Additive Manufacturing at voestalpine Current applications from Topology optimization, tool manufacturing and special engineering www.voestalpine.com
AGENDA 2 05. October 2017 Additive Manufacturing at voestalpine
Additive Manufacturing at voestalpine 3 05. October 2017 3 Additive Manufacturing at voestalpine
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 4 05. October 2017 4 Additive Manufacturing at voestalpine
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 823.3 million EBIT margin 7.3 % 3% South America 11% NAFTA 14% Other 10% Building/ Construction 34% Automotive ENERGY 13% MOBILITY: 49% 5 05. October 2017 5 Additive Manufacturing at voestalpine
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 6 05. October 2017 Additive Manufacturing at voestalpine Additive Manufacturing Center Source: voestalpine
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 7 05. October 2017 Additive Manufacturing at voestalpine Source: voestalpine
TECHNICAL ADVANCES MATERIAL PROPERTIES Several years ago Today Technical progress:» Laser technology» Optics» Software» Efforts in R&D Density ~95% Density ~99.95% 8 05. October 2017 Additive Manufacturing at voestalpine Source: vostalpine
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! 9 05. October 2017 Additive Manufacturing at voestalpine
WOULD YOU TRY TO mill this part? cast this part? Source: huber-metallgaeu.de Source: http://www.fischer-group.com fabricate this part? cast this part? Source: http://www.mirap.ch 10 05. October 2017 10 Additive Manufacturing at voestalpine
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 11 05. October 2017 Additive Manufacturing at voestalpine Source: DMRC, voestalpine
Topology optimization & AM- Design 12 05. October 2017 12 Additive Manufacturing at voestalpine
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 13 05. October 2017 13 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) 14 05. October 2017 14 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) 15 05. October 2017 15 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) 16 05. October 2017 16 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) Build direction for a minimal amount of support Support essential areas 17 05. October 2017 17 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) 18 05. October 2017 18 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (1/2) Linking area with breaking points Seperate bodys for supporting lattice window like narrowing 19 05. October 2017 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 20 05. October 2017 20 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 21 05. October 2017 21 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 22 05. October 2017 22 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 23 05. October 2017 23 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 24 05. October 2017 24 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 25 05. October 2017 25 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 26 05. October 2017 26 Additive Manufacturing at voestalpine
TOPOLOGY OPTIMIZATION FOR AM PROCESS CHAIN (2/2) 27 05. October 2017 27 Additive Manufacturing at voestalpine
Tool manufacturing with Additive Manufacturing 28 05. October 2017 28 Additive Manufacturing at voestalpine
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 29 05. October 2017 Additive Manufacturing at voestalpine
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 30 05. October 2017 Additive Manufacturing at voestalpine
BENFEFITS FOR THE TOOLING OEM THROUGH AM Plastic injection moulding Aluminium die-casting Hot forming / press hardening 31 05. 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
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. 32 05. October 2017 Additive Manufacturing at voestalpine
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 33 05. October 2017 Additive Manufacturing at voestalpine
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 34 05. October 2017 Additive Manufacturing at voestalpine
Special engineering 35 05. October 2017 35 Additive Manufacturing at voestalpine
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 36 05. October 2017 36 Additive Manufacturing at voestalpine Source: voestalpine
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 37 05. October 2017 Additive Manufacturing at voestalpine Source: voestalpine
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 38 05. October 2017 Additive Manufacturing at voestalpine flow simulation Source: voestalpine» Build time 76 hrs for 2 Jet Arrays» Part weight 1.6 kg
CONTACT ME FOR FUTHER INFORMATION Jens Christoffel Product Development Additive Manufacturing Hansaallee 321, 40549 Düsseldorf, Germany M.: +49 (170) 738 934 4 T.: +49 (211) 522-2304 Jens.Christoffel@voestalpine.com 39 05. October 2017 39 voestalpine Additive Manufacturing