however, depend on the of parts made by Selective 30 a single tap to flow through the Hall increase in oxygen and nitrogen specific requirements of the compo- funnel, while all subsequent powder levels. A comparison between the ‘as nent material properties, in which Laser Melting samples flowed freely. built’ and machined tensile test bars case a stringent blending regime may

Particle size / μm size Particle 20 D10 There was a general increase in is shown in Fig. 8. The machined bars be required for traceability. A further reported study also used a 10 D50 Hall flow speed over the period of gave higher UTS values, which can be The effects of powder reuse may Renishaw AM250 system but focused D90 the reuse. This was probably due to attributed to their smoother surfaces, potentially be different for other on Type 316L austenitic stainless 0 a reduction in the number of smaller with fewer crack initiation points materials, in terms of physical steel powder. This presentation 0 5 10 15 20 25 30 35 40 particles. D50 is compared with compared to the rougher ‘as built’ property effects. However, because came from Martin Kearns (Sandvik No. of builds Hall flow speed in Fig. 7. It is clear samples. However, an alternative titanium has a high propensity to pick Osprey, UK) and was co-authored by Fig. 6 D10, D50 and D90 values for the metal powder over the period of the that, as D50 increases, so does flow explanation could be that the values up interstitial impurities, the pick-up his Sandvik Osprey colleagues Keith reuse study [1] speed, highlighting the relationship for the two different surface finishes rates observed can be thought of as Murray and Mary-Kate Johnston, and between the two powder properties. are a result of measurement error a ‘worst case’ for commonly used Nick Lavery (MACH1 Centre, Swansea However, these changes did not in the cross-sectional area for the metal AM powders. University, UK). 0.8 35 appear to be significant in terms rougher surface. of material parameters or layer Qualitative analysis of powder 0.7 30 spreading. morphology was carried out by Particle size distribution Powder density was measured scanning electron microscopy. The 110 0.6 25 using a helium pycnometer. There virgin powder was highly spherical, 14 100 90 0.5 was little change found in the powder with a moderate level of satellites

1 12 20 from virgin to 38 builds, all values and small particles. It was clear from 80 0.4 being within 99.397-99.158%. the PSD data that smaller particles 10 70 D50 / μm

Flow/sg- 60 15 All tensile bars were heat treated had been removed over the period of 8 0.3 Flow in a vacuum furnace. Bars from the builds and this was also observed 50

D50 10 (%) Volume 6 40 0.2 builds 1, 12, 18, 24, 31 and 38 were in the SEM analyses. Other than the tested. In order to investigate as-built loss of smaller particles, the powder 4 30 0.1 5 surface and machined surface changed very little, staying spherical, 20 2 tensile properties, three of the test with the occasional misshapen 10 0 0 bars from every build were designed particle, most likely ejected from the 0 0 0 10 20 30 40 1 10 100 1000 2000 with an extra 1 mm diameter to allow melt pool or agglomerated next to No. of builds Particle size (μm) for machining, meaning that all six the weld pool. D10 18.2 μm D50 30.2 μm D90 50.4 μm Fig. 7 Powder flow generally increases in speed over the reuse study. As D50 bars conformed to the E8 ASTM The observations from this study increases, so does the flow due to loss of smaller particles [1] standard diameter of 3 mm. suggest that there is no requirement Fig. 9 Particle size distribution data for the original virgin powder [2]

The virgin 316L powder had Parameter Range Build Description Build Description the composition Fe-16.8%Cr- Laser Power (PW) 160-200 (W) L9 Reference array + vertical & horizontal 12.4%Ni-2.3%Mo-0.7%Si-0.7%Mn- 4 Single line plates 18 tensile bars Point Distance (PD) 25-105 (μm) 0.02%C-0.02%P-0.01%S and was processed to the -45+15 µm size 5 Build failed due to insufficient powder dosing 19 L9 Reference array + vertical test bars Hatch Spacing (HS) 70-175 (μm) range by sieving and air classification. L9 Reference array + vertical & horizontal Particle size distribution was as 6 20 Crucibles Exposure Time (ET) 70-150 (μs) tensile bars shown in Fig. 9. Table 3 Parameters investigated in builds 1-3 [2] The powder was processed 7 L9 Reference array + horizontal tensile bars 21 L9 Reference array + vertical test bars through over 30 AM test builds, 90 density cubes at optimal parameter 8 22 L9 Reference array + prototypes producing a range of density cubes settings and tensile test pieces for evaluation. 9 L9 Reference array + horizontal tensile bars 23 Prototypes After each test build, the remaining 1600 90 density cubes at optimal parameter powder was sieved using a 63 µm 10 24 Crucibles mesh in preparation for the next build. settings 1400 Powder samples were taken after 90 density cubes at optimal parameter L9 Reference array + vertical & horizontal 11 25 1200 each build for the characterisation of settings tensile bars particle size distribution, rheology and 12 L9 Reference array + prototypes 26 Prototypes 1000 chemical analysis. Build 1 L25 Array L9 Reference array + vertical & horizontal In builds 1-3, L25 and L9 arrays 13 Crucibles 27 800 Build 1 L9 Array were designed to determine the tensile bars Build 2 L25 Array influence of AM machine parameters 14 L9 Reference array + horizontal tensile bars 28 Prototypes Line speed mm/s 600 Build 2 L9 Array on build densities and to identify the Build 3 L9 Array 90 density cubes at optimal parameter L9 Reference array + vertical & horizontal optimum settings. The investigated 15 29 400 settings tensile bars machine parameters are shown in 200 L9 Reference array + vertical & horizontal Table 3. In Fig. 10, the circle on the 16 L9 Reference array + vertical test bars 30 lower graph shows an inflection, tensile bars 0 where the plateau high density 17 L9 Reference array + vertical test bars 31 L9 Reference array + horizontal tensile bars 0 50 100 150 achieved in the L9 array corre- Table 4 Samples built in Builds 4-31 [2] Laser Energy Density J/mm3 sponded to a laser energy density 3 of 56-60 J/ mm . This was selected as the set of conditions to be run repeatedly as a reference to monitor Fig. 12 the data for the samples 60 Batch A Batch B Batch C the effects of recycling on density in taken from the overflow after each the array. build. Fig. 12 shows more variability 50 100.00% For builds 4-31, the schedule in the D90 values, reflecting the

μm) 40 99.00% of samples built was as defined in presence of small amounts of splats Table 4. For builds 1-14, the powder formed under the laser actions, 30 98.00% used was that remaining from the but these splats were removed 20 initial virgin batch (Batch A). For each time by the sieving to restore ( size Particle 97.00% builds 15-24, the remaining powder effectively a standard starting PSD. was supplemented with an addition of No systematic trends to a coarser or 10 96.00% 66.7% fresh powder from the original finer distribution were observed. 0 Relative Density Relative virgin batch (Batch B). For builds Fig. 13 indicates a very gradual 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 95.00% 25-31, the remaining used material increase in nitrogen and oxygen Build 1 L9 Array was supplemented with an addition of levels throughout the build series. Build Number Build 2 L9 Array 94.00% 31% fresh powder from the original However, the levels of all major D10 D50 D90 Build 3 L9 Array virgin batch (Batch C). alloying elements were reported Fig. 11 Variation in particle size – Position 1 [2] 93.00% Powder sampling was carried as being consistent throughout the 30 40 50 60 70 80 90 100 out at various machine locations, build series. Fig. 14 shows results including from the freshly dosed of assessing powder rheology of tend to rise after powder reuse, as were in tests where the laser focus 3 Laser Energy Density J/mm powder prior to the build, in front samples taken from the freshly flow is compromised. Although the was not optimised. However, once of the overflow after the build, at doped powder prior to a number presented dataset is incomplete, it this focusing issue was addressed, the argon gas outlet after the build of builds, in terms of the basic does not support this view and in a much more uniform and higher and from the machine’s sieve after flow energy (BFE) parameter from fact shows a wide range of values density was achieved. Density measurements by Archimedes Method the build. Fig. 11 shows the particle tests using a Freeman FT4 Torque that is difficult to interpret. The tensile strength data from size distribution data measured on Rheometer. Received wisdom would Initial evaluations of spatial samples built with an optimal laser Fig. 10 Comparative data for builds 1-3 [2] the powder prior to each build and suggest that this parameter should variations in the density of built parts power input of 60-70 J/mm3, shown

160 those seen in other studies. The 800 800 Batch A Batch B Batch C authors drew the following overall 140 700 700 conclusions: 600 600 120 1. 316L stainless steel gas atomised 500 500 500 MPa; 72.5ksi 100 powders can be used effectively 400 400 μm) 80 in Additive Manufacturing to 300 300 produce parts with densities 200 200 60

exceeding 99% (MPa) Strength Tensile 100 (MPa) Strength Tensile 100 40

Particle size ( size Particle 2. Multiple powder reuse (in up 0 0 3 6 7 17 18 21 27 30 31 3 6 7 17 18 21 27 30 31 20 to 30 builds) with periodic 0 rejuvenation of the powder does Build Number Build Number 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 not appear to have a significant Build Number effect on powder characteristics, Vertical Tensile specimen orientation Horizontal machine performance and the D10 D50 D90 quality of built parts Fig. 15 Tensile strength data throughout the build series [2] Fig. 12 Variation in particle size – Position 2 [2] 3. There is some evidence of a gradual increase in O and N levels in Fig. 15, indicate very consistent significant scatter, but the regressed 4. Sieving after each build appears Comparing powder 23 strength levels throughout the build trend lines show no systematic effective in reconditioning the characterisation, 21 series. The built sample surface trend over the 31 build cycles. The powders to remove processing mechanical properties and 19 roughness data (Fig. 16) shows a roughness values were similar to artefacts. microstructures of virgin 17 and highly recycled 304L 15 Nitrogen Oxygen for the EOS M280 Back face 1000 600 13 Batch A Batch B Batch C Batch A Batch B Batch C Ra (micron) Right face 11 950 550 Finally, a presentation from Robin Pacheco (Los Alamos National 9 900 500 Laboratory, USA) focused on an 7 850 450 alternative austenitic stainless steel, 5 Type 304L, this time processed in an 800 400 EOS M280 system. 0 5 10 15 20 25 30 35

750 (ppm) content Oxygen 350 Nitrogen content (ppm) content Nitrogen As an alternative to the use of a Build Number 700 300 relatively expensive powder reconditioning technology such as plasma 1 4 7 10 13 17 20 23 27 31 1 4 7 10 13 17 20 23 27 31 Fig. 16 Surface roughness data throughout the build series [2] spheroidisation, this study was Build Number Build Number aimed at determining the number Fig. 13 Variation in nitrogen and oxygen levels in powder samples from position 1 [2] of reuse cycles that are feasible until powder characteristics and composition, built part mechanical a nitrogen atmosphere, a layer suggest that more oxides are present 1000 properties and overall functionality height of 40 µm with a 67° rotation in the deposited layers. The increase Batch A Batch B Batch C are compromised. In this context, between layers, a contour speed of in O should cause an increase in oxide 950 the highly recycled (HR) powder had 1400 mm/s, a contour power of 140 layer thickness and a consequent been in use for around two years. W and a total build time of 85 hours. increase in absorptivity of the laser 900 The virgin 304L powder used was Chemical analyses of the virgin during building. On the basis of the 850 sieved and classified to the -44+16 and highly recycled powder are measured low P and S contents, µm size range. The AM process given in Table 5. The increases in C solidification cracking would not be 800 used a build temperature of 100°C, and O in the highly recycled powder expected.

750 Basic Flow Energy (mJ) Energy Basic Flow 700 C Cr Cu Fe Mn Mo N Ni O P S Si

650 Virgin 0.011 18.41 0.010 69.8 1.52 0.004 0.055 9.56 0.038 <.005 .002 0.58 Highly 0.015 18.39 0.012 69.8 1.51 0.004 0.053 9.58 0.046 <.005 0.006 0.58 600 Recycled 0 5 10 15 20 25 30 35 Build Number % Diff. 36.36 ↑ 0.11 ↓ 20.00 ↑ 0.00 0.66 ↓ 0.00 3.77 ↓ 0.21 ↑ 21.05 ↑ - 200 ↑ 0.00 Fig. 14 Variation in rheology of powder samples from position 1 [2] Table 5 Chemical analyses of virgin and HR powders (wt.%) [3]

45 100 Oxides, pores and oxides in pores References Total Area Total Area Area Sample Virgin are seen in both powder types, with (μm2) (μm2) (%) 40 Avg. 31 μm 90 Highly recycled a typical size of 5 to 10 µm. These 35 80 [1] Understanding the effects of metal HR - Before MTS 16,943,010 8434.1132 0.0498 70 oxides seemed to be composed powder reuse in laser Powder Bed 30 V – Before MTS 17,039,882 4714.0815 0.0277 60 mainly of Si, Al, Ca and O, with their Fusion, Granger, L. As presented at 25 numbers being slightly higher in Avg. 33 μm 50 the AMPM2017, the Fourth Annual HR – Post MTS 15,464,585 5474.7622 0.0354 20 40 the HR samples (Table 8). However, Additive Manufacturing with Powder

Undersize % Undersize V – Post MTS 15,434,536 3727.0242 0.0242 15 30 there was less than 0.1% oxide/ Metallurgy Conference, Las Vegas, 10 20 pore area in both powder types, USA, June 13-16, 2017, and published Table 8 Oxide and pore levels in parts built from the two powder types [3] 5 10 with almost no oxides/pores being in the Conference Presentations Amount of each size by volume by of each size Amount 0 0 observable in both virgin and HR PDF by the Metal Powder Industries 0 10 20 30 40 50 60 70 80 90 100 builds. Federation (MPIF). In tensile testing, the parts built Average Max Values Diameter (μm) [2] Investigation of the effects of recy- from virgin and HR powders, tested cling 316L powder on consistency and 304L Displacement Load True Strain True Stress Fig. 17 Particle size distributions of powder samples from storage to failure, showed virtually identical (Std Dev) (Std Dev) (Std Dev) (Std Dev) properties of parts made by Selective containers [3] results (Table 9). Dimpling, oxides, Laser Melting, Kearns, M et al. As Virgin 17.34 mm 12.71 kN 0.51 906.35 MPa pores and unfused particles were presented at the AMPM2017, the (0.93) (146.19) (0.02) (2.60) seen in the fracture faces of both Fourth Annual Additive Manufacturing Highly 16.89 mm 12.80 kN 0.50 900.03 MPa virgin and HR builds. with Powder Metallurgy Conference, Recycled (0.85) (130.31) (0.02) (6.17) The PSD of the virgin and HR The comparative flow rates and Very similar microstructures Las Vegas, USA, June 13-16, 2017, powder samples, taken from storage apparent densities of the powder were observed in virgin and HR Table 9 Tensile properties for parts built from the two powder types [3] and published in the Conference containers, are compared in Fig. 17. types and the as-built part densities builds, with a ‘fish scale’ dual Presentations PDF by the Metal The HR powder had a wider PSD, are shown in Table 6. Particle layer primary solidification mode (ferrite Powder Industries Federation (MPIF). possibly caused by agglomerated packing could be more efficient for growing along the austenite). EBSD powders in previous builds being the HR powder due to the smaller, showed that the grains were not [3] Comparing powder broken by the recoater blade. This broken-off particles, yet the agglom- strongly textured. characterisation, mechanical AMPM2017 Conference AMPM2018 seemed a very likely hypothesis, erated particles can impede flow and In conclusion, the differences properties, and microstructures of as the HR powder had a smoother increase inter-particle friction during observed between HR and virgin virgin and highly recycled 304L for the Presentations Additive Manufacturing with Powder exterior than the virgin powder. recoating. powders and built samples were as EOS M280, Pacheco, R. As presented A PDF compilation of presentations Metallurgy - AMPM2018 - will take Pores within the powder particles Mechanical properties in compres- follows: at the AMPM2017, the Fourth Annual from AMPM2017, the fourth annual place in San Antonio, Texas, USA, were observed in both virgin and HR sion for parts built from the two 1. Particle size and distribution Additive Manufacturing with Powder conference focused on Additive from June 17–20, 2018. A Call for powders. powder types are given in Table 7. due to partial fusion, Metallurgy Conference, Las Vegas, Manufacturing with Powder Metal- Papers & Posters has been issued. agglomerate formation and the USA, June 13-16, 2017, and published lurgy is available from the MPIF. www.powdermet2018.org breaking of satellites by the in the Conference Presentations The PDF features 59 technical recoater blade PDF by the Metal Powder Industries Federation (MPIF). presentations and 12 technical 2. A slightly higher number of Powder As Deposited manuscripts presented by world- 304L oxides, pores and oxygen/silicon Flow Rate Apparent Density wide industry experts. It is available Part Density inclusions in deposited HR (ASTM B213 Hall Flow) (ASTM B212) Author for $150 (MPIF members $120). 3. A higher oxygen content in the www.mpif.org Virgin 13.9 s 4.39 g/cc 7.63 g/cc HR powder. Dr David Whittaker Highly Recycled 13.2 s 4.46 g/cc 7.51 g/cc On the other hand, there were no 231 Coalway Road Difference 5.04% 1.6% (HR inc. ) 1.57% significant differences in the two Wolverhampton powder types, in terms of: WV3 7NG, UK Table 6 Comparative flow rates, apparent densities and as-deposited part Tel: +44 1902 338498 1. Microstructures densities for the two powder types [3] Email: [email protected] 2. Particle morphology – the virgin and HR surface roughness difference was only 1 to 2 µm Average Max Values 3. Mechanical properties, with Displacement Load True Strain True Stress 304L (Std Dev) (Std Dev) (Std Dev) (Std Dev) similar average maximum stress and strain to failures, in Download back issues 0.52 mm 18.77 kN 0.15 795.79 MPa Virgin both compression and tension. (0.07) (1.31) (0.02) (38.67) Based on the reported results, it Highly 0.62 mm 19.94 kN 0.19 829.16 MPa free of charge was proposed that highly recycled Recycled (0.09) (0.45) (0.03) (11.02) powder can be used over the range Table 7 Mechanical properties in compression for parts built from the two of two years without compromising www.metal-am.com powder types [3] the AM product.

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126 Metal Additive ManufacturingFOR USERS.| Autumn 2017 BY USERS. © 2017 InovarWWW.AMUG.COM Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 127 CASTING WORKSHOP

Advertising | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | european powder metallurgy association advertisers’ index 3D Systems 32 MUT Heating 52 International 3DEO 65 Nanosteel 14 3DMT 30 Nanoval 68 AddUp 17 NSL 75 Congress & Exhibition Additive Manufacturing Americas 2017 114 nTopology 78 Additive Metal Alloys 58 Ntron 33 Altair 27 Oerlikon Metco 20 AMC Powders 31 OR Laser 11 14 - 18 October 2018 AMPM2018 102 Osaka Titanium Technologies 64 AMPower 57 Praxair Inside front cover Bilbao Exhibition Centre (BEC) Bilbao, Spain AMT 21 Poly-Shape 16 AMUG 126 Pyrogenesis 46 Arcam 22 Raylase 54 Arcast 44 Renishaw 43 Exhibition Stands Now Available Autodesk 8 Sandvik Osprey 24 BASF 49 Simufact 61 Bodycote 72 Sino Europe 66 Blue Power 67 Sintavia 56 First Announcement Now Available BÖHLER 9 Sisma S.p.A. 92 Carpenter 19 SLM Solutions 37 Cetim 23 Tekna Plasma 40 citim 53 Toolcraft 41 Cremer 29 Trumpf 45 Digital Metal 6 United States Metal Powders 39 Ecka Granules - Kymera 10 VBN 47 ECM 55 Voestelpine 71 Elcan 35 Wohlers Associates 101 Elnik Systems 18 World PM2018 108 EOS 13 Erasteel 51 Euro PM2018 Inside back cover ExOne Company Outside back cover Advertising Farsoon Technologies 63 formnext 2017 powered by TCT 80 opportunities GE Additive 4 The magazine for the metal Additive GKN Sinter Metals 60 Manufacturing industry

HC Starck 15 Metal AM is the business-to-business magazine that Hoeganaes Corporation 2 focuses on commercial and technical developments in Hofmann 36 the metal AM industry. Inert 28 As well as featuring the latest business and applications Innstek 77 news, technical developments in the industry will also be Linde AG 59 highlighted, making the magazine the essential resource for part manufacturers and end-users, along with Materials Solutions 34 equipment and material suppliers. Material Technology Innovations 48 Matsuura 69 For more information contact Jon Craxford Advertising Sales Director, Tel: +44 207 1939 749 Metal AM magazine 125 Email: [email protected] MPP Ltd 70

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