MODERN MANUFACTURING flow, torque, powder consumption, porosity, and so on. Should a spike in the data output be observed, the print can be halted, and the problem fixed. This innovative use of sensors acts as a monitoring device in real time.
Innovation in Laser Technology
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eAM machines, which are now part of the AddUp group, design and produce industrial metal additive manufacturing machines that apply Directed Energy Deposition (DED) technology. DED is an Additive Manufacturing process where focused thermal energy is used to fuse materials by melting them as they are deposited. The real advantages of the DED process can be found in the wide variety of industrial applications. These include, but are not limited to, extending the life of parts by providing wear resistant coatings, repairing damaged or broken parts, using multi-materials in one application and creating additional structures on pre-existing parts to provide different or improved functionality. Building precise complex geometries is a feature of the DED process. An example of a repair can be found in a worn labyrinth seal from an aircraft with a finish that met qualification standards. Here, advantages of DED processes are gained through accurate repeatability compared to a manual
welding process and the result is high mechanical strength due to very fine microstructures with no cracks or bonding failures. The process benefits from being conducted in a controlled environment that ensures high-quality in the final material, while the operation is conducted within exceptional safety standards. BeAM joins AddUp First developed in France, BeAM machines have now joined AddUp with operations commencing in Cincinnati USA. This move strengthens the offerings to customers, as AddUp provide a complimentary technology of Laser Powder Bed Fusion (L-PBF). BeAM machines include the Modulo 400 and Magic 800. Both machines use a custom-built nozzle mounted on the Z-Axis of a CNC machine, providing a simultaneous 5 axes process. The co-axial nozzle is moved in 3 linear axes while the build platform works in 2 rotational axes operating in a controlled atmosphere. This set-up allows 5 continuous axes of freedom, to build or repair components layer by layer. By utilizing traditional CNC controls and using ISO G-code customers are provided tools to which their skilled workforce is already accustomed. All BeAM machines offer automated quality assurance software displaying real-time data on a screen, which is compatible with 4.0 platforms. Some 80 different parameters can be monitored including gas
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Machines designed to meet customer needs These 5 axis machines have been designed and manufactured for industrial purposes to meet customer requirements. Each BeAM machine is modular, upgradable and offers high performance. Modulo 400 for example, has a 640 x 400 x 400 mm build volume, (the Magic 800 has an 800 x 800 x 1200 mm build chamber), a process module with 5-axis kinematics, the DED deposition nozzle, ‘powder tight’ enclosure, an air extractor and a filtration unit that provides exceptional operational safety standards. Additional peripherals can be added, but the whole system fits into a shipping container, enabling transportation and operation to remote locations. BeAM provide a range of industrial nozzles for the deposition process that offer precise, variable deposition widths from 10Vx, single gas follow, or 24Vx, dual gas flow, that varies the deposition volume depending on your needs. The laser beam is employed as a heat source to melt the metal powder that is deposited on a substrate layer by layer for the generation of a desired component. All deposition parameters are modifiable - powder mass flow, deposition speed, and laser power. The nozzles are powered by a high-quality reliable fiber laser source of 500 W or 2 kW. The heat source melts the metal powder that is deposited on a substrate, layer by layer. This unique capability enables new sections to be added to parts using ‘near net shaped’ geometries.
These can comprise large dimensions, complex shapes, embrace multi-material builds and most often do not require supports to ‘hold’ the part during the DED build. Innovative manufacturing ‘Near net shape’ refers to building a component to be close in size and shape to the desired finish, providing an innovative method of manufacturing with high-value materials. While the advantage of this process means less post-processing and less material waste, a key advantage is that new sections or additional features can be added to an existing part. A recent development in-house used a rocket nozzle made from 304
Stainless Steel and ‘over-printing’ an Isogrid in Inconel 625 using a Magic 800 DED machine. Following this a top structure was built using a layering process. The completed product was finished within 18 print hours.
Technologies combine to innovate The success of the relationship between AddUp and BeAM recently resulted in a concept part created across both platforms, Laser Beam Melting and Directed Energy Deposition. A hybrid piston head was constructed to demonstrate the technology can produce high performance parts by introducing lattice structures to reduce weight, with internally positioned oil channels that would serve to increase performance. First, the piston core was built using a FormUp 350 laser printer. The piston core was then placed in a BeAM DED machine where rings were created on the top section using a different material (Inconel 625). The 5 axes build platform in the BeAM Magic 800 deposited the rings to increase wear resistance and better performance under high temperatures. The final product demonstrated the effective combination of both technologies paving the way for innovation in manufacturing. If you would like to discuss DED technology with BeAM machines or and AddUp LBM systems come and meet Dr Cédric Chaminade, Technical Director at Raymax Applications Pty Ltd on our stand at Modern Manufacturing. Raymax Lasers raymax.com.au
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