Michele Lanzetta
University of Pisa
Department of Civil and Industrial Engineering
This presentation: www.lanzetta.unipi.it/research/am
sps ipc drives
28 - 30 maggio 2019
Fiere di Parma
Arena Robotica e Meccatronica
Pad. 4.1
29/5 h 13
Powders
Steps in Making Powder-Metallurgy Parts
Outline of processes and operations involved in making powder-metallurgy parts
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Particle Shapes in Metal Powders
Particle shapes in metal powders, and the processes by which they are produced. Iron powders are produced by many of these processes.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Sintering Time and Temperature for Metals
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mechanisms for Sintering Metal Powders
Schematic illustration of two mechanisms for sintering metal powders: (a) solid-state material transport; and (b) vapor-phase material transport. R = particle radius, r = neck radius, and p = neck-profile radius.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mechanical Properties of P/M Materials
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Comparison of Properties of Wrought and Equivalent P/M Metals
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods of Metal-Powder Production by Atomization
Methods of metal-powder production by atomization: (a) gas atomization; (b) water atomization; (c) atomization with a rotating consumable electrode; and (d) centrifugal atomization with a spinning disk or cup
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mechanical Comminution to Obtain Fine Particles
Methods of mechanical comminution to obtain fine particles: (a) roll crushing, (b) ball mill, and (c) hammer milling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mechanical Alloying
Mechanical alloying of nickel particles with dispersed smaller particles. As nickel
particles are flattened between the two balls, the second smaller phase is impresses into the nickel surface and eventually is dispersed throughout the particle due to successive flattening, fracture, and welding events.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bowl Geometries in Blending Metal Powders
(a) through (d) Some common bowl geometries for mixing or blending powders. (e) A mixer suitable for blending metal powders. Since metal powders are abrasive, mixers rely on the rotation or tumbling of enclosed geometries as opposed to using aggressive agitators. Source: Courtesy of Gardner Mixers, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Compaction
(a) Compaction of metal powder to form a bushing. The pressed-powder part is called green compact. (b) Typical tool and die set for compacting a spur gear. Source: Courtesy of Metal Powder Industries Federation.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Density as a Function of Pressure and the Effects of Density on Other Properties
(a) Density of copper- and ironpowder
compacts as a function of compacting
pressure. Density greatly influences the
mechanical and physical properties of P/M
parts. (b) Effect of density on tensile strength,
elongation, and electrical conductivity of
copper powder. Source: (a) After F. V. Lenel,
(b) IACS: International Annealed Copper
Standard (for electrical conductivity).
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Density Variation in Compacting Metal Powders
Density variation in compacting metal powders in various dies: (a) and (c) single-action press; (b) and (d) double-action press. Note in (d) the greater uniformity of density from pressing with two punches with separate movements when compared with (c). (e) Pressure contours in compacted copper powder in a single action press. Source: After P. Duwez and L. Zwell.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Compacting Pressures for Various Powders
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Press for Compacting Metal Powder
A 7.3-mn (825-ton) mechanical press for compacting metal powder. Source: Courtesy of Cincinnati Incorporated
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cold Isostatic Pressing
Schematic diagram of cold isostatic pressing, as applied to forming a tube. The powder is enclosed in a flexible container around a solid-core rod. Pressure is applied isostatically to the assembly inside a high-pressure chamber. Source: Reprinted with permission from R. M. German, Powder Metallurgy Science, Metal Powder Industries Federation, Princeton, NJ; 1984
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Capabilities Available from P/M Operations
Capabilities, with respect to part size and shape complexity, available form various P/M operations. P/F means powder forging. Source: Courtesy of Metal Powder Industries Federation.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hot Isostatic Pressing
Schematic illustration of hot isostatic pressing. The pressure and temperature variation versus time are shown in the diagram
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Powder Rolling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Spray Deposition
Spray deposition (Osprey Process) in which molten metal is sprayed over a rotating mandrel to produce seamless tubing and pipe
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Die Design for Powder-Metal Compaction
Die geometry and design features for powder-metal compaction. Source: Courtesy of Metal-Powder Industries Federation
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Poor and Good Designs of P/M Parts
Examples of P/M parts showing poor and good designs. Note that sharp radii and reentry corners should be avoided and that threads and transverse holes have to be produced separately by additional machining operations.
Source: Courtesy of Metal
Powder Industries Federation
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Design Features for Use with Unsupported Flanges or Grooves
(a) Design features for use with unsupported flanges. (b) Design features for use with grooves. Source: Courtesy of Metal Powder Industries Federation
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
International Standards Used for Metal Powder Characterisation
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
Basic Methodology with Pros (blue) and Cons (red)
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
SEM Backscatter Electron Images and Particle Size Measurement
a) powder from machine manufacturer (MM); b) powder from powder manufacturer (PM); c) powder from third party supplier (3P); d) PSD (linear scale, volume distribution) measured via laser light diffraction (red: PM, green: MM, blue: 3P); Dx(10), Dx(50) and Dx(90) shown in table
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
Particle Size Distribution
comparison between laser light diffraction (volume density: red) and image analysis method (particle number: orange, volume density: blue)
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
Powder Flow Determined Via Avalanche Angle
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
Impact of Inappropriate Storage (1 month) in Air and Recycling
a) new powder after storage – caking; b) new powder storage – decreased flowability; c) SEM image of recycled powder particles
Meisnar, M., Baker, S., Fowler, C., Pambaguian, L., & Ghidini, T. (2018). Lessons Learnt Through the Development of an Application-Specific Methodology for Metal Powder Characterisation for Additive Manufacturing. METALLURGIA ITALIANA, (3), 20-26.
Measuring the Angle of Repose and Flowability
Monitoring
Direct Metal Laser Sintering
DEFECTS ANALYSIS AND MONITORING STRATEGIES
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Direct Metal Laser Sintering (DMLS) Process
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Direct Metal Laser Sintering (DMLS) Process�Optical system
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Direct Metal Laser Sintering (DMLS) Process�Recoating system
A. Amado et al. 2011
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Direct Metal Laser Sintering (DMLS) Process�Recoating system
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Direct Metal Laser Sintering (DMLS) Process�Key hole process
H. Gong, 2013
A. Ladewiga et al. 2016
Defects classification
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Defects classification
Process defects
R. LI et al. 2012
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Defects classification
Part defects
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Defects classification
Defect sources
DMLS in situ Monitoring
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DMLS in situ Monitoring�Monitoring sensors��
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Camera Monitoring
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Accelerometer monitoring
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Accelerometer monitoring�Signal analysis
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Accelerometer monitoring�Recoater system collision with parts
Optical Tomography Monitoring
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Optical Tomography monitoring�Lack of powder
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Optical Tomography monitoring�Gas flow analysis
Hotspots in downskin area
High roughness on the part
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Optical Tomography monitoring�Defects identification examples
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Optical Tomography monitoring�Defects identification examples
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Optical Tomography monitoring�Key hole collapse
MeltPool Monitoring
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MeltPool monitoring�Lack of powder
Sensors integration
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IR camera
Camera
Accelerometer
Photodiodes
Sensor integration�Lack of powder�
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MeltPool signal and Exposure map
OT image
Accelerometer signal
Sensor integration�Recoater collision�
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Porosità
Rugosità
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Powder spreading
Powder bed defects
Melting defects
IR camera
Camera
Accelerometer
Exposure
Photodiodes
Available
sensors
YES
YES
NO
NO –––> Next layer
Sensors
integration�Online feed-back
Certification
Certification
Seifi, M., Gorelik, M., Waller, J., Hrabe, N., Shamsaei, N., Daniewicz, S., & Lewandowski, J. J. (2017). Progress towards metal additive manufacturing standardization to support qualification and certification. Jom, 69(3), 439-455.
Schematic representation of the Q&C landscape.
Seifi, M., Gorelik, M., Waller, J., Hrabe, N., Shamsaei, N., Daniewicz, S., & Lewandowski, J. J. (2017). Progress towards metal additive manufacturing standardization to support qualification and certification. Jom, 69(3), 439-455.
AM parts classification
Seifi, M., Gorelik, M., Waller, J., Hrabe, N., Shamsaei, N., Daniewicz, S., & Lewandowski, J. J. (2017). Progress towards metal additive manufacturing standardization to support qualification and certification. Jom, 69(3), 439-455.
Quality Management
System (QMS)
www.ssqi.com
Process house
Produce process
www.pqbweb.eu
Design process
www.pqbweb.eu
NIST - Important Technologies and Measurement Challenges for AM
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
LLNL’S HPC Lawrence Livermore National Laboratory High Performance Computing Modelling and Simulation Capabilities
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
AM phases
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
Q-Management Ishikawa AM
Schmid, M., & Levy, G. (2012). Quality management and estimation of quality costs for additive manufacturing with SLS. In Fraunhofer Direct Digital Manufacturing Conference 2012. ETH-Zürich.
Equipment/System
a) Q-elements of Equipment; b) Recommended Q-activities Equipment/ System
a)
b)
Schmid, M., & Levy, G. (2012). Quality management and estimation of quality costs for additive manufacturing with SLS. In Fraunhofer Direct Digital Manufacturing Conference 2012. ETH-Zürich.
Equipment/System metal powder
a)
b)
a) Q-elements of Metal Powder; b) Recommended Q-activities of Metal Powder
Schmid, M., & Levy, G. (2012). Quality management and estimation of quality costs for additive manufacturing with SLS. In Fraunhofer Direct Digital Manufacturing Conference 2012. ETH-Zürich.
Equipment/System Production and Batch
a)
b)
a) Q-elements of Production and Batch; b) Recommended Q-activities of Production and Batch
Schmid, M., & Levy, G. (2012). Quality management and estimation of quality costs for additive manufacturing with SLS. In Fraunhofer Direct Digital Manufacturing Conference 2012. ETH-Zürich.
Equipment/System Part and Finishing
a)
b)
a) Q-elements of Part and Finishing; b) Recommended Q-activities of Part and Finishing
Schmid, M., & Levy, G. (2012). Quality management and estimation of quality costs for additive manufacturing with SLS. In Fraunhofer Direct Digital Manufacturing Conference 2012. ETH-Zürich.
Manufacturing Quality Control Chart
Certification Process Flow
www.dnvgl.com
Certification Pathway for AM (3D Printing)
www.dnvgl.com
Building Block Test Structure for Certification
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
Composites and Metallic AM Materials have similar Requirements
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
IWGDD (Interagency Working Group Digital Data) Digital Data Life Cycle Model
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
GRANTA MI Additive Manufactoring Template
Mies, D. Marsden, W.,& Warde, S. (2016). Overview of additive manufacturing informatics: “a digital thread”. Integrating Materials and Manufacturing Innovation, 5(1), 6.
Classification of AM Process Models
Schoinochoritis, B. Chantzis, D., & Salonitis, K. (2017). Simulation of metallic powder bed additive manufacturing processes with the finite element method: A critical review. Proceeding of Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 231(1), 96-117.
AM networks
National Academy for
Additive Manufacturing
Funder: prof. Michele Lanzetta
University of Pisa
Department of Civil and Industrial Engineering
Interuniversity research center for
Additive Manufacturing
Co-Funder: prof. Michele Lanzetta
University of Pisa
Department of Civil and Industrial Engineering
Interest Group
Additive Manufacturing
Coordinator: prof. Michele Lanzetta
University of Pisa
Department of Civil and Industrial Engineering
Mission
The interest group Additive Manufacturing Aitem aims to increase and spread the knowledge of additive technologies and their application to the design and production of goods and services to sustainably increase national competitiveness and well-being
Members
The interest group Additive Manufacturing Aitem is born from professors of the Technologies and Processing Systems sector of Italian universities
It is open to contributions from other academic sectors and from the industrial world
Enrollment and participation is free
calendario eventi
attività e documentazione
social e notizie
mercato AM
iscrizione (gratuita)
���������������STRENGTH�100 members, from most Universities� and Polytechnics
WEAKNESSES�Small critical mass�[40 active members]�AM not primary topic
THREATS�Limited impact �not an excellence�No Italian AM providers�����
OPPORTUNITY
Strong networking
Italian AM
STRENGTH�Teaching is primary �activity for Academia
WEAKNESS�≠ language: Industry & Academia
Scouting possible cooperation��OPPORTUNITY
No overlapping interests��THREAT
University training�for Industry
STRENGTHS��Core business (third mission)�Available know-how (research)
WEAKNESSES���Low readiness level offered [≤4] vs requested [≥7]
Training demand (teaching)�Funding �[H2020, regional, self]��OPPORTUNITIES
Geographical barriers (north, center, south) and proximity�Company size (SMEs)�Trust industry vs university�THREATS
University AM
for Industry
Improving the Italian AM research potential
Lower profile (current)
Higher profile (long term)
Acknowledgements
Andrea Rossi, Francesco Morante, Pierfrancesco Ceccarelli
www.pqbweb.eu