QUALITY ASSURANCE SYSTEMS for PBF and DED

Concepts and Solutions

LAM 2018 Schaumburg/ILThomas Grünberger

plasmo USA LLC2017-08-03

Content

page02

company presentation plasmo

plasmo strategy for AM

quality assurance systems

PBFactual statefuture concepts

DEDconcepts for fullyintegrated QASsystems Building of dental crownes

Material EOS Cobalt Chrome SP2

company

plasmo

quality assurance solutions for automated joining processes.

fast. customized. independent.

100%reliable.

global. focused. independent.

page06

700more than 700 plasmo systems

in operation

100more than 100 global customers

using plasmo

plasmo quality suite.

visualization

correlation

integration

sensors

self-learningsystems.

data correlation

root cause identification

process optimization

our clients

contactus

page010

austriaplasmo Industrietechnik GmbH

Dresdner Str. 81-85

1200 Vienna

phone +43 1 236 26 07-0

fax +43 1 236 26 07-99

www.plasmo.eu

germanyplasmo Industrietechnik

GmbH NL Deutschland

Leitzstr. 45

70469 Stuttgart

phone +49 711 49066-307

fax +49 711 49066-309

www.plasmo.eu

usaplasmo USA LLC

44160 Plymouth Oks Blvd,

Plymouth, MI 48170

phone +1 734 414 7912

fax +1 734 414 5899

www.plasmo-us.com

plasmo strategyfor AM

page011

strong partnership to machine builders

strong partnership to research institutes and scienctific community

integration in our industry 4.0 strategy (IoT)

laser power 10 kW single mode, 1064 nmfocus diameter 50 µmsheet thickness 0.5 mmfeed rate 40 m/s, 5 scans

source: TU Vienna

plasmotechnologies

page012

1D measurement diode based, vis, NIR

2D measurement gray scale imaging, vis, NIR, LWIR

3D measurement (laser triangulation, OCT)

data analysis

quality inspection:the challenge

page013

inputparameters

(plant,machine, process,

part)

outputparameters

(OKNOK, strength, tightness, cosmetic)

measurements(signals, extractedfeatures)

Process development

possiblesolutions

page014

powder bed

fusionPBF

EOSTATEmonitoring suite

page016

EOSTATE Exposure OT

EOSTATE MeltPool

EOSTATE PowderBed

EOSTATE System

EOSTATE Exposure OT and EOSTATE MeltPool

EOSTATE MeltPoolplasmo fastprocessobserver

page017

Laser light

Semi reflective mirror

Spectral filter

F-Theta-Lens

Scanner

Photodiode

Ele

ctro

nics

Ele

ctro

nics

system layout plasmo fastprocessobserver

EOSTATE MeltPoolplasmo fastprocessobserver

page018

system measures process emissions

calculation of features at given positionyields in an image per layer

limits for detecting processirregularities

3 independent characteristicsbased on physics

characteristic brightness as gray value(false color presentation) for one layer

EOSTATE MeltPoolexample process flipping

page019

provoked process irregularity wrong focal position

image of building platformafter complete build

fraction of irregularitiesafter exposure of one layer

EOSTATEExposure OT

page020

system layout EOSTATE Exposure OT

Scanner

EOSTATEExposure OT

page021

overall fusing and cooling behavior detection

camera-based in-process monitoring

holistic view of the melting behavior over the entire platform

MTU-proven tool optimized for QA

integrated melt emission in the NIR range

EOSTATEExposure OT

page022

software workflow oriented and role dependent

operator role

EOSTATEExposure OT

page023

irregularities and also exposure strategies detectable

quality inspectiona new approach

page024

requ

irem

ent a

naly

sis,

def

initi

on o

f dem

onst

rato

rs

Global thermal spatial

simulation & analysis

segmentation

individual process control

individual monitoring

industrial trials, certification

transfer and beta tests

direct energy

depositionDED

quality assurance for DEDconcept

page026

all technologies from one vendor

common dataflow

common data analysis and correlation

Camera

cameras

PRE PROCESS IN PROCESS POST PROCESS

possible technologiessuggested technologies for start

vis and NIR and pyrometer

quality assurance for DEDplasmo processobserver

page027

diode based

detection of process anomalies

layer NOKlayer OK

quality assurance for DEDplasmoeye

page028

camera based

documentation

root cause analysis

visible NIR (SWIR) MWIR, LWIR

quality assurance for DED3Dobserver

page029

triangulation based

absolute measurementlayer per layer

absolute measurement complete part

… missing material

Cross section position

v Layer 1

v Layer 2

v Layer 3

v Layer 4

v Layer 5

v Layer 1

v Layer 2

v Layer 3

v Layer 4

v Layer 5

…missing material

ideal geometry

cross section position

Produce Quality. Always.