metallipinnoitus – pinnoitusmenetelmien mahdollisuudet ... 2015 tuominen.pdf · metallipinnoitus...

Metallipinnoitus –pinnoitusmenetelmienmahdollisuudet ainetta

lisäävässä valmistuksessa

J. TuominenTampereen teknillinen yliopisto

Materiaaliopin laitosLaser Application Laboratory

Sisältö• Yleistä pinnoitusmenetelmistä• Laserpinnoitus

– Jauhe– Lanka– Hybridimenetelmät– Kaupalliset laitteet & sovellukset– Materiaalit– Komponenttien ominaisuudet

• Päällehitsaus kaarimenetelmillä– CMT

• Terminen ruiskutus– Kylmäruiskutus

• Edut, rajoitukset• Yhteenveto

18.9.2015Alihankinta 2015 2

• Fusion bond• Low dilution (single layer)

Classification of coating methods


Energy from:

• High intensity light

• Combustion gases

• Kinetic energy

• Electric arc

kJ/m2:

Moder

Low

Low

High

Surface engineering


§ Composite solution§ Sustainable§ Material efficient

, cladding

”Let there be light”, Genesis 1:3

Global cladding/overlay weldingmarkets expected to rise from 3.8 to7.6 billion USD by 2015*

* Abakan Inc.

Global thermal spraying marketswere 7.1 billion Eur in 2011** The Linde Group

Global market for AM willreach 3.5 billion USD by2015*

* Wohlers report

Principle of laser cladding


Feedstock material (coatingmaterial in the form ofpowder, wire or strip) is fedto the melt pool created bylaser beam

Thin layer of base materialis melted, which providesfusion bond, low dilution,dense clad layer withexcellent properties

Several layers on top ofeach other -> 3D printing

Laser cladding methods


2-step: preplaced powder

Shielding gas

Laser beamPowder andcarrier gas

Clad layer

Substrate

1-step: off-axis powder

Shielding gas

Powder andcarrier gas

Clad layer

Substrate

Laserbeam

1-step: coaxial powder

1-step: off-axis hot-wire (tandem) 1-step: coaxial cold-wire 1-step: coaxial hot-wire

Industrial laser cladding &applications


1-step: coaxial powder On-site cladding

ID cladding

§ Metallic and MMC coatings on metallicbase 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)

High power laser cladding


§ Inconel 625: 15 kW, 1 m/min, 15 kg/h (500 mm3/s)§ New world record!!!

Induction assisted laser cladding


Without induction

With induction

Stellite 12 on M238 mould steel (646 x 230 x 196 mm3)

Chromalloy Gas Turbine Corp, USA

Fully closed-loop cladding processJ. Tuominen, TUT

Stellite 20 onAISI 1045F. Brückner,FraunhoferIWS

Laser cladding cell

18.9.2015Alihankinta 2015 10

Process variables affecting theoutcome

18.9.2015Alihankinta 2015 11

Kaupalliset laitteet (jauhe)

18.9.2015Alihankinta 2015 12

LENS 850-R (Optomec Inc.)EasyCLAD (BeAM)

HC-254 (Huffman)

DMD 505 (DM3D Inc.) RPM’s 557 (RPMInnovations Inc)

§ 1 – 5 kW fiber, disc or diode laser§ 5-axis CNC machine§ Several powder hoppers§ Working volume 900 x 1500 x 900 mm3

§ Max component weight 200 – 300 kg§ Controlled atmosphere (O2≤10ppm,

H2O<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 mm3/s

Yhdistelmäkoneet (AM + subtractive)

18.9.2015Alihankinta 2015 13

Optomec Lens + Fadal CNC millDMG Mori: Lasertec 65 3D

Yhdistelmäkoneet (AM + subtractive+ laser microprocessing)

18.9.2015Alihankinta 2015 14

MAZAK INTEGREX i-400AM

Laser marking

Yhdistelmäkoneet (AM + subtractive+ inspection with touch probe +laser microprocessing)

18.9.2015Alihankinta 2015 15

Hybrid Manufacturing Technologies

Sovellusesimerkkejä

18.9.2015Alihankinta 2015 16

Laskutelineen osa

Ti6Al4V alloy

AeroMet Corp.

Pituus 600 mm

Airfoil (siipiprofiili)

Inconel 625

NRC-CNRC


18.9.2015Alihankinta 2015 17

DMG Mori

Aihio Suorakerrostus Jälkityöstö

Efesto


18.9.2015Alihankinta 2015 18

Hip implant manufactured byLENS method

Ti alloy

Manufactured by DMDmethod

Femoral component

Manufactured by DMDmethod

Materiaalit

18.9.2015Alihankinta 2015 19

• 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/W2C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al,

synthetic diamonds)• Solid lubricants (MoS2, WS2, CaF2, graphite)• Intermetallics (Cr13Ni5Si2, MoSi2, FeAl, NiTi)• Gradient layers (FGM) (metal matrix composites, monolithes)• Nanostructured and amorphous alloys, intelligent materials• High entropy alloys (development of new alloys)

IN-625 microstructure

18.9.2015Alihankinta 2015 20

Lähde: IMTI National Research Council Canada

Mechanical properties (static)

18.9.2015Alihankinta 2015 21


§ Complex thermal history (directional heat extraction, repeated melting & rapid solidification, repeated solidstate transformations)

§ Reduced grain size due to high solidification rates§ Directionally solidified structures§ Anisotropic mechanical properties


Mechanical properties (dynamic)

18.9.2015Alihankinta 2015 22

Corrosion resistance

18.9.2015Alihankinta 2015 23


§ High cooling ratesreduce partitioning§ Corrosion properties

close to wrought alloysand better than caststructures

Dimensional accuracy & surfacefinish

18.9.2015Alihankinta 2015 24


Laser wire cladding & additivemanufacturing

18.9.2015Alihankinta 2015 25

University West, Trollhättan

§ 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

Fraunhofer IPT, Aachen

Coaxial wire laser cladding &additive manufacturing

18.9.2015Alihankinta 2015 26

HighYAG/IWS

Precitec

Mitsubishi Cavipro

Fraunhofer IWS

Coaxial hot-wire laser cladding &additive manufacturing

18.9.2015Alihankinta 2015 27

§ Main benefits:§ High process stability§ Less parameters in wire

alignment§ Omni-directional§ Increased productivity§ Material efficient

Duplex: 3.5kW, 4m/min, 250A, 7V, 5kg/h (150 mm3/s)

Examples of laser wiremanufactured parts

18.9.2015Alihankinta 2015 28

Laser + arc hybrid cladding &additive manufacturing

18.9.2015Alihankinta 2015 29

§ 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

Twin wire 10kg/hLaser + MIG/MAG, single wire

Arc betweentwo wires

1.8401 steel

1.8401 steel, 38 HRC, 2 kg/h

Mild steel

1.4718 steel, 63 HRC

Kaupalliset laitteet (EB lanka)

18.9.2015Alihankinta 2015 30

Sciaky Inc.

§ Working space 5791 x 1219 x 1219 mm3

§ Deposition rate 3 – 9 kg/h§ Titanium, Tantalum, Inconel, Stainless steels§ Closed loop process control

Cold metal transfer (CMT) cladding &additive manufacturing

18.9.2015Alihankinta 2015 31

§ 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

Single wire, ~5kg/hTwin wire, ~10kg/h

§ 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

Cold metal transfer (CMT) cladding &additive manufacturing

18.9.2015Alihankinta 2015 32

Alloy 625

Refuse incinerators and power stationsBoiler walls and pipes (coal, waste, biofuel) (400-550°C)Turbine rotors (hydropower)Ship propellersMould repairValves Alloy 625

Cold metal transfer (CMT) additivemanufacturing

18.9.2015Alihankinta 2015 33

11 µm

4.1 mm

Al

15 µm

Si150 layers 40 mm3/s

Hypoeutectic AlSi5 (4043) by robot-guided CMT process

Elemental maps of Al and Si

Transverse cross-section of AlSi5 build-up

Ra 3.0µm

α-Al primary dendrite (light)

Al/Sieutectic(dark)

50 HV0.05


18.9.2015Alihankinta 2015 34

Pelton runners for hydropowerstations

Cranfield University

Steel/bronzeCranfield University

Cranfield University Stiffened panel / AluminiumCranfield University

Cranfield University

Suorakerrostus vs. jauhepeti

18.9.2015Alihankinta 2015 35

Ominaisuudet Suorakerrostus Jauhepeti

Materiaalit • laaja materiaalivalikoima• jauhe, lanka

• rajoittunut(materiaalvalikoima kasvaanopeasti)

Kappaleiden koko • kappaleiden/suutinpäänkäsittelyjärjestelmä rajoittaa • prosessikammio rajoittaa

Kappaleidenmonimutkaisuus • rajoittunut • lähes rajoittamaton

Tarkkuus ≥ 0.5 mm ≥ 0.1 mm

Tuotto – 150 mm3/s – 20 mm3/s

Alusta • 3D-pinta• aihio

• tasainen pinta• tasainen aihio

Pinnankarheus Rz 60 – 100 µm 10 – 50 µm

Kerrosten paksuus ≥ 0.1 – 2 mm ≥ 0.015 – 0.1 mm

Tukirakenteidentarve Ei Kyllä (ulkonemat)

Terminen ruiskutus muodonanto-menetelmänä

18.9.2015Alihankinta 2015 36

Additive manufacturing by cold spray

18.9.2015Alihankinta 2015 37

18.9.2015Alihankinta 2015 38

Ref. Peter Richter Jr, Advanced HighPressure Cold SprayInnovative Technology „Playground“,North American Cold SprayConference, Canada, 2014

Coaxially laser assisted cold spray

18.9.2015Alihankinta 2015 39

COLA (http://www.cola-project.eu/, The European Union 7th Framework Programme ):new, cost-effective laser-assisted cold-spray technique, for high-qualitydeposition and repair

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

18.9.2015Alihankinta 2015 40

metallipinnoitus – pinnoitusmenetelmien mahdollisuudet ... 2015 tuominen.pdf · metallipinnoitus...

Documents