PROJECT POSSIBILITIES AND AVAILABLE EQUIPMENT

CIAM Pilot Project MeetingStavanger

September 2016

Amin S. Azar1, Olav Åsebø2 ,Erik Andreassen1

1SINTEF Materials and Chemistry, Oslo2SINTEF Raufoss Manufacturing, Trondheim

SINTEF Raufoss Manufacturing ASSINTEF VentureSINTEF NBLSINTEF NordSINTEF Business DevelopmentSINTEF BrasilMoLab

AM core activities in SINTEF

AM Project portfolio

Metal PrintingProsess

CubitalSolider 5600

3D systemsSLA-250

Prod

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Concept Laser

Facts:1814 metal AM machines were sold in the whole world by 2015.

Source: Wohlers Assocoiates, Inc.

Powder based machines in Norway (2016)

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Tronrud Engineering ASEOSINT M280 from EOS250 mm x 250 mm x 325 mmCold building chamberGass atmosphere0.4 kW laser

NTNU GjøvikA2X from Arcam200 mm x 200 mm x 380 mmWarm building chamberVacuum atmosphere3 kW Electron Beam

Promet ASSLM 280 HL from SLM solutions280 mm x 280 mm x 350 mmWarm building chamberGass atmosphere0.4 kW laser

NTNU TrondheimM2 Cusing from ConceptLaser250 mm x 250 mm x 280 mmCold building chamberGass atmosphere0.2 kW laser

Different technologiesGains and losses

Expe

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Design and Modelling

End of part IFeel free to ask questions!

Part IIKPN-MKRAM project and detailed

description of the facilities

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Hyp

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AM is a key enabling technology

Complex geometries (e.g. conformal cooling channels)

Lightweight designs (e.g. by topology optimisation and lattice structures)

Individual variation at (almost) no additional cost

"Game changer" for materials technology

Additive manufacturing – Challenges

■There are several challenges for AM technology, as highlighted in roadmaps andreports:

■ The cost per part is still high compared to traditional processes (but AM should not beconsidered as a "replacement" process).

■ Today, AM based production includes many manual operations, in particular post-processing.

■ Engineers lack knowledge about the AM technologies and how to utilize their advantages.

■ There is no current database of properties of "AM materials" for production use.

■Regarding the mechanical performance of AM parts, the main challenges are related to:

■ limited knowledge about the effective material properties.

o process-microstructure-property relationships, including anisotropy, defects and inhomogeneity.

■Part-to-part consistency.

■Machine-to-machine variation.

■Material-to-material variation.

■Availability of materials.

Additive manufacturing – Challenges

Building AM competence for the Norwegian manufacturing industry

■BIA-KPN MKRAM (2015-2019) "Material Knowledge for Robust Additive Manufacturing"

■ In-depth investigations of specific AM materials and processes to achieve robust and predictable material properties for industrial AM

■Participants:

■GKN Aerospace Norway, Kongsberg Automotive, Nammo Raufoss, OM BE Plast, Sandvik Teeness

■SINTEF, NTNU/Gjøvik, NTNU

BIA-KPN project (2015-2019) Material Knowledge for Robust Additive Manufacturing

■ Focus on powder bed fusion processes and materials that are in progress of industrial implementation:

■ Metals: Maraging tool steel Stainless steel Ni-base super alloy (Inconel)

■ Polymers: Polyamides Reinforced polyamides

BIA-KPN project (2015-2019)Material Knowledge for Robust Additive Manufacturing

• Powder bed fusion as a process in an industrial manufacturing cycle

■Material properties may e.g. be affected by:

■ Differences between powder batches

■ Storage and handling of powder

■ Exposure to repeated process cycles, – sifting & rinsing of powder…

■ Environmental conditions

■ Processing parameters

■ Part orientation in the build chamber

MKRAM: Investigate these effects and develop best-practice guidelines

BIA-KPN Project (2015-2019) Material Knowledge for Robust Additive Manufacturing

■ "Effective" material properties of components made by AM, including repeatability

■ "Materials science" approach:

Process → microstructure → mechanical performance

BIA-KPN project (2015-2019)Material Knowledge for Robust Additive Manufacturing

■Microstructure, mechanical performance, NDE and post-processing

■Mechanical testing (test specimens and real parts)

■Characterization of microstructures and defects Including NDE methods.

■Effect of post-processing operations, e.g.■ Blasting, machining and polishing of critical surfaces■ Annealing – reduction of residual stresses■ Various treatments to manipulate the microstructure and mechanical

properties

CT instruments at NTNU/SINTEF and partner in Austria

BIA-KPN Project (2015-2019) Material Knowledge for Robust Additive Manufacturing

AM Material Densification Process Development

■Material models for FEA , also with failure criteria

■For fatigue crack growth in metals we will explore afracture mechanics concept modelling the additionalcontribution to the crack driving force by materialinhomogeneity.

■Such models can be used to optimize "buildorientation" and layer thickness, and establish designrules for part features in critical applications.

BIA-KPN Project (2015-2019) Material Knowledge for Robust Additive Manufacturing

Summary:■ Establish a "materials technology basis" for selected AM materials and processes■ Establish practical guidelines, e.g. for reducing part-to-part variation

BIA-KPN Project (2015-2019) Material Knowledge for Robust Additive Manufacturing

End of part IIFeel free to ask questions!

Teknologi for et bedre samfunn