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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Session I: “3D Ti – Additive Manufacturing” sponsored by ALD Vacuum Technologies GmbH
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Session I: “3D Ti – Additive Manufacturing” sponsored by ALD Vacuum Technologies GmbH
14:00 - 14:15 Inert Gas Atomization for Metal-AM Powder Production
Laurenz Ploechl ALD Vacuum Technologies GmbH
14:15 - 14:30 Ti based Powders Supply Chain for Industrial Additive Manufacture
Paolo Gennaro GE-Avioaero
14:30 - 14:45 The Use of Metal Powders in Additive Manufacturing, a View into the Associated Machine Technology
Hendrik Schonefeld SLM-Solutions
14:45 - 15:00 Minimizing Contamination in Titanium Gas Atomization
Eric Bono Summit Materials, LLC
15:00 - 15:15 Q & A
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Inert Gas Atomization for Metal Additive Manufacturing Powder
Production
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Irregular vs. Spherical Metal Powder Inert gas atomized powder exhibits always spherical particle shape, whereas metal powder out of alternative production processes (e.g. chemical precipitation, HDH, crushed, ball-milled, etc.) exhibits irregular particle shape.
Powder flowability: good Compactability in uni-axial powder press: poor
Powder processing consequences of spherical powder:
• Consolidation into a PM-semifinished product is more costly with spherical powder, because compaction usually not by simple uni-axial press
• Multiaxial compaction processes (HIP, hot extrusion) are required. This is acceptable where no alternative powders are available (e.g. high-speed steel, Ni-base superalloys, titanium, specialty materials, precious metals)
For novel near-net shape processes (such as MIM, AM) as well as for thermal spray and for shaped-HIP-parts, the spherical powder particle shape is a desired feature due to the better powder flowability
Ti-powder, HDH (source: Ivasishin et.al.)
Ti-power, EIGA (inert gas atomized)
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Inert Gas Atomization Vacuum Induction-melting with or without Ceramic Liner
VIGA EIGA
VIGA Vacuum Induction Melting Inert Gas Atomization EIGA Electrode Induction Melting Inert Gas Atomization
ALD has the capability to combine various vacuum melting technologies with inert gas atomization, which enables the production of superclean metal powders, such as superalloy, titanium, γ-TiAl, zirconium and precious metal powders for Metal Additive Manufacturing (and other consolidation techniques).
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Applications: …where high-cleanliness, spherical metal powder is required, such as:
VIGA Metal Additive Manufacturing Applications/Alloys: PBF (Powder Bed Fusion) and DED (Directed Energy Deposition) Typical Alloys: high-alloy steels, In625, In718, In738, CoCr, precious metal alloys
EIGA Metal Additive Manufacturing Applications/Alloys:
PBF (Powder Bed Fusion) and DED (Directed Energy Deposition) Typical Alloys: TiAl6V4, γ-TiAl, Zr702, precious metal alloys
SLM In718 turbine blade (courtesy of SLM Solutions) EIGA TiAl6V4 powder (courtesy of HZG)
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
VIGA/EIGA Process Data
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
EIGA Process Fundamentals
EIGA atomization of CP-Ti 100mm Ingot (courtesy of HZG)
EIGA atomization of gamma-TiAl 60mm Ingot (courtesy of HZG)
An alloy barstick is fed at constant speed vertically from the top into a conical induction coil A high-frequency electromagnetic field induces Eddy-currents in the barstick which starts to form
a melt film at the conical surface The melt film flows to the cone tip and melt drops separate. A constant melt flow evolves after
start-up and flows vertically into the inert gas nozzle The process enables melting and inert gas atomizing of refractory and/or reactive alloys without
a ceramic liner or cold wall
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
EIGA Process Modelling
ALD has a 3D FEM-model of the standard EIGA coil and cylindrical barstick with conical tip. With this model, we can compute total power induced into barstick [kW], power density in barstick [W/m3],
inductivity [µH] and ohmic resistance [mΩ] of coil-barstick arrangement. Model parameters are feedstock metal, coil current, frequency, barstick cone diameter and cone angle,
barstick immersion into coil
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
EIGA for Large-Scale Ti Powder Production
Barstick diameter: max. ∅ 50mm max. ∅ 100mm
Barstick length: 500 - 1000 mm max. 1000 mm
Batch weight (Ti): 5 – 10 kg 35 kg
Atomization rate (Ti): max. 0.5 kg/min max. 1 – 1.5 kg/min
Batch cycle time: approx. 15 min approx. 45 min
Ar gas flow rate: 8 - 18 m3/min STP 8 – 18 m3/min STP
Nominal power: 60 kW 250 kW
Powder output p.a. max. 70 MT max. 250 MT
CAPEX 1.0 Mio. EUR 1.5 Mio. EUR
EIGA 50-500 (standard type)
EIGA 100-1000 („Large EIGA“ prototype)
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
EIGA Benchmark with other ceramic-free atomization processes PREP (Plasma Rotating Electrode Process)
CICAP (Cold-wall Induction Crucible Atomization Process)
ICPS (Inductively-coupled Plasma Spheroidization)
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+ Flexible alloy and feedstock options including possibility to melt in revert material (scrap, chips)
+ Reasonable fine powder yield
− High energy consumption − Complex machine and process − Safety concerns about potential
water leakage − Ceramic orifice as potential
contamination source − Frequent orifice clogging − Possibility of Ar pores in coarse
particles − Relatively high Ar flow rate
(internal recycling possible)
+ Relatively low Ar flow rate (internal recycling possible)
+ Reasonable fine powder yield
− Relatively high energy consumption
− Less flexible alloy and feedstock options (subject to availabilty of alloy powder)
− Exclusive, proprietary process − Possibility of Ar pores in
coarse particles − Low throughput
+ Low CAPEX + Proven, robust, simple, safe
and economic process + Relatively low energy
consumption + Reasonable fine powder yield + Commercially available plant
and process (by ALD) + Flexible alloy and feedstock
options (cast barstick from CIC, EB or PH furnace or VAR ingot), including possibility to melt in revert material (scrap, chips)
− Possibility of Ar pores in coarse particles
− Relatively high Ar flow rate (internal recycling possible)
− Relatively high energy consumption
− Expensive feedstock (thin Ti wire)
− Less flexible alloy and feedstock options (subject to availabilty of thin wire)
− Exclusive, proprietary process − Possibility of Ar pores in
coarse particles − Possibility of tungsten spitting
off plasma torch electrodes − Today no commercial vendor
of PWAP plant
+ Narrow PSD + No or less Ar pores + Relatively low Ar flow
rate (internal recycling possible)
− Relatively high energy consumption
− Not 100% liquid (slushy) before atomization (anisotropic particles)
− Expensive feedstock (precision-machined ingot)
− Low fine powder yield − Possibility of tungsten
spitting off plasma torch electrodes
− Today no commercial vendor of PREP plant
+ Relatively low Ar flow rate (internal recycling possible)
+ Reasonable fine powder yield
PWAP (Plasma Wire Atomization Process)
EIGA (Electrode Induction-melt Inert Gas Atomization)
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Laurenz Plöchl, Inert Gas Atomization for Metal Additive Manufacturing Powder Production May 19-21, 2014 • Hilton Sorrento Palace, Sorrento, Italy
Thank you for your attention!
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