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Webinar - Adding to Additive Manufacturing with Particle Size and Shape Analysis

Many Additive Manufacturing (3D printing) techniques such as selective laser sintering (SLS) and selective laser melting (SLM) use particle powders as a raw material. The particle size and shape have a strong effect on the manufacturing result. Therefore it is important for manufacturers and suppliers to control the particle size and shape of their powders used in this process. In order to control particle size and shape these parameters must be measured. We discuss how to use the CAMSIZER technology to improve additive manufacturing results by monitoring the incoming particles. Value of Dynamic Image Analysis in 3D additive manufacturing How does Dynamic Image Analysis work? Why two cameras can control and monitor dust and oversize? Check the production of 3D printing powders Check the incoming raw material and the recycled powder for reuse

CAMSIZER XT 3D Printing

Additive Manufacturing

June 23 of 2016

Jeff Bodycomb HORIBA Scientific

Gert Beckmann

Retsch Technology GmbH

4

Classification Technology Description Materials Developers (Country)

Binder Jetting 3D Printing Ink-Jetting

S-Print M-Print

Creates objects by depositing a binding agent to join powdered

material.

Metal, Polymer, Ceramic

ExOne (USA) VoxelJet (Germany) 3D Systems (USA)

Direct Energy Deposition

Direct Metal Deposition Laser Deposition

Laser Consolidation Electron Beam Direct Melting

Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate.

Metal powder, Metal wire

DV3D (USA) NRC-IMI (Canada)

Irepa Laser (France) Trumpf (Germany)

Sciaky (USA) Material Extrusion

Fused Deposition Modelling Creates objects by dispensing material through a nozzle to build

layers.

Polymer Stratasys (USA) Delta Micro Factory (China)

3D Systems (USA) Material Jetting Polyjet

Ink-Jetting Thermojet

Builds parts by depositing small droplets of build material, which

are then cured by exposure to light.

Photo-polymer, Wax

Stratasys (USA) LUXeXcel (Netherlands)

3D Systems (USA) Powder Bed

Fusion Direct Metal Laser Sintering

Selective Laser Melting Electron Beam Melting

Selective Laser Sintering

Creates objects by using thermal energy to fuse regions of a powder

bed.

Metal, Polymer, Ceramic

EOS (Germany), Renishaw (UK) Phenix Systems (France)

Matsuna Machinery (Japan) ARCAM (Sweden) 3D Systems (USA)

Sheet Lamination

Ultrasonic Consolidation Laminated Object Manufacture

Builds parts by trimming sheets of material and binding them together

in layers.

Hybrids, Metallic, Ceramic

Fabrisonic (USA) CAM-LEM (USA)

VAT Photopoly-merisation

Stereolithography Digital Light Processing

Builds parts by using light to selectively cure layers of material in

a vat of photopolymer.

Photo-polymer, Ceramic

3D Systems (USA) EnvisionTEC (Germany)

DWS Srl (Italy) Lithoz (Austria)

Processes

5

Type Technologies Materials

Extrusion Fused deposition modeling (FDM) or Fused Filament Fabrication (FFF)

Thermoplastics, Eutectic metals, Edible materials, Rubbers, Modeling clay, Plasticine, Metal clay (including Precious Metal Clay)

Robocasting or Direct Ink Writing (DIW)

Ceramic materials, Metal alloy, Cermet, Metal matrix composite, Ceramic matrix composite

Light polymerized Stereolithography (SLA) Photopolymer Digital Light Processing (DLP) Photopolymer

Powder Bed Powder bed and inkjet head 3D Printing (3DP)

Almost any metal alloy, Powdered polymers, Plaster

Electron-Beam Melting (EBM) Almost any metal alloy including Titanium alloys

Selective Laser Melting (SLM) Titanium alloys, Cobalt Chrome alloys, Stainless Steel, Aluminium

Selective Heat Sintering (SHS) Thermoplastic powder

Selective Laser Sintering (SLS) Thermoplastics, Metal powders, Ceramic powders

Direct metal laser sintering (DMLS)

Almost any metal alloy

Laminated Laminated Object Manufacturing (LOM)

Paper, Metal foil, Plastic film

Powder Fed Directed Energy Deposition Almost any metal alloy

Wire Electron Beam Freeform Fabrication (EBF3)

Almost any metal alloy

Processes

Example of 3D Printing

6

Example for 3D printing

7 © Retsch Technology GmbH

3D Printing (Plastic and Metal Powder) Applications Plastic, Ceramic & Metal Powder


Automotive, Airospace Industry, Fast Prototyping => small numbers => individual modifications Paper => Plastics => Metal Laser Melting (3D Metal Printing)

Vacuum or Nylon Casting

Product Examples (3D Printing Powders)


The world’s first 3D printed metal gun is a beautiful .45 caliber M1911 pistol

The world’s first 3D printed dress

3D Printing of Metal Construstions


3D printing with metal: The final frontier of additive manufacturing

CAMSIZER XT 3D Printing & Rapid Prototyping




Now



Future ?

Present !

Content

Instrument

1.Measurement principle

2.Results

Applications

3. Markets and applications

4. Alternative analysis methods


CCD - Basic CCD - Zoom Detection of particles

One pixel is element of a projection when at least half of the pixel is covered.

Measurement principle

Resolution

Measurement principle (CAMSIZER XT)


Advanced, patented optics design

Sample flow

Light source 2

Light source 1

Basic Camera

Zoom Camera



Sample flow

Light source 2

Light source 1

Basic Camera

Zoom Camera


Measurement Results


What is the size of this particle?

Particle Size


xc min

xc min

“width”

A

A‘ = A x a

rea

“diameter over projection surface”

xarea

“length”

xFe max

xFe max

CAMSIZER results are

compatible with

sieve analysis

Results X-Jet


Better Size Analysis due to Understanding of Particle Shape: Length, Width, Average Diameter


• Breadth-/ Length-Ratio

• Roundness

• Symmetry

• Convexity

xFe max

xc min

A

r1

r2

C

A convex

A real

Particle Shape (CAMSIZER and CAMSIZER XT)

P


Roundness with Krumbein‘s Chart


Manual Roundness Measurement

© Retsch Technology GmbH

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Correlation RDNS_C - Roundness 1

2

3

4

5

1

2

3

4

5

Rou

ndne

ss (R

DN

S_C

CA

MS

IZE

R)

Roundness (visual ISO procedure)

R² = 0.9694


Powdered Metal

Sorting metals by Roundness (“Willingness” to roll)

Reports and Warnings



Optical Process Control Analysis for Size and Shape

Dispersion Modules (CAMSIZER XT)


Particle Size Range from 1 µm to 3 mm

Three modes in 2 modules (dry and wet):

X-Fall: for dry and free flowing particles X-Jet: air pressure dispersion for fine and agglomerated powders X-Flow: wet module for emulsions and suspensions, with ultrasonic probe, optional for organic solvents

Modular "X-Change" Concept


Flexible configuration for a wide application range

simple • safe • fast



Dry Dispersion Inserts (2 Plug-In Options)

X- Fall (Gravity dispersion)

X-Jet (Air pressure dispersion)

Advantages

fast repeatable and reproducible

maintenance free and robust

precise




Dry Dispersion with X-Jet

Measurement range from 1 µm to 3 mm

For fine powders and agglomerating materials

Dry Dispersion by pressurized air

Measurement principle – X-Jet


Results


For agglomerating powders

- Metal powder - Coal dust - Wheat flour

Particle size

Lower Measurement Range



Reproducibility of Metal Powder Results

Customer had sent 30 different samples to Retsch Technology but some of these samples were the same (red, blue and green). We found out the groups and showed to the customer the good reproducibility of CAMSIZER XT (and proofed his sample splitting as well)

xc_min [µm] 10 15 20 25 30 35 40 45 50 0

10

20

30

40

50

60

70

80

90

Q3 [%]

0

1

2

3

4

5

6

7

8

9

q3 [%/µm]

Powder-#8-X-Jet-30kPa_vvv_xc_min_Mv.rdf Powder-#8-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#8-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#13-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#13-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#13-X-Jet-30kPa_vvv_xc_min_Mv.rdf Powder-#27-X-Jet-30kPa_TP1_vvv_xc_min_001.rdf Powder-#27-X-Jet-30kPa_TP2_vvv_xc_min_002.rdf Powder-#27-X-Jet-30kPa_vvv_xc_min_Mv.rdf

CAMSIZER XT for Metal Powders


CAMSIZER XT for Metal Powders


Metal Powder

Reproducibility and Instrument-to-Instrument agreement Δ = 0.1µm – 0.3µm

Features of the CAMSIZER®


Calibration Reticule

- Traceble to an International Standard - Covering the Whole Measurement Range - Instrument to Instrument Agreement

Static Calibration


Features of the CAMSIZER XT


Static Calibration

Physical Dynamic Partical Standards


Whitehouse Glass Bead Standard XX030 for X-Dry and X-Fall

Dynamic Calibration

Size Range and Sieve Correlation


System Comparison



Particle size

Results X-Flow

Particle Size Distribution 2.5 µm + 5 µm, Wet Dispersion

xc_min [µm]4 6 8 10 120

5

10

15

20

25

30

35

40

45

50

q3 [%/µm]

Duke10um12um_gl0_xc_min_009.rdfDuke10um12um_gl0_xc_min_010.rdfDuke10um12um_gl0_xc_min_011.rdfDuke10um_xc_min_002.rdfDuke10um_xc_min_003.rdfDuke10um_xc_min_004.rdf


Particle size

Results X-Flow (Calibration)

Particle Size Distribution 10 µm + 12 µm, Wet Dispersion

Content


Instrument


2.Results

Applications



• Digital image processing with patented 2-camera system (ISO 13322-2)

• Wide dynamic range from 1 µm to > 3 mm

• Newly developed optical system with ultra bright LEDs for sharp contrasts and large depth of focus

• Short analysis time 1 – 3 minutes for few million particles

• Safe detection of oversized and undersized

• Modules for dry and wet dispersion

• Analysis results compatible to sieve analysis

Advantages


Content


Instrument


2.Results

Applications



• Industrial labs

• Research institutes

• Production control

• Quality control for final products

• Quality control of incoming raw materials

• Immediate control and optimisation of

production processes

Application areas


Application areas


Typical sample materials

• Pharmaceutical powders, granules or

small pellets

• Pulverized and granulated food, spices

• Detergents, enzymes, fillers for washing powders

• Metal or ore powders

• Abrasives (medium and small grit)

• Sand and cement, building materials, limestone

• Fibres

Content


Instrument


2.Results

Applications



Alternative Methods


Sieving CAMSIZER XT Size range 10 µm - 63 mm 1 µm – 3 mm Shape analysis no yes Detection of oversized particles each particle few big particles

from < 0.1% Vol. Resolution poor high resolution

Multi-modal distributions poor size resolution better resolution

Repeatability and lab-to-lab comparison „difficult“ superior

Comparison with sieving identical results possible

Handling simple, but time consuming easy and fast

Sieving CAMSIZER XT


Results X-Jet


Identical results to sieve analysis

xc_min [mm] 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0

10

20

30

40

50

60

70

80

90

Q3 [%]

Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_005.rdf Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_003.rdf Ca-hydrogenphosphate_100kPa-T38567-vvv_xc_min_004.rdf T38567-Sieve-Analysis-Customer-Site.ref


Sieving CAMSIZER XT

Spheroidal Particles

x [µm] 200 400 600 800 1000 1200 0

10

20

30

40

50

60

70

80

90 Passing [%]

Sample-1__xc_min_002.rdf Sample-1__xc_min_001.rdf Sieving-Nominal-S1.ref

xc min = ∅ = d = Xc min

particle-width


Sieving CAMSIZER XT

Influence of Mesh Width

1400µm 1400µm 1429.5µm

Mesh sizes warp Mesh sizes weft

Nominal Sieve Mesh = 1400µm Real Sieve Mesh >1400 = 1455

only beads < 1400µm

will pass the sieve mesh

beads > 1400µm will not pass the sieve mesh

Upper mesh size range ~1455µm sieve No. 03033531 (nominal 1400µm)

Theory: Reality:


Sieving CAMSIZER XT

Real Mesh Width

x [µm] 200 400 600 800 1000 1200 0

10

20

30

40

50

60

70

80

90 Passing [%]

Sample-1__xc_min_002.rdf Sieving-upper-range-S1.ref


Sample Reproducibility of CAMSIZER XT measurements of xc min (red, and blue) with Basic + Zoom or Zoom only, Retsch sieve result (real mesh sizes from optical inspection) AS 200 TAB (*black), Customer nominal sieve results (*blue)

Results of Metal Powder

xc_min [µm] 10 20 30 40 50 0

10

20

30

40

50

60

70

80

90

Q3 [%] Solder_Sample_G_xc_min_001.rdf Solder_Sample_G_xc_min_002.rdf Solder_Sample_G_xc_min_003.rdf Tin-Solder_Sample_G__xc_min_001.rdf Tin-Solder_Sample_G__xc_min_002.rdf Tin-Solder_Sample_G__xc_min_003.rdf RT1763 Sieve-Analysis G customer-site-nominal.ref RT1763 Sieve-Analysis_G_AS200tap_real-sizes.ref

Applications: Metal powders Material: Cu


Identical results to the sieve analysis

xc_min [mm]0.04 0.1 0.2 0.4 1 20

10

20

30

40

50

60

70

80

90

Q3 [%]

Automatic reports, many languages

available

Comparison of Methods: Sieving • robust and industrial-suited • easy handling • references available from user

Advantages

Disadvantages

• high amount of time and work • low resolution, small number

of investigatable classes • limited sample amount

(overloading is critical) • Difference between

nominal and real sizes

Competing Measuring Methods

Worn out sieves


F2

F1

1. Move

2. Sliding friction

3. Static friction

xc_min [mm]0.5 0.6 0.7 0.8 0.9 1.00

10

20

30

40

50

60

70

80

90

Q3 [%]

0

50

100

150

200

250

300

350

400

450

q3 [%/m m]5454_PT100_xc_min_008.rdf5454_random_xc_m in_009.rdf5454_Huntsman-sieve.ref

Round particles with low density

are captured without

rerelease

Sieving Problems (here Blinding and Overloading)

Test Sieves that comply with standards

If sieve analysis is used for quality control within the context of DIN EN ISO 9000:2000

then both the sieve shaker and the test sieves must be subjected to

test agent monitoring.

w = mesh width d = wire diameter

Tolerance for mean value (Y): The mean value of the mesh width must not differ from the nominal value w by more than the tolerance ± Y. w

w

Ø d

Ø d

Technical requirements & testing according to ISO 3310

CAMSIZER XT finding Fibers in Beads


Finding the Fibers


Finding the Fibers

CAMSIZER XT finding Fibers in Beads

CAMSIZER XT Laser sizer


Laser sizer CAMSIZER XT Size range down to 20 nm > 1 µm Shape analysis no yes Detection of oversized particles percent range few big particles

< 0.1% Vol.

Resolution good for fines better resolution for large particles

Multi-modal distributions more difficult better volume model, better size resolution

Comparison with sieving not possible identical results

Information content black box + mathematics pictures

CAMSIZER XT Optical Microscope


Microscope CAMSIZER XT Size range 0.5 – 500 µm 1 µm -3 mm

Shape analysis yes superior image quality yes

Detection of oversized particles no few big particles

< 0.1% Vol. Resolution better good

Statistics Low, few 1,000 particles million particles/minute

Comparison with sieving not possible identical results possible

Handling time consuming fast Representative Sample Amounts

difficult, only narrow distributions

yes, small and large amounts


xc_min [µm]200 400 600 800 10000

10

20

30

40

50

60

70

80

90

Q3 [%]

PPO-646_xc_min_001.rdfRT1766_ppo646_sieve.ref



CAMSIZER XT CAMSIZER

CAMSIZER CAMSIZER XT Size range 30 µm – 30mm 1 µm -3 mm Shape analysis yes yes Detection of oversized particles yes yes

Images / second 60 277 Resolution CCD-Cameras 790,000 1,300,000

Comparison with sieving identical results possible

identical results possible

Handling fast fast Representative Sample Amounts




Comparison of CAMSIZER and CAMSIZER XT

Results of CAMSIZER (black) and CAMSIZER-XT (red) of sample #30 CAMSIZER distribution is wider, the results are not that accurate and

repeatable as results from CAMSIZER XT.

Results of Metal Powder

xc_min [µm] 15 20 25 30 35 40 45 50 0

10

20

30

40

50

60

70

80

90

Q3 [%]

XT-with-X-Jet-#30-Einzel-250kPa_xc_min_005.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_006.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_007.rdf XT-with-X-Jet-#30-Einzel-250kPa_xc_min_008.rdf #30-classic-CAMSIZER-Repeatability-xc_min_013.rdf #30-classic-CAMSIZER-Repeatability-xc_min_014.rdf #30-classic-CAMSIZER-Repeatability-xc_min_015.rdf #30-classic-CAMSIZER-Repeatability-xc_min_Mv.rdf

CAMSIZER XT for 3D Printing Powders


• Unique, almost 100% agreement with sieve results (particle width = xc min) • Reliable detection of oversized and undersized particles down to 0.01% • Fast: typically 1-3 minutes per measurement • Flexible dispersion options (air pressure, liquid, free fall) • Shape analysis (roundness, aspect ratio, circularity, etc.) • Surface area calculation • Independent measurement of particle length and width provides more details • CAMSIZER’s “equivalent circle area” (xarea) to compare with laser particle sizers • Very repeatable and reproducible results, with excellent instrument-to-instrument agreement • Very high resolution (excellent capability to detect multimodal distributions!) • Easy to operate, results independent from operators

Applications Plastic, Ceramic & Metal Powder

Thank you for your attention!

webinar - adding to additive manufacturing with …...1 webinar - adding to additive manufacturing...

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