APPLICATIONS IN DIRECT METAL …...APPLICATIONS IN DIRECT METAL LASERAPPLICATIONS IN DIRECT METAL...
Transcript of APPLICATIONS IN DIRECT METAL …...APPLICATIONS IN DIRECT METAL LASERAPPLICATIONS IN DIRECT METAL...
Quad City Manufacturing Quad City Manufacturing LaboratoryLaboratoryWestern Illinois University Western Illinois University
APPLICATIONS IN DIRECT METAL LASERAPPLICATIONS IN DIRECT METAL LASER MANUFACTURING
James W Sears, PhDExec Director Quad City Manufacturing Laboratory (QCML)Exec. Director – Quad City Manufacturing Laboratory (QCML)
Eric Faierson, PhD and Korby Heinsen
This work is funded under the cooperative agreement W15QKN-11-2-0008 with the Army Research, Development and Engineering Center (ARDEC) and Western Illinois University.
OutlineOutline
Quad City Manufacturing Laboratory Quad City Manufacturing Laboratory Introduction: Where did this come from? History of Metal Deposition History of Metal Deposition
Applications Prototypes: Castings, Metal Injection Molding, Prototypes: Castings, Metal Injection Molding, Qualification hardware Legacy parts V l M f i S Bi M d Low Volume Manufacturing: Sports, Bio-Med, Defense, NASA
Current Applications & Results at QCML Current Applications & Results at QCMLTi, IN 718, Al
Summary Summary
The Quad City AreaQuad Cities (all 17 of us)QCML
The Quad City Area
I-80 QCML
I-88
I-80
John Deere WWHQRock Island Arsenal
I-74
Rock Island Arsenal & QCMLRock Island Arsenal & QCML
Quad City Manufacturing Laboratory(QCML)
h QC i f fi ( 01 (3))The QCML is a Not-for-Profit (501c(3)) Research and Development Company imbeddedResearch and Development Company imbedded
within the R k I l d A lRock Island Arsenal
Joint Manufacturing and Technology CenterJoint Manufacturing and Technology Center
MissionMission The Quad City Manufacturing Laboratory (QCML) The Quad City Manufacturing Laboratory (QCML)
provides integrated manufacturing solutions for the use of titanium, magnesium, aluminum, silicon carbide and other light advanced metal composite materials forother light advanced metal composite materials for Department of Defense and private industry.
The primary mission of QCML is to provide local and The primary mission of QCML is to provide local and regional job creation and retention for the Rock Island Arsenal’s Joint Manufacturing and Technology Center (JMTC) and Quad City companies(JMTC) and Quad City companies.
Assist in application developments through advanced materials processing for incubation of new business formaterials processing for incubation of new business for the Quad City region.
QCML - Vision“The Technology and Talent Gateway”
Rock Island Arsenal John Deere
QCMLEducator’s Forum
Technology & Process Training
QCMLPrimary Mission
Technology Development
TalentTechnology
Technology & Process TrainingUniversities
Community CollegesSmall Business Incubation
Industry
Titanium PMAdvanced Metal Matrix CompositesNear Net Shape ManufacturingAdvanced Material ProcessingEfficiency Industry
RIA/JMTC
g
QCMLPartnering
Education
Knowhow
Efficiency
ForwardLooking g
Industry &TechnologyTitanium, Advanced MMCs,
Castings Forgings, Adv. Materials (Nano Mg AlMgB etc )
Innovation
Sustainable
g
(Nano, Mg, AlMgB, etc.),,“Green’ Technologies,
Many more JobsResponsive
Community Business CommunityAlcoaIndustry
yAlcoa
Equipment(Current & Future)
LAM LAM
SPS(Laser Additive Manufacturing)
HIP(Spark Plasma Sintering)
(Hot Isostatic Pressing)
Installed 11/11
DMLM
UAM
(Hot Isostatic Pressing)
(Direct Metal Laser Manufacturing)
UAM
FSW/FSP(Ultrasonic Additive Manufacturing)
Installed 9/16/11
FSW/FSP
IBLC(Internal Bore Laser Cladding)
(Friction Stir Welding/ Friction Stir Processing)
Future 4/12
http://QCML.org8
(Internal Bore Laser Cladding)
Future 4/12
History of Metal Powder Deposition
1910 - Schoop - Spray Metallizing 1940 - Brennan - Spray Metal Strips 1960 - Singer - Spray Rolling, CSD, SSPg p y g, , 1974 - Osprey - Spray Forming 1979 - Breinan - LASERGLAZE™ (UTRC) 1979 Breinan LASERGLAZE (UTRC) 1985 - Hull - Stereo lithography (.stl file) 1991 - Deckard - Selective Laser Sintering (DTM-SLS) 1991 - Deckard - Selective Laser Sintering (DTM-SLS) 1990’s - LPD, DLF™, DMD™, LENS®, LasForm, LAM™,... 1994 DMLS (DMLM) 1994 - DMLS (DMLM) 1997 - EBAM (Electron Beam Additive Manufacturing)
Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing
Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing
( )Applications: (Limited by Imagination)
Prototypes for:Castings, Metal Injection Molding, PM parts
Tooling:Injection Molding (plastic and metal), Die Casting
Legacy parts:Defense, Auto, Collectors, etc
Low Volume Manufacturing:Sports, Bio-Med, Defense, Jewelry, Art, etc
Direct Metal Laser ManufacturingDirect Metal Laser Manufacturing
Part Design:
Important to engage customers early on as possible to design for DMLM.possible to design for DMLM.
Material Selection for ApplicationMaterial Selection for Application
Application dictates post process requirementsApplication dictates post process requirements
Not a tool for everythingNot a tool for everything
DMLM – Titanium (Ti-6Al-4V)DMLM Titanium (Ti 6Al 4V)
Parts:UAV Engine PartsM2 C bi P tM2 Carbine PartsTest Specimensp
Titanium UAV Engine PartsTitanium UAV Engine Parts
Titanium UAV Engine Partsg
Titanium M2 Carbine Parts
http://QCML.org
EOS Ti-6Al-4V PowderEOS Ti 6Al 4V PowderEOS Ti 6Al 4V powderEOS Ti-6Al-4V powder
Mean particle size ~ 33 µmOxygen content – 1400 ppm
As Built Ti-6Al-4V MicrostructureAs Built Ti 6Al 4V Microstructure
LongitudinalTransverse
As Built Ti-6Al-4V PropertiesAs Built Ti 6Al 4V Properties
Hardness (Hv)Transverse Top - 317Transverse Middle- 316
Longitudinal Top - 346Longitudinal Middle - 353o g tud a dd e 353
Fully Annealed Plate - 340Fully Annealed Plate 340
Oxygen Content 1500 ppmOxygen Content 1500 ppm
Post HIP Ti-6Al-4V Microstructures
LongitudinalTransverse
Post HIP Ti-6Al-4V PropertiesPost HIP Ti 6Al 4V Properties
H d (H )Hardness (Hv)Transverse Top - 350Transverse Middle- 351
Longitudinal Top - 347Longitudinal Middle - 348g
Fully Annealed Plate - 340Fully Annealed Plate 340
Oxygen Content ** 2200 ppmOxygen Content 2200 ppm** HIP gas contaminated
Ti-6Al-4V Microstructure (X-ray)Ti 6Al 4V Microstructure (X ray)
600
800
ount
s)
200
400
Inte
nsity
(Co
Hip
0
200
Al6Ti19 - Aluminum TitaniumPre-Hip
AlTiHx - Aluminum Titanium Hydride
10 20 30 40 50 60 70Two Theta (deg)
p
Two-Theta (deg)
DMLM IN718 partp
DMLM IN718 partp
http://QCML.org24
EOS IN 718 Powder
EOS IN 718 powder
Mean particle size ~ 36 µm
As Built IN 718 MicrostructureAs Built IN 718 Microstructure
LongitudinalTransverse
As Built IN 718 PropertiesAs Built IN 718 Properties
Hardness (Hv)Transverse Top - 314Transverse Middle- 312
Longitudinal Top - 325Longitudinal Middle - 323o g tud a dd e 3 3
*T pical hardness of stress relie ed IN 718 is 330 H*Typical hardness of stress relieved IN 718 is 330 Hv
DMLM Al-10Si-0.3Mg PartDMLM Al 10Si 0.3Mg Part
B-52 legacy Al partB 52 legacy Al part
B-52 legacy Al partB 52 legacy Al part
B-52 legacy Al partg y p
EOS AlSi10Mg PowderEOS AlSi10Mg Powder
EOS Al-10Si-0.3Mg powder
Mean particle size ~ 29 µm
As Built Al-10Si-0.3Mg Microstructureg
LongitudinalTransverse
As Built Al-10Si-0.3Mg Propertiesg p
Hardness (R ) Brinell*Hardness (RB) BrinellTransverse - 70 122
Longitudinal - 68 117
*Typical hardness of AL 10Si Mg as listed by EOS is 120 (Brinell)*Typical hardness of AL 10Si Mg as listed by EOS is 120 (Brinell)
What is Next?What is Next?
One issue is the lack of alloys available for One issue is the lack of alloys available for DMLM. The alloys we plan to develop for this technology include but are not limited to:toMagnesium – WE 43 Other Aluminum Alloys 4047 Al bronzeOther Aluminum Alloys – 4047, Al-bronzeTiAl – Ti 48-2-2Other sources of Ti-6Al-4V, IN 625, IN 718Refractory alloysRefractory alloys
SummarySummary
QCML is providing DMLM services, specializing in reactive alloys (Ti, Al, IN 718)y ( , , )
QCML has demonstrated the ability to produce Ti-6Al-4V, Al-10Si-0.3Mg and IN 718 parts6Al 4V, Al 10Si 0.3Mg and IN 718 parts
DMLM offers part complexity without tooling DMLM ideal for: DMLM ideal for:
PrototypesToolingToolingLegacy partsLow Volume ManufacturingLow Volume Manufacturing
Near Net Shape ManufacturingNear Net Shape Manufacturing
NNSM 2012Moline, IL
April 11-13, 2012p ,www.tms.org