Metal Additive Manufacturing | Spring 2017

124 Pages·2017·14.7 MB·English

by  Inovar Communications Ltd.

7 THE MAGAZINE FOR THE METAL ADDITIVE MANUFACTURING INDUSTRY
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METAL AM SOFTWARE FOCUS
EOS: ADDITIVE MINDS
WORLD PM2016 TECHNICAL REPORTS
Published by Inovar Communications Ltd www.metal-am.com
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Making your
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for metal AM
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With Praxair powders, the sky isn’t the limit
Look to Praxair Surface Technologies for the metal
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© Copyright 2017 Praxair S.T. Technology, Inc. All rights reserved.
Publisher & Editorial Offices METAL
Inovar Communications Ltd
2 The Rural Enterprise Centre
ADDITIVE
Battlefield Enterprise Park
Shrewsbury SY1 3FE, United Kingdom
Tel: [phone] MANUFACTURING
Fax: [phone]
Email: [email protected]
www.metal-am.com
Managing Director, Features Editor
Nick Williams
Tel: [phone]
Email: [email protected]
Publishing Director, News Editor
Paul Whittaker
Tel: [phone]
Email: [email protected]
Advertising
Software solutions key to
Jon Craxford, Advertising Sales Director
Tel: [phone]
application development
Fax: [phone]
Email: [email protected]

Production
Hugo Ribeiro, Production Manager When it comes to metal Additive Manufacturing it can be all
Tel: [phone] too easy to overlook the impact that software can have on the
Fax: [phone] success or failure of a new application or venture. Yes, you
Email: [email protected] really want that new machine to get building your part and
Subscriptions there’s no shortage of materials suppliers willing to help fill
Metal Additive Manufacturing is published the build chamber. However, there is a sense that not many
on a quarterly basis as either a free digital new entrants into the industry are fully aware of just how
publication or via a paid print subscription. The much the latest software solutions can help influence the
annual print subscription charge for four issues
development of a component.
is £95.00 including shipping. Rates in € and US$
are available on application.
For newcomers to the industry, the pressures to progress
Accuracy of contents that first application come from all sides. A lack of experience
Whilst every effort has been made to ensure the
works against you and, as time goes by, the inevitable build
accuracy of the information in this publication,
failures have a very high cost. This cost can be in terms of lost
the publisher accepts no responsibility for
machine time, wasted materials, machine damage and, last
errors or omissions or for any consequences
arising there from. Inovar Communications Ltd but not least, a slow but steady erosion of confidence in the
cannot be held responsible for views or claims technology by your colleagues and management.
expressed by contributors or advertisers, which
are not necessarily those of the publisher. In this issue of Metal AM magazine two leading AM software
Advertisements providers, Autodesk and Materialise, explain how their latest
Although all advertising material is expected software solutions help speed up the application development
to conform to ethical standards, inclusion in cycle through distortion simulation and innovative part
this publication does not constitute a guarantee
orientation and support technologies.
or endorsement of the quality or value of
such product or of the claims made by its
It is clear that such software solutions have the potential to
manufacturer.
dramatically reduce the number of build failures in metal
Reproduction, storage and usage
AM and can help make the ‘trial-and-error’ approach to part
Single photocopies of articles may be made
development a thing of the past.
for personal use in accordance with national
copyright laws. All rights reserved. Except as
outlined above, no part of this publication may Nick Williams
be reproduced, modified or extracted in any Managing Director
form or by any means without prior permission
of the publisher and copyright owner.
Printed by
Cambrian Printers, Aberystwyth, UK
ISSN 2057-3014 (print edition) Cover image
ISSN 2055-7183 (digital edition) Metal Additive Manufacturing at
Vol. 3. No. 1 Spring 2017 Materialise’s Bremen production
This magazine is also available for free facility (Courtesy Materialise)
download from www.metal-am.com
© 2017 Inovar Communications Ltd
Metal Additive Manufacturing | Spring 2017 1
MetalAM 2017.pdf 1 2/17/17 3:33 PM
MEDICAL
AEROSPACE
GKN Hoeganaes, a world leader in the development of metal powders, has been the driving force behind
the growth in the Powder Metallurgy industry for over 65 years. GKN Hoeganaes has fueled that growth
with successive waves of technology, expanding the use of metal powders for a wide variety of applications.
AncorTi™
• Spherical Titanium Powder for Additive
Manufacturing
• Particle Size Engineered for Selective
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• Rigorous Quality Testing
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© 2017 Hoeganaes Corporation
Spring 2017 METAL
ADDITIVE
MANUFACTURING
5 35 61 74 87
91 The science behind a basic consumer
Contents
product: Bottle openers by metal AM
In the first of a new series of articles for Metal AM
magazine, Olaf Diegel and Terry Wohlers reveal
how bottler openers demonstrate several key
5 Industry News
concepts that designers need to understand in the
development of parts for production by metal AM.
61 Distortion in metal Additive
Manufacturing: Modelling and mitigation
97 Accelerating AM component design
Autodesk’s Michael Gouge and Pan Michaleris workflow with new optimisation
explain how software can now quickly and
technology
accurately simulate distortion in metal AM,
LimitState’s Prof Matthew Gilbert reveals how a
significantly reducing build failure rates,
new optimisation approach means that engineers
minimising the associated economic impact and
can now directly identify optimised truss forms for
enhancing the technology’s reputation.
AM components, saving time and effort.
73 Materialise Magics: Advanced part
101 Opportunities for AM with water
orientation and support solutions to
atomised metal powders
speed up application development
We review two papers from the World PM2016
Kirsten Van Praet reveals how the latest release of
Congress that assess the viability of the water
the Materialise Magics suite helps users achieve
atomisation process for the production of powders
higher levels of AM production success through
for AM.
advanced part orientation and support solutions.
Advantages of the metal AM process are also
109 Extending the range of materials in
reviewed through various application examples.
Powder Bed Fusion AM
83 EOS GmbH: Transforming companies into We report on papers from the World PM2016
AM champions with Additive Minds Congress that addressed Inconel 625 superalloy
produced by EBM, Metal Matrix Composites
The launch of EOS’s Additive Minds service
with ceramic reinforcement and the Additive
represents a significant expansion of the support
manufacturing of zinc.
that the company can offer to those entering
the industry. We talk Güngör Kara about the
119 Events guide
evolution of metal AM and the changing approach
that customers are taking to implement the
technology. 120 Advertisers’ index
Vol. 3 No. 1 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Spring 2017 33
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| contents page | news | events | advertisers’ index | contact | Industry News
industry news
Renault Trucks: Metal Additive The number of components in
the DTI 5 engine has been reduced
Manufacturing could reduce engine
by 25%, making a total of 200 fewer
weight by 25% parts. Following on from these
successful initial tests, engineers
at Renault Trucks will be continuing
A team of Renault Trucks engineers the creativity of engineers,” added their work on this manufacturing
and designers is looking to metal Lemasson. “This procedure is a process to further increase the
Additive Manufacturing to boost the source of disruptive technology for the performance and functionality of
performance of its engines. The engines of tomorrow, which will be truck components
Renault Trucks Lyon Powertrain lighter and more functional, thereby www.corporate.renault-trucks.
Engineering department has focused offering optimal performance.” com
on using the technology as a future
engine manufacturing process,
resulting in a prototype DTI 5 4 -
cylinder Euro-6 step C engine being
designed exclusively using Additive
Manufacturing.
Renault has reported that rocker
arms and camshaft bearing caps
were manufactured by metal AM and
successfully bench-tested for 600
hours inside a Euro-6 engine.
“The aim of this project is to
demonstrate the positive impact of
metal Additive Manufacturing on the
size and weight of an engine. This
process has enabled us to reduce
the weight of a 4-cylinder engine
The re-designed metal AM version of the rocker arm is shown during a bench
by 120 kg or 25%,” stated Damien
test inside a Euro 6 engine
Lemasson, project manager at
Renault Trucks. “The tests we have
carried out prove the durability of
engine components made using 3D
printing. It’s not just cosmetic.”
Metal Additive Manufacturing is
opening up new opportunities for
engine manufacturers. The process
allows engineers to optimise the
size of parts, reducing the number of
assembly operations and therefore
the number of components in an
engine. In the short-term, this
manufacturing procedure can be
used for highly specific applications
or small runs.
“Additive Manufacturing releases
us from constraints and unlocks The original rocker arm in a Renault Trucks Euro 6 DTI 5 engine
Vol. 3 No. 1 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Spring 2017 5
Pushing your imagination
Höganäs’ proprietary technology Digital Metal® is making great strides into territories
What’s so good
previously ruled by conventional manufacturing technologies. High productivity has
brought our 3D metal printing services into large series production. about it?
• High productivity
However, Digital Metal does not only provide a cost-effective way of manufacturing
• Excellent surface quality
small, complex metal parts not achievable through any other technology. It is also an
• High resolution
ideal solution for the production of mass-customised components, or flexible serial
• Serial production
volumes.
• Mass-customisation
• Repeatability
Every single part in a batch of components can be custom-made, no matter the
number. So, yes, it is time so start thinking beyond imagination.
Inspire industry to make more with less. www.hoganas.com/digitalmetal
| contents page | news | events | advertisers’ index | contact | Industry News
Siemens reports success for turbine blades are made
out of a powder of high
additively manufactured gas
performing polycrystalline
turbine blades nickel superalloy, allowing
them to endure high pres-
sure, hot temperatures and
Siemens has completed its first full load engine tests the rotational forces of the
for gas turbine blades produced entirely using Additive turbine’s high speed opera-
Manufacturing technology. Components were tested at tion. At full load each of these
13,000 rpm and temperatures beyond 1,250°C, with the turbine blades is travelling
company successfully validating multiple AM turbine at over 1600 km/h, carrying
blades of conventional blade design at full engine 11 tons, is surrounded by gas
conditions. at 1250°C and cooled by air
The project team used blades manufactured at at over 400°C. The advanced
its recently acquired Materials Solutions facility in blade design tested in Lincoln
The advanced blade
Worcester, UK. Materials Solutions specialises in high provides improved cooling
design provides improved
performance parts for high temperature applications features that can increase
cooling features
in turbomachinery where accuracy, surface finish and overall efficiency of the
the materials quality is critical to ensure operational Siemens gas turbines.
performance of the parts in service. Siemens extensively uses AM technology for rapid
Tests were conducted at the Siemens testing facility prototyping, but has already introduced serial production
in the industrial gas turbine factory in Lincoln, UK. solutions for components in the gas turbines’ compressor
The company also tested a new blade design with and combustion system. The first AM component for a
a completely revised and improved internal cooling Siemens heavy-duty gas turbine has been in commercial
geometry manufactured using AM technology. “This is operation since July 2016.
a breakthrough success for the use of Additive Manu- www.siemens.com/press/3D-printing
facturing in the power generation field, which is one of
the most challenging applications for this technology,”
stated Willi Meixner, CEO of the Siemens Power and Gas
Division.
“Additive Manufacturing is one of our main pillars in
our digitalisation strategy. The successful tests were
the result of a dedicated international project team with
contributions from Siemens engineers in Finspång,
Lincoln and Berlin together with experts from Materials
Solutions. In just 18 months they completed the entire
chain from component design and AM material develop-
ment to new methods for lifing simulations and quality
controls. With our combined know-how in 3D printing, we
will continue to drive the technological development and
application in this field,” added Meixner.
The blades were installed in a Siemens SGT-400
industrial gas turbine with a capacity of 13 MW. The AM
Siemens tested AM turbine blades of conventional and
advanced blade design
Vol. 3 No. 1 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Spring 2017 7
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