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Procedia CIRP 46 (2016) 579 – 582
7th HPC 2016 – CIRP Conference on High Performance Cutting
Study on consistently optimum deposition conditions of typical metal
material using additive/subtractive hybrid machine tool
Adam Hansel(3)a*, Masahiko Mori(1)a, Makoto Fujishima (3)a, Yohei Odaa, Greg Hyatta, Enrique
Laverniab, Jean-Pierre Delplanqued
a DMG MORI SEIKI CO., LTD., 2-35-16 Meieki, Nakamura-ku, Nagoya City, Aichi 450-0002, Japan
b University of California, Davis, One Shields Avenue Davis, California 95616-5294
Submitted by Tojiro Aoyama (1)
* Corresponding author. Tel.: +1-916-718-3042; E-mail address:
[email protected] Abstract
Additive manufacturing (AM) is increasingly being pursued as a practical approach for component manufacturing. Current AM technologies
present certain challenges that are solvable with novel additive/subtractive hybrid machine platforms. Production of work pieces with
consistent and viable material properties remains elusive. This work reports on a primary study to define combinations of additive process
parameters and nozzle selection that result in quality work pieces. Specifically, AM work pieces of X2CrNiMo17-12-2 and Inconel 625 where
characterized principally by porosity followed by tensile strength, hardness, and microstructure to determine optimal process parameters. A
Taguchi analysis suggested desired work piece quality is achievable on a hybrid machine platform by adjusting AM process parameters
© 2016
© 2016Published
The Authors. Published
by Elsevier by Elsevier
B.V This is an openB.V.
access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair Prof.
Peer-review
Matthias Putz.under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair
Prof. Matthias Putz
Keywords: Rapid prototyping, Material, Additive manufacturing
1. Introduction developing suitable hybrid additive/subtractive machine
platforms is desirable.
Additive manufacturing (AM) technology is increasingly There are two main methods for additive manufacturing
being recognized as a viable and cost effective manufacturing using metals today. The first is Directed Energy Deposition
approach for producing high quality parts for various (DED). DED is defined by ASTM as an additive
industries. AM has been deployed, not only for prototype manufacturing process using focused thermal energy to fuse
parts, but also for industrial components, in an effort to reduce materials by melting as the material is being deposited. The
tooling requirements or to produce parts with higher
complexity that cannot be made with conventional machining
[1]. AM is often used for making automotive parts, aerospace
parts and medical parts; therefore quality and reliability of
finished work pieces is of paramount importance. Recently,
AM has been employed for flight critical engine parts by
Space-X in their SuperDraco thruster [2]. In addition to new
parts, remanufacturing of high value added parts such as
turbines blades utilizes additive methods to repair voids and
cracks in order to extend the working life of the component
[3]. When combined with conventional subtractive machining
processes for finishing, AM in more and more cases is able to
produce definitive parts for a variety of industries, thus Figure 1 Space-X SuperDraco engine chamber [4]
2212-8271 © 2016 Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair
Prof. Matthias Putz
doi:10.1016/j.procir.2016.04.113
580 Adam Hansel et al. / Procedia CIRP 46 (2016) 579 – 582
thermal energy is supplied by laser, electron beam, or other sensitivity to varying process parameters to achieve industry
means. The second method is a powder bed. Rather than acceptable quality and accuracy is lacking and a method to
build parts by depositing material as in DED, the part is built easily quantify the quality of an additive manufactured part
in many thin layers. Subsequent layers are then fused to the has yet to be completed.
previous layers by selective laser sintering (SLS) or other In this paper, in order to enable the use additive/subtractive
similar processes. Subsequent post processing by milling or fabricated parts as industrial parts, appropriate nozzle
other procedure is obligatory. geometry is concluded and suitable process parameter
Additive manufacturing is similar to near net shape casting combinations are determined by experimental methods.
parts. They cannot be used directly in their additive finished Fabricated materials are evaluated by microscopic
state without additional conventional post processing. examination and mechanical tests of hardness and tensile
Additional disadvantages from conventional milling processes strength. An optimal set of process parameters is established
that must be solved include protracted metal deposition rates, for single wall, steady state AM and applied to an aerospace
inferior surface and form accuracy, variable material test part.
properties, and expensive capital equipment. In order to
address some of the challenges as well as to improve additive 2. Experimental methods
manufacturing technology, the authors have developed an
additive/subtractive hybrid machine that uses a DED type Integral to the DED process, the nozzle geometry was
laser unit with the objective of combining advantages of both suspected to have a major impact on the final quality of the
additive and subtractive processes. deposited material as well as the AM disadvantages
Hybrid additive/subtractive machine platforms have the aforementioned of metal deposition rates, surface finish,
potential to realize rapid manufacturing and high accuracy in material quality, and form accuracy. A widely accepted
a single setup. The DED method was adopted as an additive nozzle design is the coaxial form with the laser and shielding
manufacturing method, primarily because of high deposition gas directed through the center orifice and the material
rates and adaptability of the equipment to a milling platform. particles and carrier gas directed through a concentric ring. A
It is important to note that a milling platform cannot maintain second type variation of this nozzle is the pseudo coaxial
an inert environment which must be overcome in the process. nozzle with individual particle channels arranged around the
In order to take advantage of a hybrid platform, the center orifice. To check the performance of both variations, a
additive process must be stable and predictable, although it is flow analysis was conducted.
variable in nature and produces significant residual stresses. To find optimal deposition parameters, stainless steel 316l
While intermediate heat treatment can be used to reduce (X2CrNiMo17-12-2) and Inconel 625 were chosen as a test
residual stresses and obtain suitable material properties [5], it material in this study due to their common use in industry.
defeats the advantage of producing a finished part in a single The tests were carried out varying four parameters: laser
setup. Therefore, it is necessary to optimize parameters for the power (Kw), feed rate (mm/min), powder flow (g/min), and
additive process to achieve desirable results using a hybrid carrier gas flow (l/min). The median value of each parameter
platform. Parameters hypothesized to have fundamental was selected on the basis of process know-how. The
influences on the final quality of the work piece are laser minimum and maximum values were selected by applying a
power, powder flow rate, shield/carrier gas flow rate, and feed range based on equipment capacity.
rate. Using the Taguchi Method with an L9 orthogonal table, the
Inspection of the literature confirms that these are indeed optimal parameter values were obtained in this study with
important parameters. For example, Furumoto et al. only nine experiments. Test samples of 40mm (W) * 35mm
investigated laser consolidation process by the measurement (H) * 3mm (D) were fabricated as indicated in the L9 array.
of temperature with the selected laser sintering (SLS) method Each test sample was cut and polished then examined. Test
[6]. Amine et al. researched the microstructures of fabricated results were assessed by counting the number of pores larger
stainless steel 316 material under several process parameter than 0.010 mm diameter, as a preliminary metric of
combinations with directed energy deposition [7]. Telesang et microstructural integrity. Subsequently metallographic
al. researched microstructure and hardness of fabricated AISI characterization of the samples was performed to provide a
H14 tool steel material with directed energy deposition [8]. comparison of the relative influence of the various parameters
However, a systematic study of work piece integrity studied. Additional tensile and hardness testing was
conducted to confirm stable material.
Figure 3 Coaxial nozzle (left), psuedo coaxial nozzle (rights
Figure 2 Developed hybrid machine (image courtesy of DMG MORI)
Adam Hansel et al. / Procedia CIRP 46 (2016) 579 – 582 581
3. Result and discussion 3.2. Metallurgical observations of porosity and microstruture
3.1. Nozzle analysis and selection The examples of microscopic examination results for SUS
316 and Inconel are shown in Figure 7 and Figure 8. The
In order to consistently integrate metal particles at a number of 0.010 mm or larger pores was recorded. Many
constant temperature into the melt pool formed at the focal pores are observed in Figure 7(a) and good quality is observed
point of the laser, it is desirable to have a concentration of in Figure 7(b), a large pore is observed in Figure 8(b) and
particles as close to the center of the melt pool as possible. good quality is observed in Figure 8(a).
The coaxial nozzle simulation exhibited a wide distribution Figure 9 shows typical small dendrites formed in deposited
pattern with particles concentrated some distance from the materials. The dendritic structure did vary in size, but in
center of the melt pool. For particles with nominal sizes from general, was not well developed which indicates that the
10 to 63 microns, which is the acceptable range for this additive machined samples experienced medium cooling rates
nozzle, the dead spot was two to three millimeters in during the solidification which is desirable for consistent
diameter. This effect can be attributed to the shielding gas material formation.
being directed away from the center along the substrate which
in turn pushes the particles away from the center. The
distribution is only marginally dependent on particle size.
The pseudo coaxial nozzle has paths between the particle
streams for the carrier gas to escape which results in some
particles reaching the center of the melt pool and the main
concentration of particles is located within 1.5 millimeters of (a) Test result of #1 (b) test result of #9
center as indicated by the simulation. This is more than a Figure 7 Microscopic examination result of SUS316
50% improvement on the coaxial nozzle. As a result of these
simulations, the pseudo coaxial nozzle was selected as the
nozzle which would result in optimal deposition.
(a) Test result of #2 (b) test result of #7
Figure 8 Microscopic examination result of Inconel
Figure 4 Planar particle distribution for co-axial (left) and pseudo (right)
(a) SUS 316 (b) Inconel
Figure 9 Typical dendritic microstructure found in both materials
3.3. Process parameter sensitivity
Using the porosity measurements, the SN ratio is specified
by the Taguchi Method, shown in equation (1),
σ మ
సభ ௬
ܵܰ ൌ (1)
Figure 5 Cross section particle distribution coaxial nozzle where yi is the total number of pores larger than 0.01 mm and
n is the number of experiments per condition (n = 3 in all
cases). Sensitivity of process parameters to the work piece
quality is determined and an optimal set of parameters is
selected for additional testing.
Figure 10 Factorial effect graph of SUS 316
Figure 6 Cross section particle distribution pseudo coaxial nozzle
582 Adam Hansel et al. / Procedia CIRP 46 (2016) 579 – 582
Table 2 Deposited samples compared to cast and wrought states
Cast Deposited Wrought
SUS316 Tensile (MPa) 517 520 580
Yield (MPa) 172 297 290
% elong 39 27 50
Inconel 625 Tensile (MPa) 620 751 978
Figure 11 Factorial effect graph of Inconel Yield (MPa) 327 460 593
% elong 23 37 42
For stainless steel, on the basis of the Taguchi analysis,
laser output = 2000 W, feed rate= 1000 mm/min, powder flow 4. Summary and conclusion
= 18 g/min, carrier gas flow = 4 l/min performed optimally as
shown in Figure 10. For Inconel, laser output = 2000 W, feed In order to validate the use of DED on a hybrid platform,
rate = 1000 mm/min, powder flow = 18 g/min, carrier gas two common materials, SUS 316 and Inconel 625, were tested
flow = 4.8 l/min performed optimally as shown in Figure 11. by varying four process parameters using nozzle geometry
Both optimal parameter sets for each material yielded chosen by simulation for best particle distribution. A Taguchi
results with minimal pores when compared to experimental analysis was used to find the optimal parameters by
runs of other parameter sets. Additionally, they yielded the considering porosity to be the critical factor of merit.
same appropriate dendritic microstructure previously seen. Subsequent process parameters were selected as optimal and
tested for porosity.
3.4. Tensile test result Further tensile testing was conducted for yield strength,
tensile strength, and % elongation. The optimal set of
To validate the optimal set of parameters chosen, parameters for Inconel 625 was roughly between cast and
additional testing of tensile testing and hardness was wrought while the SUS 316 exhibited yield strength similar to
conducted. Figure 12 depicts a completed tensile test in the wrought. Inconel 625 parameters were suitable for high
SUS 316 material. Table 1 is sample data of tensile testing integrity castings-type parts. The SUS 316 had a low tensile
drawn from specimens created for porosity checks previously. strength, but a suitable yield strength which is normally more
The rows of the table with yellow shading are the tensile and important than tensile strength for most applications, so the
hardness results from the parts created using the optimal set of SUS316 parameters are suitable.
parameters. Thus, it is concluded that optimal build process parameters
chosen through a Taguchi analysis are well suited for a hybrid
additive/subtractive machining that has a non-inert
environment.
Figure 12 SUS 316 specimen post tensile test References
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