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ZEISS 3D ManuFACTLeverage Holistic Quality Assurance and Correlations to improve yield
Challenges:
Ensuring reliability of 3D printed process and parts.
3D printing – additive Manufacturing – is increasingly becoming part of
industrial production chains.
Medical, aerospace and automotive are among the leading industries in
developing applications for additive manufacturing and implementing the
technology.
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• Lead time for part and material development takes very long. Range are years rather than days.
• Once having a developed part in the serial production the quality is not stable because of many unrecognized instabilities in the process chain.
AM todayAt the process development starting point
SPOILER, TODAY:
Donisi, Sven; Rosswag; Efficient and holistic qualification process for new materials in AMThe gap between the number of materials used for conventional manufacturing methods compared to AM is in
the range of thousands when looking at steel for example.
Munk, Alexander; KSB SE & Co. KGaA; Quality assurance in serial AM with focus on SLMOnly by having a stable process chain it is possible to assure the quality of LPBF parts in serial AM.
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Outer and Inner
Structure
Build Defects, Porosity,
Inclusions
Process Characterization
Surface
Characterization
Powder
Characterization
Microstructural Characterization
ZEISS 3D ManuFACTAdditive Manufacturing is a Multiscale Quality Challenge with unique information at each length scale.
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Digital
MIC
Sub-micron
XRM
Widefield
MICConfocal
MICC-SEM FE-SEM
1 μm 700 nm 250 nm 200 nm < 2 nm < 1 nm < 1 nm
•Outer dimensions
•Inner dimensions
•Surface Roughness
Geometry
• Cracks
• Pores
• Inclusions
• Grains
Microstructure
• Defect Characterization
• Powder Quality
Material
CT
3,5 μm20 μm
3D
Sensor
CMM
ZEISS Solution Portfolio for AMIndustry Leading Quality Control Portfolio from µm to nm
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ZEISS 3D ManuFACTThe Holistic Quality Solution for Additive Manufacturing coveringthe whole process chain
Powder and Material Characterization
SEM, CT, LM
In-Process Metrology & Data Analysis
Post Prints Heat Treatmentand Part Removal
CMM, 3D-Scanning
Defect and Inner Structure Inspection
CT, LM
Post Print Material Quality Inspection
SEM, CT, LM
Dimensional and Surface Quality Inspection
CMM, CT, LM, 3D-Scanning
Process Data Statistics and AnalyticsPiWeb, Analysis, correlation tools
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ZEISS AM application centre in ORNLLongterm Investment at Zeiss AM application centre to develop AM know-how
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ZEISS AM application centre in ORNLDuramax HTG, Comet L3D 2, EVO LS15, XB550, Metrotom 800 HR, Versa 620, SmartProof 5, LM Imager.M2M, LM SmartZoom 5, 2x Stereo Stemi305
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From Powder to PerformanceZEISS 3D ManuFACT
Powder and Material Characterization
Light Microscope (LM) Scanning Electron Microscope (SEM)X-Ray Computed Tomography (CT X-Ray)
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Imaging of AM PowderParticle Size DistributionLight Microscope
Light Microscopy image of metal powder Automated segmentation Particle size distribution
▪ Light microscopy offers quick way to assess powder particle size distribution▪ Enables assurance of essential powder quality characteristics
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Imaging of AM PowderHow round and solid is the powder?Scanning Electron Microscope
Fresh powder with open pores Recycled powder with satellites Cross-cut powder with porosities
▪ Scanning electron microscopy offer nanometer level resolution ▪ Evaluation of batches or single particles possible ▪ Focused ion beam (FIB) offers possibility for sample preparation in nanometer scale
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Imaging of AM PowderA205 – Recycled powder X-Ray Microscope
0
200
400
600
800
1.000
1.200
1.400
1.600
Aspect Ratio
Particle diameter
0
200
400
600
800
1.000
1.200
1.400
1.600
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From Powder to PerformanceZEISS 3D ManuFACT
Post Print Heat Treatmentand Part Removal
Coordinate Measuring Machine (CMM)3D Scanning
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Post print heat treatment and part removalBuild → heat → remove
As build
After heat treatment (650°C for 1h in Ar atmosphere)
After removal from build plate
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From Powder to PerformanceZEISS 3D ManuFACT
Defect and Inner Structure Inspection
X-Ray Computed Tomography (CT X-Ray)Light Microscope (LM)
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Defect and Inner Structure InspectionSurface defects, defects in microstructure and inspectionLight Microscope
DelaminationMicro cracks
Fatigue cracks
Part inspectionDefect inspection
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Inner DefectsAL Artefact X-Ray Microscope
Versa scan of gear wheel Analysis of scan Detail scan of ROI
Detail scan of ROI
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Correlative workflow for the determination and analysis of inner defects inadditively manufactured parts
▪ Additively manufactured
gear part
▪ XRM-Scan for non-destructive
determination of inner defects
▪ Correlation of XRM and
FIB/SEM for further investigation
▪ Detailed investigation
of inner defect
▪ Reconstruction of XRM-
volume and localization of
defects
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EDS-element-mapping of abnormality shows Fe, Mn, Cr and Co whereasmatrix consists of Al and Si
EDS-element-map, dispersion of
Al-signal on FIB-crossection
EDS-element-map, dispersion of
Fe-signal on FIB-crossection
EDS-element-map, dispersion of
Mn-signal on FIB-crossection
EDS-element-map, dispersion of
Si-signal on FIB-crossection
EDS-element-map, dispersion of
Cr-signal on FIB-crossection
EDS-element-map, dispersion of
Co-signal on FIB-crossection
Matrix Abnormality
Chemical composition point to H13 tool steel which was used in a previous build job on the manufacturing device
Inclusion in AlSi10Mg most likely due to insufficient cleaning of device prior to build of gear part
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From Powder to PerformanceZEISS 3D ManuFACT
X-Ray Computed Tomography (CT X-Ray)Scanning Electron Microscope (SEM)Light Microscope (LM)
Post Print Material Quality
Inspection
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Analysis of Grain StructureMicrostructure FormationLight Microscope
Microstructure vertical to the build direction
Microstructure along the build direction
Bau
rich
tun
g
Hatch distanceHatch width
Laye
r th
ickn
ess
Build
dir
ecti
on
Image courtesy of University Aalen
Laser beam
2mm
500µm
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Analysis of Grain StructureAdditive Manufactured Parts
Fig. 2: AlSi10Mg, crossection transverse to build direction a) Light microscopic, brightfield contrast, lattice-like
laser structure is visible; b) EBSD-Mapping, individual grains colored, laser structure not visible.
a) b)
Fig. 1: View inside the SEM chamber with
inserted EBSD-camera and 70° tilted
specimen.
Grain distribution
and orientation in
EBSD (b)
independend from
laser track and
cellular structure (a)
LM, Laser tracks Same area EM, EBSD
Fig. 3: AlSi10Mg, crossection transverse to build direction, a) Light microscopic, brightfield contrast, cellular
structure, fine Si-eutectic in Al-rich matrix; b) EBSD-Mapping, individual grains colored, crystal formation does not follow cellular microstructure.
a) b) Same area EBSDLM, Zoomed in
cellular structures
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In a typical DCT experiment, the source, sample, and detector are placed in a
symmetric Laue geometry; then, during sample rotation, the polycrystallinity of
the sample will give rise to diffraction spots on the detector plane as and when
different grains satisfy the Bragg condition. By tracking the motion of these
diffraction spots during sample rotation, the grain structure can be reconstructed
in 3D.
Learn more: S.A. McDonald et al., Scientific Reports (2015) 5:14655
C. Holzner, et al., Microsc. Microanal. 22, 1970-1971 (2016).
https://www.zeiss.com/microscopy/int/local-content/labdct.html
LabDCTDifraction Computer Tomography in the lab: understanding 3D crystallography
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3D grain analysis together with defect detectionCorrosion propagation along grain boundariesCT
Several inclusions fall on grain boundaries as identified by the
Lab DCT and absorption data.
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From Powder to PerformanceZEISS 3D ManuFACT
Light Microscope (LM)X-Ray Computed Tomography (CT X-Ray)Coordinate Measuring Machine (CMM)3D Scanning
Dimensional and Surface
Quality Inspection
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Surface Metrology Ti-6AI-4V – As built X-Ray Microscope, Light Microscope
Confocal
µm
-50
0
50
100
150
XRM
µm
-50
0
50
100
150
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Surface Metrology Ti-6AI-4V – After sand blastingX-Ray Microscope, Light Microscope
µm
-10
-5
0
5
10
15
20
Confocal
µm
-10
-5
0
5
10
15
20
XRM
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Comparison of roughness measured with Light Microscope and X-Ray Microscope delivers very similar results
µm
-10
-5
0
5
10
15
20
µm
-50
0
50
100
150
After sand blastingAs built
µm
-50
0
50
100
150µm
-10
-5
0
5
10
15
20
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MeasurementNominal
ValueRun 1 Run 2 Run 3 Average Delta
Diameter -Outside
Cover2.0000 2.0010 2.0010 2.0010 2.0010 0.0010
Radius of the
handle0.4300 0.4344 0.4344 0.4343 0.4344 0.0044
Width of the part 4.3550 4.3550 4.3540 4.3550 4.3547 -0.0003
Radius of the
internal hole10.5690 0.5690 0.5690 0.5680 0.5687 -0.0003
Radius of the
internal hole20.5690 0.5680 0.5680 0.5680 0.5680 -0.0010
Measurement results of several features with dimensional significance
ORNL test partRepeatability Test
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From Powder to PerformanceZEISS 3D ManuFACT
Process Data Statistics and Analytics
PiWeb + Analytics and Correlation