Metal AM in a Holistic Process Chain

TraCLight Workshop

Additive Manufacturing: Ready for the Future?

Dr.-Ing. Sven Donisi, Managing Director, Rosswag GmbH

Rosswag GmbH

Profile

Edelstahl Rosswag

Biggest open-die Forge in Southern Germany

Rosswag Engineering

Construction, Development and Additive Manufacturing

Philosophy

Connection of our Strengths

Extensive Know-how and innovative Approach

Holistic and internal Process Chain

Edelstahl Rosswag

Integrated Process Chain

Ring rolling and open-die forging

Heat treatment

Postprocessing and Finishing

Quality Assurance and Testing

Unique Variety of Certifications

Special Approvals (e.g. HAF 604 NNSA)

Experience with challenging Certification

Processes

Annually over 30 Audits

Tradition and Innovation

Traditional Forming Processes

with a holistic and

company-internal Process

Chain

Complementing the Process

Chain and extending the

range of Services

Future-oriented manufacturing

Technologies

and innovative Products

Rosswag Engineering

Range of Services

Development, Design and Consulting

Qualification and Production of Metal Powders

Selective Laser Melting

Process Planning, Production and Quality Assurance

Development of the Company

Several Years of Experience with AM

Patents for Components and Processes

Pronounced Innovation Management

Team of over 10 Engineers

Efficiency Increase in Product Development

Savings Potential for Mold and Tool Costs

Experimental Planning with a great Diversity of Variants

Scrum in Product Development

Product Development Process

Design Tool / Form Prototype Validation

Design Prototype Validation Time Savings per Iteration

Freedom and Restrictions of Design

Functionally optimized Components in most Cases not possible with conventional Production Processes

Design of Component Influence on the Process Chain of Production

Ø 70% of total Costs are set during the Design Process

Design

AM-Design

Focus on the Value and Function of the Component

Design Guidelines and Process Restrictions of AM Processes

Paying Attention to Postprocessing

Topology Optimization

Influencing Factors and Production Processes

Heat Treatment Process for Homogenization and Reduction of Residual Stresses

Mechanical Rework on functional Surfaces

Surface Postprocessing and Coating

Finishing Processes

Influencing Factors and Test Methods

Optical and Tactile Measurement technology

Structural Investigations and industrial Computed Tomography (µCT)

Mechanical-Technological Testing

Interpretation of Results

Quality Assurance

Holistic Process Review

Multi-Dimensional link of Design, Material Development, Manufacturing Process, Postprocessing and

Quality Assurance

Overall Pptimum does not result from the Sum of the optimal individual Processes

Smoothing the Interfaces (CAX-Chain, Data Formats, Clamping Systems ..)

Process Linking

„Only the correct Combination of Production Processes, Materials and Quality Assurance Methods makes it possible to produce a good Component.“

Risks and Variety of Standards

No uniform Standards for Metal Powders and Production Equipment Failure of Process or Component

Short Period of Application Few Experiences Limited Base for Standardization

Pseudo-automatic Manufacturing Process with various influencing Variables

Great Dynamics in Process Development

Qualification Issue

Opportunities and Risks

Risk of Component Failure despite careful Process control and Testing

Difficult to identify the Cause of Failure Situation unclear by Law Warranty Issues

Early enforced Standards endanger further Development Check „Process Freeze“

Varying Component Properties due to material Anisotropy and local Defects

Market Launch

Bypass of the Qualification Issue

Production of loaded Geometry Elements using conventional Production Technology

Additive Construction for "uncritical" but complex Geometry Elements

Complementary Connection of the respective, process-related Advantages

Source: Hybrid Manufacturing Technologies

Hybrid for Interim Solution

Additive Structure

Convetional Base Body

ForgeBrid®

Additive Manufacturing of complex Geometries on high-strength, forged Basic Bodies

Optimization of the Joining Zone by Parameter Adjustment

Combination of Load Capacity and Functional Integration

Forge-SLM®-Hybrid

ForgedMicrostructure

Additive Microstructure

Joining Zone

Internal and integrated Value Chain

Hybrid Component Manufacturing from identical Batch of Material

Reuse of the Forging Residues in the Additive Manufacturing Processes

Cross-process Value Creation

Resource Efficiency

Sawing Forging

Atomization

AM-Hybrid

Current Field of Issues

Strongly varying Quality and only rudimentary Standardization

Limited Selection of Materials and Alloys

Low Availability of Parameter Sets for special Applications

Variety of Influencing Factors by the Metal Powder Quality on the Quality of the AM Part

Powder Materials

Powder Testing and Influencing Factors

Chemical Composition, Foreign Body and Hollow Particle Analysis

Particle Size Fractionation and Particle Shape Bulk Density and Flowability

Residual Moisture and Oxygen Consumption

Processability in the AM Process

Quelle: Retsch

Powder Qualification

Optimization for AM Requirements

Close Coupled Atomization

Hot Gas Atomization

High Output Rate due to narrow Particle Size Distribution in the AM-compatible Range

Low Satellite Formation

Quelle: Indutherm

Metal atomization

Melt

Melting Pot

Gas Flow

Metal Drops

Metal Powder

AM Parameter Adjustment

Approach and Interpretation

Thermal Conductivity

Melting Point

Materials Simulation

Energy Input

Influencing Parameters

Laser Power

Hatch Distance

Scan Speed

Layer Thickness

AM Special Materials

Development of new Materials Systems and Special Alloys for AM Applications

Gradation of Component Properties in the Microstructure

Amorphous metal structures by high Self-Quenching Rates in the AM Process

Added Value in the Material - not only in the Part

Material Development

Thank Youfor your attention

Dr.-Ing. Sven Donisi, Managing Director, Rosswag GmbH