1. Metal Additive Manufacturing
Overview of the process, mechanical properties
and MME facility
Romain Gerard EN-MME-FW

2. PS Internal Dump review - 12/10/2016
Outline
Metal Additive Manufacturing with
Laser Powder Bed Fusion
Mechanical properties and Microstructure
Fatigue and Metal AM
EN-MME Metal AM Facility
PS Internal Dump review - 12/10/2016

3. Metal Additive Manufacturing with Laser Powder Bed Fusion
Selective laser melting is an additive manufacturing process that uses 3D CAD data as a digital information source and energy in the form of a high-power laser beam, to create three-dimensional metal parts by fusing fine metal powders together. Manufacturing applications in aerospace or medical orthopedics are being pioneered. (WIKI)
PS Internal Dump review - 12/10/2016

4. AM Parts at CERN LIEBE: Heat Exchanger Lead-Bishmut/Water
Vincent Barozier EN-ACE
Melanie Delonca EN-STI
RF LOAD: Cooling channel & UHV
Alexej Grudiev BE-RF
Beamscreen Stability Springs
Cedric Garion TE-VSC
Rotary beam wire scanner of SPS
Ray Veness BE-BI
PS Internal Dump review - 12/10/2016

5. Metallurgy and heat treatment in AM
Laser AM parts can be found under 4 states
As-Build:
directly out of the machine
Non-critical applications/tolerances
Stress-relieve heat treatment 650°C)
Standard for most parts
Best geometrical tolerances
Similar microstructure with As-Build
Recrystallization annealing heat treatment (ex. 950°C )
Change of microstructure
Improved ductility
Hot Isostatic Pressure (HIP) Heat Treatment (920°C & 1000Bars Ar)
Closes all internal pores (porosity 99.95%)
Improved Fatigue properties
Being studied: Improved UHV Compatibility?
PS Internal Dump review - 12/10/2016

6. PS Internal Dump review - 12/10/2016
Heat = Stress relieve
Temp.: 700 °C, 1 h,
cooled 60 °C/h
Tensile properties
As build materials have low ductility and high strength (similar to quenched materials)
HIPPED materials feature behaviour closer to reference Wrought materials
©DLR (Dr. G. Kasperovich)
PS Internal Dump review - 12/10/2016

7. PS Internal Dump review - 12/10/2016
Heat = Stress relieve
Temp.: 700 °C, 1 h,
cooled 60 °C/h
Microstructure
HIP features a microstructure similar to reference Wrought materials
©DLR (Dr. G. Kasperovich)
PS Internal Dump review - 12/10/2016

8. PS Internal Dump review - 12/10/2016
HIP effect on porosity
Material: Ti-6Al-4V, SLM
Post-fabrication HIPing has completely closed all the pores
©M. M. Attallah, University of Birmingham
PS Internal Dump review - 12/10/2016

9. Fatigue properties PS Internal Dump review - 12/10/2016
Black dots = runout (no rupture at 10Million cycles)
Woehler diagram for polished (left) and “as-built” specimen (right).
©Wycisk et al.
bonding defect (polished)
Surface defect (polished)
Surface defect (As-Build)
100% failure mode
PS Internal Dump review - 12/10/2016

10. Roughness impact on fatigue
©Kwai S. Chan et al.
Roughness impact on fatigue
Stress level
𝜎=600𝑀𝑃𝑎
𝑅=0.1
Rolled
SLM
Cast
PS Internal Dump review - 12/10/2016

11. PS Internal Dump review - 12/10/2016
HIP on fatigue
Roughness: Machined surfaces
HIPping results in an improvement in the fatigue life
©M. M. Attallah, University of Birmingham
PS Internal Dump review - 12/10/2016

12. PS Internal Dump review - 12/10/2016
Conclusion on fatigue
Fatigue properties “seem suitable for many applications in the aviation and medical industry.” (Wyciska et al.)
HIP improves the fatigue life (with polished/machined surfaces)
Data is available (free and private database)
Prerequisite: define the exact loading conditions, and identify the type of surface (as-build or re- machined)
PS Internal Dump review - 12/10/2016

13. EN-MME Metal AM Workshop
PS Internal Dump review - 12/10/2016

14. EN-MME Metal AM Workshop
PS Internal Dump review - 12/10/2016