Quad City Manufacturing Quad City Manufacturing LaboratoryLaboratoryWestern Illinois University Western Illinois University

APPLICATIONS IN DIRECT METAL LASERAPPLICATIONS IN DIRECT METAL LASER MANUFACTURING

James W Sears, PhDExec Director Quad City Manufacturing Laboratory (QCML)Exec. Director – Quad City Manufacturing Laboratory (QCML)

Eric Faierson, PhD and Korby Heinsen

This work is funded under the cooperative agreement W15QKN-11-2-0008 with the Army Research, Development and Engineering Center (ARDEC) and Western Illinois University.

OutlineOutline

Quad City Manufacturing Laboratory Quad City Manufacturing Laboratory Introduction: Where did this come from? History of Metal Deposition History of Metal Deposition

Applications Prototypes: Castings, Metal Injection Molding, Prototypes: Castings, Metal Injection Molding, Qualification hardware Legacy parts V l M f i S Bi M d Low Volume Manufacturing: Sports, Bio-Med, Defense, NASA

Current Applications & Results at QCML Current Applications & Results at QCMLTi, IN 718, Al

Summary Summary

The Quad City AreaQuad Cities (all 17 of us)QCML

The Quad City Area

I-80 QCML

I-88

I-80

John Deere WWHQRock Island Arsenal

I-74

Rock Island Arsenal & QCMLRock Island Arsenal & QCML

Quad City Manufacturing Laboratory(QCML)

h QC i f fi ( 01 (3))The QCML is a Not-for-Profit (501c(3)) Research and Development Company imbeddedResearch and Development Company imbedded

within the R k I l d A lRock Island Arsenal

Joint Manufacturing and Technology CenterJoint Manufacturing and Technology Center

MissionMission The Quad City Manufacturing Laboratory (QCML) The Quad City Manufacturing Laboratory (QCML)

provides integrated manufacturing solutions for the use of titanium, magnesium, aluminum, silicon carbide and other light advanced metal composite materials forother light advanced metal composite materials for Department of Defense and private industry.

The primary mission of QCML is to provide local and The primary mission of QCML is to provide local and regional job creation and retention for the Rock Island Arsenal’s Joint Manufacturing and Technology Center (JMTC) and Quad City companies(JMTC) and Quad City companies.

Assist in application developments through advanced materials processing for incubation of new business formaterials processing for incubation of new business for the Quad City region.

QCML - Vision“The  Technology and Talent Gateway”

Rock Island Arsenal John Deere

QCMLEducator’s Forum

Technology & Process Training

QCMLPrimary Mission

Technology Development

TalentTechnology

Technology & Process TrainingUniversities

Community CollegesSmall Business Incubation

Industry

Titanium PMAdvanced Metal Matrix CompositesNear Net Shape ManufacturingAdvanced Material  ProcessingEfficiency Industry

RIA/JMTC

g

QCMLPartnering

Education

Knowhow

Efficiency

ForwardLooking g

Industry &TechnologyTitanium, Advanced MMCs,

Castings Forgings, Adv. Materials (Nano  Mg  AlMgB  etc )

Innovation

Sustainable

g

(Nano, Mg, AlMgB, etc.),,“Green’ Technologies,

Many more JobsResponsive

Community Business CommunityAlcoaIndustry

yAlcoa

Equipment(Current & Future)

LAM LAM

SPS(Laser Additive Manufacturing)

HIP(Spark Plasma Sintering)

(Hot Isostatic Pressing)

Installed 11/11

DMLM

UAM

(Hot Isostatic Pressing)

(Direct Metal Laser Manufacturing)

UAM

FSW/FSP(Ultrasonic Additive Manufacturing)

Installed 9/16/11

FSW/FSP

IBLC(Internal Bore Laser Cladding)

(Friction Stir Welding/ Friction Stir Processing)

Future 4/12

http://QCML.org8

(Internal Bore Laser Cladding)

Future 4/12

History of Metal Powder Deposition

1910 - Schoop - Spray Metallizing 1940 - Brennan - Spray Metal Strips 1960 - Singer - Spray Rolling, CSD, SSPg p y g, , 1974 - Osprey - Spray Forming 1979 - Breinan - LASERGLAZE™ (UTRC) 1979 Breinan LASERGLAZE (UTRC) 1985 - Hull - Stereo lithography (.stl file) 1991 - Deckard - Selective Laser Sintering (DTM-SLS) 1991 - Deckard - Selective Laser Sintering (DTM-SLS) 1990’s - LPD, DLF™, DMD™, LENS®, LasForm, LAM™,... 1994 DMLS (DMLM) 1994 - DMLS (DMLM) 1997 - EBAM (Electron Beam Additive Manufacturing)

Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing

Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing

( )Applications: (Limited by Imagination)

Prototypes for:Castings, Metal Injection Molding, PM parts

Tooling:Injection Molding (plastic and metal), Die Casting

Legacy parts:Defense, Auto, Collectors, etc

Low Volume Manufacturing:Sports, Bio-Med, Defense, Jewelry, Art, etc

Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing

Part Design:

Important to engage customers early on as possible to design for DMLM.possible to design for DMLM.

Material Selection for ApplicationMaterial Selection for Application

Application dictates post process requirementsApplication dictates post process requirements

Not a tool for everythingNot a tool for everything

DMLM – Titanium (Ti-6Al-4V)DMLM Titanium (Ti 6Al 4V)

Parts:UAV Engine PartsM2 C bi P tM2 Carbine PartsTest Specimensp

Titanium UAV Engine PartsTitanium UAV Engine Parts

Titanium UAV Engine Partsg

Titanium M2 Carbine Parts

http://QCML.org

EOS Ti-6Al-4V PowderEOS Ti 6Al 4V PowderEOS Ti 6Al 4V powderEOS Ti-6Al-4V powder

Mean particle size ~ 33 µmOxygen content – 1400 ppm

As Built Ti-6Al-4V MicrostructureAs Built Ti 6Al 4V Microstructure

LongitudinalTransverse

As Built Ti-6Al-4V PropertiesAs Built Ti 6Al 4V Properties

Hardness (Hv)Transverse Top - 317Transverse Middle- 316

Longitudinal Top - 346Longitudinal Middle - 353o g tud a dd e 353

Fully Annealed Plate - 340Fully Annealed Plate 340

Oxygen Content 1500 ppmOxygen Content 1500 ppm

Post HIP Ti-6Al-4V Microstructures

LongitudinalTransverse

Post HIP Ti-6Al-4V PropertiesPost HIP Ti 6Al 4V Properties

H d (H )Hardness (Hv)Transverse Top - 350Transverse Middle- 351

Longitudinal Top - 347Longitudinal Middle - 348g

Fully Annealed Plate - 340Fully Annealed Plate 340

Oxygen Content ** 2200 ppmOxygen Content 2200 ppm** HIP gas contaminated

Ti-6Al-4V Microstructure (X-ray)Ti 6Al 4V Microstructure (X ray)

600

800

ount

s)

200

400

Inte

nsity

(Co

Hip

0

200

Al6Ti19 - Aluminum TitaniumPre-Hip

AlTiHx - Aluminum Titanium Hydride

10 20 30 40 50 60 70Two Theta (deg)

p

Two-Theta (deg)

DMLM IN718 partp

DMLM IN718 partp

http://QCML.org24

EOS IN 718 Powder

EOS IN 718 powder

Mean particle size ~ 36 µm

As Built IN 718 MicrostructureAs Built IN 718 Microstructure

LongitudinalTransverse

As Built IN 718 PropertiesAs Built IN 718 Properties

Hardness (Hv)Transverse Top - 314Transverse Middle- 312

Longitudinal Top - 325Longitudinal Middle - 323o g tud a dd e 3 3

*T pical hardness of stress relie ed IN 718 is 330 H*Typical hardness of stress relieved IN 718 is 330 Hv

DMLM Al-10Si-0.3Mg PartDMLM Al 10Si 0.3Mg Part

B-52 legacy Al partB 52 legacy Al part

B-52 legacy Al partB 52 legacy Al part

B-52 legacy Al partg y p

EOS AlSi10Mg PowderEOS AlSi10Mg Powder

EOS Al-10Si-0.3Mg powder

Mean particle size ~ 29 µm

As Built Al-10Si-0.3Mg Microstructureg

LongitudinalTransverse

As Built Al-10Si-0.3Mg Propertiesg p

Hardness (R ) Brinell*Hardness (RB) BrinellTransverse - 70 122

Longitudinal - 68 117

*Typical hardness of AL 10Si Mg as listed by EOS is 120 (Brinell)*Typical hardness of AL 10Si Mg as listed by EOS is 120 (Brinell)

What is Next?What is Next?

One issue is the lack of alloys available for One issue is the lack of alloys available for DMLM. The alloys we plan to develop for this technology include but are not limited to:toMagnesium – WE 43 Other Aluminum Alloys 4047 Al bronzeOther Aluminum Alloys – 4047, Al-bronzeTiAl – Ti 48-2-2Other sources of Ti-6Al-4V, IN 625, IN 718Refractory alloysRefractory alloys

SummarySummary

QCML is providing DMLM services, specializing in reactive alloys (Ti, Al, IN 718)y ( , , )

QCML has demonstrated the ability to produce Ti-6Al-4V, Al-10Si-0.3Mg and IN 718 parts6Al 4V, Al 10Si 0.3Mg and IN 718 parts

DMLM offers part complexity without tooling DMLM ideal for: DMLM ideal for:

PrototypesToolingToolingLegacy partsLow Volume ManufacturingLow Volume Manufacturing

Near Net Shape ManufacturingNear Net Shape Manufacturing

NNSM 2012Moline, IL

April 11-13, 2012p ,www.tms.org