Metallitulostuksen materiaalit

Transkriptio

1 TEKNOLOGIAN TUTKIMUSKESKUS VTT OY Metallitulostuksen materiaalit Metallien 3D tulostus seminaari Tutkimusalueen päällikkö, tohtori Tarja Laitinen

2 MultiScale Design WHAT? LCA Material DESIGN Revenue System 3D manufacturing Component 2

3 MultiScale Design WHY? LEAN, AGILE, ECOLOGICAL, FAST Life cycle assessment Energy efficiency Recent Raw materials scarcity New manufacturing methods Optimized performance, low cost manufacturing 2025?? Eco-efficient, intelligent design and manufacturing Robust, service oriented business, cost optimized manufacturing 3

4 Talvivaara: 0,22% Ni 0,49% Zn 0,13% Cu 0,02% Co Difference between waste and primary raw material? Mine tailing: 0,28% Ni 0,12% Cu 0,10% Cr Laivakangas: 1,9 ppm Au Photo: Tuulikki Nousiainen MSWI bottom ash: 0,47% Cu 0,38% Zn 0,03% Ni 0,04% Cr Mobile phone PCB: ppm Au ppm Ag 10 27% Cu 1,5 7% Al 1 8% Fe

5 DATA INFORMATION KNOWLEDGE ACTION NEED Multiscale Design IMPACT COST EFFICIENCY Faster R&D cycles Lean, profitable, quality products and services AGILITY Competitive edge over low cost, labour intensive manufacturing Comprehensive phenomena understanding Scenario building Parallel design Less physical prototypes Digital material, design & manufacturing Up to 50 % faster R&D cycle 10 % lower TCO Growing manufacturing industry in Finland ECOLOGY Imperative legal provision Customer demand LCA optimized design process Radical innovations, early stage adaption 5

6 Core competences in material technology in VTT Material efficiency via tailored material and production routes Multiscale material modeling VTT ProperTune TM Performance Properties Structure Processing Powder Piloting Service Materials for 3D printing Coatings Additives, reinforcements 3D metal printing Feasibility studies Design Topological optimisation Printing process Post treatments Performance Materials and structures in service environments Degradation mechanisms Lifetime evaluation Efficient performance, profitable operation Optimised cost per production Sustainable and reliable production 6

7 VTT ProperTune is a computational modeling assisted material design, tailoring and performance evaluation methodology and software platform. Digital presentation of material microstructure Digital presentation of loading conditions Verified industrial data 7

8 Case example: Inconel 625 Performance demands: Fatigue strength Creep strength Non-Ageing Extreme environment durance Smooth surface roughness Internal flow channels DIGITAL MATERIAL + DIGITAL DESIGN + DIGITAL MANUFACTURING Atomization of metal powders Layer wise thermal history 3D design, topological optimisation Printed component with supports = PERFORMANCE BASED, OPTIMISED COMPONENT

9 Inconel 625, powder characterization Powder D 10 D 50 D 90 SLM alloy VTT low oxygen sieved -45 µm VTT low oxygen sieved -63 µm SLM, green slot VTT, blue slot More small particles in VTT powder

10 Inconel 625, tensile properties Inconel 625 tensile bars* Yield strength Rp0.2 (MPa) Tensile strength Rm (MPa) Elongation A (%) Hardness HRC 150 kg As manufactured: Inconel 625 commercial SLM powder, horizontal ,5 Inconel 625 commercial SLM powder, Inconel 625 commercial SLM powder, vertical ,3 Inconel 625 powder manufactured at VTT, horizontal ,6 Inconel 625 powder manufactured at VTT, Inconel 625 powder manufactured at VTT, vertical ,8 After stress relieve heat treatment **: Inconel 625 commercial SLM powder, horizontal ,5 Inconel 625 commercial SLM powder, Inconel 625 commercial SLM powder, vertical ,3 Inconel 625 powder manufactured at VTT, horizontal ,9 Inconel 625 powder manufactured at VTT, Inconel 625 powder manufactured at VTT, vertical ,7 * Powder layer thickness 50 µm ** 20 C -> 900 C 5 C/min, hold at 900 C for 60 min. -> cooling in air

11 Inconel 625 Surface roughness Ra 70 Ra 15.8 ± 2.0 µm 90 Ra 9.3 ± 0.7 µm 70 Ra 9.7 ± 2.2 µm 60 Ra 9.2 ± 1.0 µm 60 Ra 25.5 ± 2.5 µm 45 Ra 13.1 ± 2.4 µm 45 Ra 58.7 ± 6.7 µm 40 Ra 14.8 ± 3.3 µm 40 Ra 68.0 ± 9.0 µm Top Ra 6.1 ± 1.0 µm

12 Example: speed, power, hatch width vs. density

13 Example speed, power, hatch width vs. density

14 Inconel 625 Post treatments Conventional machining Abrasive finishing / traditional grinding and polishing Abrasive blasting Abrasive flow machining AFM Magnetic abrasive finishing Shot peening Ultrasonic/electric filing and polishing Centrifugal methods Spindle finishing Electrical discharge machining EDM Laser polishing Chemical etching / polishing Electropolishing Electrolytic plasma polishing Electrochemical brushing REM Isotropic superfinishing (ISF) Electroplating Electroless plating Chemical vapour deposition, CVD

15 Automatic handling and finishing of 3D printed turbine blade Background: real customer case Need Automation of handlig of casting channels or support structures Possibility to add more automatic post-machining AM components: 1. Robot gripper inserts 2. Positioning stand for the blade 3. Turbine blade

16 Commercially available AM metal powders Metal alloys High grade steels Hot work steels Stainless steels Aluminium alloys Nickel base alloys Titanium alloys Cobal-chromium alloys Bronze alloys Precious metal alloys Providers SLM Solutions EOS ConceptLaser LPW Technology Erasteel Höganäs Sandvik Ospray Carpenter Powder Products

17 Hype Cycle for 3D printing, 2015 Source: Gartner (July 2015)

18 Services R&D partner from feasibility review up to total revolution Technology and market surveys Foresight & business landscape Networks and value chains Co-creation with right partners Ideas and feasibility studies Creativity workshops combined with engineering reality Piloting and verification Proof-of-concepts in real life field tests Improving current products and trouble shooting Analyzing & identification of opportunities & problems Visualization of phenomena via modeling Solutions via tailoring materials & production process Design of materials and manufacturing Harder, stronger, more economical, more ecological New and improved manufacturing processes Market potential and technical feasibility Conceptual design Development phase Piloting and verification Production development Mass production 18

19 TEKNOLOGIASTA TULOSTA

20 Hype Cycle for 3D printing,

21 Materiaaleista - EOS

22 Metallisten AM-kappaleiden ominaisuuksista Ovat samalla tavalla jälkikäsiteltävissä kuin muutenkin valmistetut kappaleet Lämpökäsittely, hitsaus, kiillottaminen, poraus, Ominaisuudet riippuvat valmistusparametreistä Staattiset ominaisuudet vastaavat yleisesti ottaen taottua materiaalia ja ovat paremmat kuin valetuissa kappaleissa Nopea jäähtyminen Ei suotaumia Anisotropiaa voi esiintyä (Z-suunta heikoin) Väsymisominaisuudet as fabricated ilmeisesti jonkin verran heikommat kuin taotulla materiaalilla Pinnan laatu Jatkuvasti paranemassa Pintojen työstö vaaditaan usein joka tapauksessa Mikrohuokoisuus HIP-käsittely

23 Hybridivalmistus Matsuura Lumex Avance-25 Jauhepetimenetelmä ja CNC-koneistus DMG Mori Seiki Lasertec 65 Suorakerrostus ja CNC-koneistus HYBRID HST 1000 kone Konseptivaiheessa Hurco Hakenut patenttia USA:ssa Hermlen MPA-menetelmä Teknologia ei myynnissä Olemassa olevien CNC-koneiden täydentäminen suorakerrostuksella LENS Engine Hybrid Manufacturing Technologies AMBIT multi-task system Esim. Mazakin INTEGREX-i-400AM koneessa Fraunhofer IWS

24 Metallitulostimet Suomessa EOS Finland Oy 10+ konetta Käytetään sisäiseen tuotekehitykseen Oulu PMC ja LUT EOSINT M 270 (LUTin kone modifioitu koelaitteisto) Kappalekoko 250x250x215 mm Ajettu EOSin ruostumattomia teräksiä ja maraging-terästä AM Finland Oy VTT Concept Laserin Mlab cusing Kappalekoko 90x90x80 mm Materiaalit: ruostumaton 316L, CoCrW-seos, pronssi, hopea 925, kulta 18 K, valkokulta SLM 125 HL

25 Metallitulostin SLM 125 HL Laite: 1200x1800(2300)x800 mm pit x kork x lev.), 400 kg Kammion koko: 125x125x125 mm Laserlähde: 400W IR kuitulaser Suojakaasu: Typpi/Argon Valmistusparametrit: Säädettävissä Soveltuvuus: Ruostumattomat teräkset, työkaluteräkset, CoCr, Inconel, titaaniseokset, alumiiniseokset, yms.

26 Multiscale modelling methods of powder metallurgical problems

27 VTT Approach from raw materials to component performance Experimental AM design, optimization Hot isostatic pressing (HIP) Raw materials Other posttreatments Gas atomization Post treatments Laser melting Component testing Performance Processing Structure Properties Modelling