Laser metal deposition manufacturing (LMD)
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- Опубліковано 4 жов 2024
- To find out more please visit the project website:www.merlin-proj... or go to TWI's website: www.twi-global....
A 5 axis laser metal deposition manufacturing method is being developed by TWI for an EU-funded project which is demonstrating drastic time reduction in the manufacture of aero engine casings.
In LMD, a weld track is formed using metal powder as a filler material which is fed, through a coaxial nozzle, to a melt pool created by a focused high-power laser beam. By traversing both the nozzle and laser, a new material layer develops with precise accuracy and user-defined properties. The application of multi-layering techniques allows 3D structures to be created.
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Hello ptonpc - it took 7.5 hours to build in a single visit (the time clock in the video is counting up in hours). It is a thin walled component and producing flaws in this particular geometry is unlikely (but always possible). The focus of the work was the manufacture of casings for aero engine test beds. When a small design change is implemented a traditional manufactured part can have a turn around of 6-8 weeks (taking into account the need to manufacture tooling). Carl@TWI
+carl hauser
wherein type of helicopter that is used?
carl hauser hello, can please explain if this technology is so slow can it in future compete with forging or casting which are very fast.?? if no then what is its use??
Would be awesome to see an orbital 3d printing platform to build large satellites and space stations in space
A good discussion - where to start? This method is certainly for low volume and high value components. But considerations have to be given across the entire production chain and the intended purpose of application. The part in the video is a real ‘hot’ casing for an aero engine. It was manufactured using off the shelf aerospace alloy powder, argon gas shielding (insignificant cost) and no clean room in site. The part is for test bed prototyping > hence each part is unique. With this in mind, tooling costs alone can be >$75k per part (I will translate to dollars) and lead times of several months. This is obviously a targeted application; not all applications will be appropriate for this method. Hardware is expensive, but lower cost alternatives are available (e.g. industrial manipulators), and maintenance costs scale accordingly. Yes its not cheap, certainly out of reach of the typical DIYer, but for some applications in some industries the material, time and cost savings are being taken seriously. carl@TWI
how u came to 75$ .he use el power ,and powder ,1 bag of powder is 100€ -20kg's
@@MrCcflyit’s not $75, it’s $75,000
Great job: find us if you need Inconel or Titanium alloy wire feed!
@Green98 money
Is your technology capable of printing a steel version of what resembles closed-cell foam? Steel's disadvantage for making lightweight bicycle frames is that tubing's wall thickness has a limit to how thin it can be made. One possibility with future LMD is to fabricate bike frames with cross sections that resemble bird's bones.
How far are we in LMD technology?
like the hollow bones of flight birds?
amazing
This is the superior method of printing IMO.
Of all the ways to 3d Print alloys, this is the way.
All other ways have added cost and time .
I don't think so. Added cost is a minor aspect when accuracy is lower
SLS where the whole part is covered might be faster actually
Tech is Dope!
This is not EBM, correct? Stratasys has a online class that links to this video, saying it's an EBM process. This is using lasers not an electron gun.
You are correct this was done on a Trumpf 505 with a Co2 laser
Impressive
Damn ! The guy who built this machine really wanted its aluminum rim!
It woulb be awesome if you would do it in this speed
Im assuming this works the same way a 3d printer works. Design your part in a CAD program then upload the file? What kind of tolerances can this mechine print in? I was one of the few in my high school to be trained on CAD design, cnc mechines, laser engravers and 3d printers. I believe i was one of two students that could freely print and had the knowledge to opporate the mechine. I love this tech. Its going to take us beyond this stoneage manufacturing era.
I see a long term vision in this technology. Do you?
1InfinityShade programmed path , not like a 3D printer
@@navishkotwal Yeah mate you were true.!
What pressure is used to deliver powder to print bed ? Is it 200W laser tube or something stronger ?
so ... how much power was consumed in the process?
+jannwestermann - power or powder? 1.1Kg of powder was used. The part weights 750g (70% efficient)
+carl hauser Sorry ... I meant how much power was consumed ... in watts
+jannwestermann ~950W
1.1 Kg in 7h 35 min means a flow rate of 2,41 g/min... seriously so low?
@@carlhauser1073 to clarify, that's 950W of power while welding, right? So for basically 7.5 hours of runtime, that part required about 7.2 kilowatt hours of energy. I think that's actually very efficient if that is the case.
Is any post-processing like sintering required to achieve final mechanical properties?
I don't believe so, it's basically like additive tig welding, but on a near microscopic scale. This allows the metal particles to align in a uniform direction, which makes the metal much stronger.
Video was great, up until a giant picture-in-picture box showed up and blocked the main screen :(
Pretty cool!
Though it is very useful for manufacturing of intricate shapes.. But i doubt it's strength
What material is the build plate made of and how is the part separated from it?
Which metal is used here..?
Looks very good. How many different metals can you print?
+Vatsek - most metals that can be welded (and some that cannot) can be processed by this route - providing they are available in power form.
Could this process be done using a simple mig welder?
Only if you can weld inside a totally inert gas environment.
Imagine if every object/part made of metal was constructed this way. :D We'd eliminate so much waste.
Maybe, maybe not. It would take a lot of material to build enough of these machines to meet world demand for metal parts, as these machines are not fast. The same part could have been made in a less demanding application (and with worse form tolerance) from pipe stock with metal spin bending in a few minutes or a press brake in a few seconds, and likewise with zero waste. It really depends on form tolerance and materials properties what's appropriate.
→ to the knee using high power laser to melt metal power to produce a CAD design is very costly. The machine can be 1 million dollars US, the periodic maintenances, adjustments, the precision parts change, laser beam deterioration, etc, etc.
One hour of operation can easily be a couple of thousand dollars.
This type of technology is used for making moulds, or one-off really expensive difficult to produce parts.
golferchin76 It doesn't have to be expensive though, if not for the patents i imagine you could do it for $1000 or so. It doesn't require the rigidity that CNC milling machines do, this is more like a cheap plastic filament 3D printer, coupled with a laser cutter.
I imagine that the major drawbacks of the tech are pretty straightforward, and similar to existing metal-powder deposition 3D printers:
- It requires an oxygen-free and wind-free environment (ie: it must be done inside a sealed box).
- The metal powders are often proprietary and thus expensive, and somewhat dangerous to handle (fine particle breathing hazard).
puddingpimp Yes, but if said machine makes a million wheels I think he's comment applies.
roidroid That initial laser set up alone would cost an arm and a leg do DIYers. The hourly running cost is amazing as well. Also 5 axis = huge money in software and hardware. You are right, such things has to run in dust free clean room, probably with inert gas shooting at focal point, specially made materials, and any short-cut attempted to save cost will guarantee a downtime causing bigger costs. (Without frequent periodically maintenance, that laser would burn its own lens-mirrors set up even in clean room.)
I understand that there are sub $1,000 DIY kits out there for building xy plotter style 3D prototype machine. Those are strictly hobby use, the layer resolution is really bad even for DIYers.
For industrial and business, where precision, speed, power output, durability, etc, etc, are needed, there is just no cheap solution.
The 'cheapest' 3d printer layer by layer with the very fine resolution normally needed by businesses, costs $150k upward, and we are talking resin materials only. (There are cheaper machines but the use-ability, low efficiency, problems in production, would translate to more costly.)
When factor in all the upkeep thus the hourly running cost, it's like +$500 per hour. But that $500x3hrs we can produce like 10- 20 pcs of small prototypes depending on item size. Definitely cost a lot less compare to traditional production methods.
I guess at the end of the day these 3d prototype machines are really unique, niche to each business model. Some use these to produce toolings, some use these for one offs, some use these for small/fast/variable production runs, etc.
One thing for sure, when it is 3D building with metallic material, it is super expensive.
I don't know what it was building in the video. But that 8 hours can translate to $5000 dollars with ease.
1 ramro lagyo
RUB !
What is WAAM and DED? This is
how strong is this compared to other materials used? it looks bad ass,!! :)
@DANTHETUBEMAN
From what I've heard, much stronger. Particles are aligned more uniformly than other manufacturing methods, resulting in a much stronger molecular structure.
WOW!
I feel like this part could have been spun.
I cant see the end of this video because you overshow others lnks
How to remove the structure from build plate?
use scraper
how is going this technologie versus leyer by leyer. This is like FDM and the other one is lie SLA.
Сделал одну деталь, вот и смена рабочая закончилась. :-)
made one detail, so the change of work ended.
Юрий Анисимов гугл кому надо лучше бы перевел. не пиши больше на английском, пожалуйста
гуглом и перевёл :-)
ok mind is blown
hey could you please mention the build plate material, thanks.
I believe it was carbon steel.
@@tomasomaccio7606 thanks man!
How long did it take and how much of a difference is this compared to conventional production methods?
Is there an increased chance of flaws with this method?
As far as flaws go, rare but possible. Turnaround is ~8 hours from modification to new part vs 6-8 weeks with traditional machining.
Richard, Really? Don't go spreading false information. As a lathe machinist I can make that part in a matter of minutes not six to eight weeks.
@@brandons9138 That turnaround includes sending out plans, machinists getting proper materials, waiting until there's time to get to the work order, then ship/courier it back. Also, many of these parts are made with more exotic metals, such as titanium. It's much more difficult and/or expensive to find chunks of titanium that large to machine a part like that out of. In the case of additive machining, you just have all the necessary metal powders on hand, load up your design and "print".
@@brandons9138 Lmao pls dont embarrass yourself if u aint got a clue what turnaround time refers to.
@@johnwig285 I've been a machinist for 15+ years now. I'm plenty versed in what turn around time involves. The simple fact is that 3D printing is slower than machining. As far as Andrews comment all of that same lead time applies to printing the part as well. I can have tooling for machining just about any material in my hands on the same day it's ordered.
can this produce structural steel?
We can process many Fe based alloys
Suppose LDT (or LMD) is the same technology as EBAM !
No, this uses lasers, EBAM uses electron beams. Hence the "E" in EBAM and the "L" in LMD.
I would like to buy this nozzle from the head.
whether it can be used to make dental crowns and bridges?
I assume you have to cut the part off of the base
Speed 1.5x and enjoy
You made a bowl
Damn that is some fresh meme