Optimization of EBM build processes by localized preheat strategies
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1 Optimization of EBM build processes by localized preheat strategies Fluid Technology and Microfluidics Dipl.-Ing. Philipp Drescher Prof. Dr.-Ing. Hermann Seitz UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK
2 Table of Content Motivation Powder removal Sintering process Parameter variation Porosity mearsurements Mechanical properties Build time Summary Source: Arcam UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 2
3 Motivation Post-processing of parts produced by EBM involves the removal of sintered powder. Problem: Sintering of powder is time consuming Removal of powder is time consuming Removal of powder is sometimes impossible Solution: Modification of post-processing techniques Modification of the sintering process UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 3
4 Powder removal Source: Arcam UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 4
5 Powder removal Source: Drescher, P.; Reimann, T.; Seitz, H.: Investigation of powder removal of net-structured titanium parts made from electron beam melting. Int. J. Rapid Manufacturing, Vol. 4, Nos. 2/3/4, UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 5
6 Sintering process Source: Arcam UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 6
7 Sintering process Source: Arcam UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 7
8 Sintering process What is the purpose of the sintering/preheating process? Soft sintering of the whole powder area (Preheating I). Allows the beam to jump over unmelted powder during the melting steps, without risk of smoke. Helps to maintain the build at elevated temperature. Local powder sintering over the areas to be melted only (Preheating II). Gives smoother melting with reduced risk of fireworks, flaking and smoke UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 8
9 Sintering process Original process: Black area: Build platform Yellow area: Preheating I Red area: Preheating II Blue area: Melt area UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 9
10 Sintering process Modified process: Black area: Build platform Yellow area: Preheating I Red area: Preheating II Blue area: Melt area UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 10
11 Sintering process UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 11
12 Sintering process UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 12
13 Parameter variation Variation of scan speed: mm/s (original) mm/s mm/s mm/s mm/s 9600 mm/s 8600 mm/s (unstable) UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 13
14 Density in g/cm³ Porosity in % Porosity measurements 5 48 Sinter cake at 14.6 m/s 4,5 4 3,5 3 2, ,6 13,6 12,6 11,6 10,6 9,6 8,6 Speed in m/s 40 Density Apparent density Porosity Sinter cake at 9.6 m/s Melted area Linear (Density) Linear (Apparent density) Linear (Porosity) UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 14
15 Compressive strength in MPa Mechanical properties Beam speed in m/s UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 15
16 Compressive strength in MPa Mechanical properties Beam speed in m/s UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 16
17 Mechanical properties UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 17
18 Mechanical properties Properties Tensile Strength (MPa) E-Modulus (GPa) Elongation (%) Reference ± ± ± 0.2 Modified ± ± ± 0.1 Courtesy of Chair of Materials Science, University of Rostock UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 18
19 Build time Build job Duration original (min) Duration modified (min) Time savings (%) Small build Small build Small build Small build Medium build Medium build Large build Large build Large build Large build Average time savings: UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 19
20 Conclusion Powder removal is an issue after the EBM process Modification of sintering parameters as a solution Loose sinter cake for easier removal of residual powder Mechanical properties comparable to original values Improved productivity (~ 20%) Manufacturing of highly porous sinter components UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 20
21 Thank you for your attention! Dipl.-Ing. Philipp Drescher Universität Rostock Lehrstuhl für Fluidtechnik & Mikrofluidtechnik Justus-von-Liebig-Weg Rostock UNIVERSITÄT ROSTOCK FAKULTÄT FÜR MASCHINENBAU UND SCHIFFSTECHNIK 21
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