Metallipinnoitus pinnoitusmenetelmien mahdollisuudet ainetta lisäävässä valmistuksessa J. Tuominen Tampereen teknillinen yliopisto Materiaaliopin laitos Laser Application Laboratory
Sisältö Yleistä pinnoitusmenetelmistä Laserpinnoitus Jauhe Lanka Hybridimenetelmät Kaupalliset laitteet & sovellukset Materiaalit Komponenttien ominaisuudet Päällehitsaus kaarimenetelmillä CMT Terminen ruiskutus Kylmäruiskutus Edut, rajoitukset Yhteenveto Fusion bond Low dilution (single layer) 2
Classification of coating methods Energy from: High intensity light Combustion gases Kinetic energy Electric arc kj/m 2 : Moder Low Low High 3
Surface engineering Composite solution Sustainable Material efficient Global cladding/overlay welding markets expected to rise from 3.8 to 7.6 billion USD by 2015* * Abakan Inc. Global thermal spraying markets were 7.1 billion Eur in 2011* * The Linde Group, cladding Global market for AM will reach 3.5 billion USD by 2015* * Wohlers report Let there be light, Genesis 1:3 4
Principle of laser cladding Feedstock material (coating material in the form of powder, wire or strip) is fed to the melt pool created by laser beam Thin layer of base material is melted, which provides fusion bond, low dilution, dense clad layer with excellent properties Several layers on top of each other -> 3D printing 5
Laser cladding methods Powder and carrier gas Laser beam Powder and carrier gas Laser beam Shielding gas Clad layer Shielding gas Clad layer Substrate Substrate 2-step: preplaced powder 1-step: off-axis powder 1-step: coaxial powder 1-step: off-axis hot-wire (tandem) 1-step: coaxial cold-wire 1-step: coaxial hot-wire 6
Industrial laser cladding & applications 1-step: coaxial powder ID cladding On-site cladding Metallic and MMC coatings on metallic base materials Main benefits: Fusion bond Low dilution Low distortion Industrial cladding with 3-6kW lasers & powder feedstock: Low deposition rates (1-2 kg/h) Low material efficiency (~70%) New components / Remanufacturing (50/50) 7
High power laser cladding Inconel 625: 15 kw, 1 m/min, 15 kg/h (500 mm 3 /s) New world record!!! 8
Induction assisted laser cladding Without induction With induction Stellite 12 on M238 mould steel (646 x 230 x 196 mm 3 ) Fully closed-loop cladding process J. Tuominen, TUT Chromalloy Gas Turbine Corp, USA Stellite 20 on AISI 1045 F. Brückner, Fraunhofer IWS 9
Laser cladding cell 10
Process variables affecting the outcome 11
Kaupalliset laitteet (jauhe) HC-254 (Huffman) LENS 850-R (Optomec Inc.) DMD 505 (DM3D Inc.) EasyCLAD (BeAM) RPM s 557 (RPM Innovations Inc) 1 5 kw fiber, disc or diode laser 5-axis CNC machine Several powder hoppers Working volume 900 x 1500 x 900 mm 3 Max component weight 200 300 kg Controlled atmosphere (O 2 10ppm, H 2 O<50ppm) Closed-loop process control Software to create tool path from 3D CAD data Powder is recycled Track width 0.5 5 mm Up to 50 mm 3 /s 12
Yhdistelmäkoneet (AM + subtractive) DMG Mori: Lasertec 65 3D Optomec Lens + Fadal CNC mill 13
Yhdistelmäkoneet (AM + subtractive + laser microprocessing) Laser marking MAZAK INTEGREX i-400am 14
Yhdistelmäkoneet (AM + subtractive + inspection with touch probe + laser microprocessing) Hybrid Manufacturing Technologies 15
Sovellusesimerkkejä Pituus 600 mm Airfoil (siipiprofiili) Inconel 625 NRC-CNRC Laskutelineen osa Ti6Al4V alloy AeroMet Corp. 16
Sovellusesimerkkejä DMG Mori Efesto Aihio Suorakerrostus Jälkityöstö 17
Sovellusesimerkkejä Manufactured by DMD method Hip implant manufactured by LENS method Ti alloy Femoral component Manufactured by DMD method 18
Materiaalit Hardfacing alloys (Stellites, Tribaloy, Norem, Nanosteel, Self-fluxing alloys, Nistelle, Nucalloy) Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-cr NiCr) Tool steels (P20, M4, H13, CPM 10V) Stainless steels (316L, 254SMO, 420, 17-4 PH, duplex) Hadfield-steels (12-19%Mn, 1.1-1.4%C, 0-2.5%Cr ) Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2) Copper alloys (CuAl, CuNi, CuSn) Aluminium alloys (AlSi5 (4043), AlSi10Mg, AlSi12, AlSi7Mg) Metal matrix composites (WC/W 2 C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al, synthetic diamonds) Solid lubricants (MoS 2, WS 2, CaF 2, graphite) Intermetallics (Cr 13 Ni 5 Si 2, MoSi 2, FeAl, NiTi) Gradient layers (FGM) (metal matrix composites, monolithes) Nanostructured and amorphous alloys, intelligent materials High entropy alloys (development of new alloys) 19
IN-625 microstructure Lähde: IMTI National Research Council Canada 20
Mechanical properties (static) Complex thermal history (directional heat extraction, repeated melting & rapid solidification, repeated solid state transformations) Reduced grain size due to high solidification rates Directionally solidified structures Anisotropic mechanical properties Lähde: IMTI National Research Council Canada Lähde: IMTI National Research Council Canada 21
Mechanical properties (dynamic) 22
Corrosion resistance High cooling rates reduce partitioning Corrosion properties close to wrought alloys and better than cast structures Lähde: IMTI National Research Council Canada 23
Dimensional accuracy & surface finish Lähde: IMTI National Research Council Canada 24
Laser wire cladding & additive manufacturing University West, Trollhättan Fraunhofer IPT, Aachen Main benefits over powder: Material efficient (100%) Clean Possible to heat by resistive heating Chemically cleaner feedstock Less contamination during processing Cheaper than powder Tubular wires more challenging 25
Coaxial wire laser cladding & additive manufacturing Precitec Mitsubishi Cavipro Fraunhofer IWS HighYAG/IWS 26
Coaxial hot-wire laser cladding & additive manufacturing Duplex: 3.5kW, 4m/min, 250A, 7V, 5kg/h (150 mm 3 /s) Main benefits: High process stability Less parameters in wire alignment Omni-directional Increased productivity Material efficient 27
Examples of laser wire manufactured parts 28
Laser + arc hybrid cladding & additive manufacturing Arc between two wires 1.4718 steel, 63 HRC 1.8401 steel Laser + MIG/MAG, single wire 1.8401 steel, 38 HRC, 2 kg/h Mild steel Twin wire 10kg/h Main benefits: Low dilution Low heat input Increased productivity Low power capacity laser source (<500W) Stabilization & guidance of electrical arc by laser More stable process 29
Kaupalliset laitteet (EB lanka) Sciaky Inc. Working space 5791 x 1219 x 1219 mm 3 Deposition rate 3 9 kg/h Titanium, Tantalum, Inconel, Stainless steels Closed loop process control 30
Cold metal transfer (CMT) cladding & additive manufacturing Advanced MIG High speed digital control Wire retracted at up to 140Hz Wire motion directly incorporated to electrical contol Max I = 280 A Solid wires up to Ø1.2mm Tubular wires up to Ø1.6mm Single wire, ~5kg/h Twin wire, ~10kg/h Main benefits: Low dilution Low heat input High productivity Material efficient Energy efficient (wall-plug, process) Power by aggregate On-site eligible ID cladding, Ø>100mm Low investments No optical elements Low safety precautions 31
Cold metal transfer (CMT) cladding & additive manufacturing Alloy 625 Refuse incinerators and power stations Boiler walls and pipes (coal, waste, biofuel) (400-550 C) Turbine rotors (hydropower) Ship propellers Mould repair Valves Alloy 625 32
Cold metal transfer (CMT) additive manufacturing α-al primary dendrite (light) 4.1 mm Al/Si eutectic (dark) 50 HV 0.05 11 µm Transverse cross-section of AlSi5 build-up Al Si R a 3.0µm 150 layers 40 mm 3 /s Hypoeutectic AlSi5 (4043) by robotguided CMT process 15 µm Elemental maps of Al and Si 33
Sovellusesimerkkejä Cranfield University Steel/bronze Cranfield University Pelton runners for hydropower stations Cranfield University Stiffened panel / Aluminium Cranfield University Cranfield University 34
Suorakerrostus vs. jauhepeti Ominaisuudet Suorakerrostus Jauhepeti Materiaalit Kappaleiden koko Kappaleiden monimutkaisuus laaja materiaalivalikoima jauhe, lanka kappaleiden/suutinpään käsittelyjärjestelmä rajoittaa rajoittunut Tarkkuus 0.5 mm 0.1 mm rajoittunut (materiaalvalikoima kasvaa nopeasti) prosessikammio rajoittaa lähes rajoittamaton Tuotto 150 mm 3 /s 20 mm 3 /s Alusta 3D-pinta aihio tasainen pinta tasainen aihio Pinnankarheus R z 60 100 µm 10 50 µm Kerrosten paksuus 0.1 2 mm 0.015 0.1 mm Tukirakenteiden tarve Ei Kyllä (ulkonemat) 35
Terminen ruiskutus muodonantomenetelmänä 36
Additive manufacturing by cold spray 37
Ref. Peter Richter Jr, Advanced High Pressure Cold Spray Innovative Technology Playground, North American Cold Spray Conference, Canada, 2014 38
Coaxially laser assisted cold spray COLA (http://www.cola-project.eu/, The European Union 7 th Framework Programme ): new, cost-effective laser-assisted cold-spray technique, for high-quality deposition and repair 39
Yhteenveto Metallien 3D-tulostukseen soveltuvia pinnoitusmenetelmiä ovat: Laserpinnoitus Päällehitsaukseen soveltuvat kaarihitsausmenetelmät (kylmäkaari) Terminen ruiskutus (kylmäruiskutus) Hybridimenetelmät (laserkuumalanka, laser+kaari, laser+ruisku, laser+induktio) Jauhepetimenetelmään verrattuna: Suurempi tuottavuus (isommat kappaleet) Muodonanto jo olemassa olevaan kappaleeseen, korjaus Mahdollisuus yhdistää ainetta lisäävä ja poistava valmistus (esi-, väli-, loppukoneistus) Tukirakenteiden tarpeettomuus Adaptiivinen prosessinsäätö Alhaisempi resoluutio ja mittatarkkuus Alhaisempi pinnanlaatu 40