Additive Manufacturing at voestalpine

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1 Additive Manufacturing at voestalpine Current applications from Topology optimization, tool manufacturing and special engineering

2 AGENDA October 2017 Additive Manufacturing at voestalpine

3 Additive Manufacturing at voestalpine October Additive Manufacturing at voestalpine

4 voestalpine AG High-tech steel is the base of voestalpine, but 15 years of downstream strategy have converted the group from a steelmaker to a technology and industrial goods corporation The combination of leading steel making know-how and top processing expertise creates innovative technical solutions and new products Clear focus on strategically in the long run most promising sectors like mobility and energy From a steel producer to a technology and industrial goods corporation Long-term relationships with customers, suppliers and R&D-institutions are key drivers for innovation voestalpine has been holding over years a leading position versus its peers with regards to quality, technology and financial performance October Additive Manufacturing at voestalpine

5 voestalpine AG Key figures for 2016/17 Sales by regions Sales by industries Employees 49,703 Revenue EUR 11,294.5 million Business year 2016/17 Business year 2016/17 9% Asia 7% Rest of world 70% European Union (of which Austria 7%) 5% White goods/ Consumer goods 9% Mechanical engineering 3% Aerospace 12% Railway systems EBITDA EUR 1,540.7 million EBIT EUR million EBIT margin 7.3 % 3% South America 11% NAFTA 14% Other 10% Building/ Construction 34% Automotive ENERGY 13% MOBILITY: 49% October Additive Manufacturing at voestalpine

6 voestalpine ADDITIVE MANUFACTURING APPROACH Be the Solution Provider (One-Stop-Shop) within Additive Manufacturing Technologies for powder & parts Customer Consulting Powder development Powder production Design AM-Parts Heat treatment & post processing & Parameter development for different applications October 2017 Additive Manufacturing at voestalpine Additive Manufacturing Center Source: voestalpine

7 ADDITIVE MANUFACTURING NAMES A PROCESS WHICH BUILDS UP PARTS LAYER-UPON-LAYER (I) (II) Definition Additive Manufacturing is defined as the process of joining materials to make objects from 3D model data, usually layer upon layer (Definition by ASTM). (III) Process of layer wise manufacturing» (I) lowering the building platform» (II) recoating with new layer of powder» (III) exposing with laser beam October 2017 Additive Manufacturing at voestalpine Source: voestalpine

8 TECHNICAL ADVANCES MATERIAL PROPERTIES Several years ago Today Technical progress:» Laser technology» Optics» Software» Efforts in R&D Density ~95% Density ~99.95% October 2017 Additive Manufacturing at voestalpine Source: vostalpine

9 Don t try to use AM for parts which are dedicated to other manufacturing technologies! AM is only economically if you can add value to the part! October 2017 Additive Manufacturing at voestalpine

10 WOULD YOU TRY TO mill this part? cast this part? Source: huber-metallgaeu.de Source: fabricate this part? cast this part? Source: October Additive Manufacturing at voestalpine

11 ADDITIVE MANUFACTURING HAS TO OFFER A LOT OF BENEFITS WHICH NEEDS TO BE EXPLOITED flexible production / design freedom temperature / flow optimization separation/mixing of liquids/gaseous less assembly/ monolithic design less time-to-market porous structures/ ventilation fast deployment of design changes integration of functions/sensors lightweight October 2017 Additive Manufacturing at voestalpine Source: DMRC, voestalpine

12 Topology optimization & AM- Design October Additive Manufacturing at voestalpine

13 TOPOLOGY OPTIMIZATION CHALLENGES» Topology optimizations may allow great material reduction» Results often don t lead to a clear build direction» Afterwards structural editing and newly analysis October Additive Manufacturing at voestalpine

14 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) October Additive Manufacturing at voestalpine

15 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) October Additive Manufacturing at voestalpine

16 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) October Additive Manufacturing at voestalpine

17 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) Build direction for a minimal amount of support Support essential areas October Additive Manufacturing at voestalpine

18 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) October Additive Manufacturing at voestalpine

19 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) Linking area with breaking points Seperate bodys for supporting lattice window like narrowing October 2017 Additive Manufacturing at voestalpine

20 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

21 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

22 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

23 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

24 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

25 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

26 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

27 TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) October Additive Manufacturing at voestalpine

28 Tool manufacturing with Additive Manufacturing October Additive Manufacturing at voestalpine

29 ADVENTAGES AND LIMITS OF CONVENTIONEL TOOL MANUFACTURING Tool manufacturing typical for milling:» High cutting volume» Outstanding tolerances» Very good surface roughness But: limitations of the functionally possible» Tool accessibility required» Design eventually on cost of fabricational function» Processing time» Process quality» Tool lifetime Conventional machining October 2017 Additive Manufacturing at voestalpine

30 COMPLEMENTARY PROCESS ADDITIVE MANUFACTURING Process properties of additive manufacturing:» Small building rates (~13cm³/h)» Average Tolerances» rough surfaces Conformal cooling through AM But: complexity and costs are not linked» Cooling of any geometries possible» Design follows function not machining process» Redesign required October 2017 Additive Manufacturing at voestalpine

31 BENFEFITS FOR THE TOOLING OEM THROUGH AM Plastic injection moulding Aluminium die-casting Hot forming / press hardening October 2017 Additive Manufacturing at voestalpine Advantages of AM» Conformal cooling possible» Cooling channels closer to the surface» Homogenous cooling/heating» Variothermal processes easier feasible» Thermal barriers possible Benefit for the OEM» Faster cycle time» Less scrap rate» More homogenous material properties» Less energy consumption» Better part surface qualities possible Source: voestalpine

32 HYBRID MANUFACTURING MOTIVATION Benefit by combination» reduction of the AM- volumes to functional area» Conventional machining of the remaining parts» (and) finishing of AM surfaces» Reduction of manufacturing costs» Definition: Manufacturing of a part, where it is existing at least at one part of bar material and a second part which was generated from molten metal powder October 2017 Additive Manufacturing at voestalpine

33 STEP BY STEP: HYBRID MANUFACTURING Approach: SLM280HL» Positioning of the build platform and Stock (milled part)» Flat surface grinding in mounted condition» Import /positioning assembly» AM - part to Z = 0mm» contur check/ Position correction» Fill up powder and compress it» Job start October 2017 Additive Manufacturing at voestalpine

34 PRICE COMPARISON TOTAL BUILD vs. HYBRID MANUFACTURING Personal 6,5% HT 1,15% Material 15,7% AMtotal build savings 35,5% Hybrid Manufacturing *) Mashine 32,3% Mashine 77,8% HT 1,15% Stock Personal 18,5% 6,5% Material 6,2% *) referring to AM-total build October 2017 Additive Manufacturing at voestalpine

35 Special engineering October Additive Manufacturing at voestalpine

36 TECHNOLOGIE SHOWCASE JET ARRAY» Cooling surface» Sheets size: 200 x 400 mm» Temperature range: 800 C 200 C» Cooling rate 70K/sec» Temperature gradient on sheet: +/- 10K» Combination of water cooling and gas flow» Challenges» High temperatures» Small cooling distance (15 mm)» Large area October Additive Manufacturing at voestalpine Source: voestalpine

37 TECHNOLOGIE SHOWCASE: JET ARRAY» Basic Properties» N2 -inlet and -outlet combined» Water cooled» Combinable side by side N 2 N 2» Design suitable for AM» Internal guiding plates steer gas flow» Less support structures» Remaining powder should be easy to remove H 2 O H 2 O H 2 O H 2 O October 2017 Additive Manufacturing at voestalpine Source: voestalpine

38 TECHNOLOGIE SHOWCASE KONSTRKTIONSENWICKLUNG UND AUSBLICK» AM-Design 4 weeks» Simulations 1 week Manufacturing Evaluation & further optimization (if necessary) Design optimization Initial Design suggestion thermal simulation part configuration October 2017 Additive Manufacturing at voestalpine flow simulation Source: voestalpine» Build time 76 hrs for 2 Jet Arrays» Part weight 1.6 kg

39 CONTACT ME FOR FUTHER INFORMATION Jens Christoffel Product Development Additive Manufacturing Hansaallee 321, Düsseldorf, Germany M.: +49 (170) T.: +49 (211) Jens.Christoffel@voestalpine.com October voestalpine Additive Manufacturing