Fundació CIM
C/Llorens i Artigas, 12
Parc Tecnològic de Barcelona
Barcelona, Spain
ADDITIVE MANUFACTURING
PROJECT CLUSTER MEETING
TOPIC: EX: AM for Metal Parts – Project REProMag
Prof. Carlo Burkhardt, PhD
OBE Ohnmacht & Baumgärtner GmbH & Co. KG
[email protected]
2 May 2016
REProMag PROJECT DESCRIPTION
• REProMag = Ressource Efficient Production of Magnets
100% waste free production of Rare-Earth Magnets (Nd-Fe-B) from recycled
material in a closed material loop
Potentially available Nd-Fe-B magnets for recycling (2015, Germany only)
• Computer/Laptops
>60 tons per year
• Passenger cars (ICE)
>450 tons per year
• Electrical motors (industrial)
>30 tons per year
 today available
>500 tons per year
Outlook:
Hybrid cars:
Electrical cars:
Wind turbine
>10 kg/ car
>30 kg/car
>600kg/MW
REProMag PROJECT DESCRIPTION
• REProMag = Ressource Efficient Production of Magnets
Ni- Beschichtung
(wird abgesiebt)
NdFeB Pulver
3
REProMag PROJECT DESCRIPTION
Nd-Fe-B-Powder
Mixing
Extruding
Feedstock
Binder
Injection Moulding
Green part
green part
alternative: 3D- print (FFF)
4
REProMag PROJECT DESCRIPTION
Nd-Fe-B-Powder
Mixing
Extruding
Feedstock
Nd2Fe14B
Binder
Nd1+eFe4B4
Solvent
debinding
Injection Moulding
Nd-rich grain boundary phase
Green part
Thermal
debinding
Sintering
Brown part
Sintering
5
REProMag PROJECT DESCRIPTION
Magnets with complex shapes
High Precision
Lower torque ripple
Integration of cooling, fixations etxc
New concepts, miniaturisation
High level of individualisation
Fast Proof of Concept, fast serial
production
6
REProMag PROJECT DESCRIPTION
• Additive Manufacturing Process:
Fused Filament Fabrication (FFF / FDM)
laser polished
in the green
part state
___ 1 mm
as printed
___ 1 mm
filament production
green part
sintered part
surface appearances in sintered state
7
Exploitable results (ERs)
• ER 1
• Industrial production of hard magnets based on NdFeB with complex geometrical
features 100% waste free from recycled material in a circular industry in large quantities.
• ER2
• Industrial production of hard magnets based on NdFeB with complex geometrical
features 100% waste free from recycling material in a circular industry in small
quantities/ prototype scale without tooling for fast proof of concept.
• ER3
• Applicability of the production method for Ti- and Ni-based alloys, ferrites (magnetic
material), alloys with complicated microstructures (e.g. where longer diffusion processes
and or liquid phase sintering required)
ER 1
Describe the type of result and the resulting innovation
• Demonstrator parts with high energy product and complex geometry
Potential customers
• Industries using magnets and sensors
•
•
•
•
Automobile
Electronics
Aerospace
Medical
Customer Benefits
• Better accuracy
• Higher performance
• New applications possible (miniaturisation)
ER 1
Technological Readiness Level
•5
Milestones in the TRL progression up to TRL9
• setup of demonstrator toolings (07/2016)
• complete qualification of the process (10/2017)
Main technical challenges in this result
• Extreme reactivity of the material with C and O to form oxides and carbides
• magnetic alignment of particles
Time to market (Mth/yr): Dec 2017
ER 1
IPRs
• Have you protected or will you protect this result before disclosing it?
• Processing technology and 2 typical applications (design features of electrical motor)
• How?
• International patents (PCT)
• When?
• Dec 2015
ER 2
Describe the type of result and the resulting innovation
• Demonstrator parts with high energy product and complex geometry
Potential customers
• Industries using magnets and sensors
•
•
•
•
Automobile
Electronics
Aerospace
Medical
Customer Benefits
•
•
•
•
•
Better accuracy
Higher performance
New applications possible (miniaturisation)
Fast proof of concept /quick time to market
Solution for small quantities
ER 2
Technological Readiness Level
•3
Milestones in the TRL progression up to TRL9
• Qualification of the 3D printer (12/2016)
• Complete qualification of the process (7/2018)
Main technical challenges in this result
•
•
•
•
Extreme reactivity of the material with C and O to form oxides and carbides
Selection of suitable feedstock formula
Magnetic alignment of particles
Machine technology to improve surface quality
Time to market (Mth/yr): Mid 2018
ER 2
IPRs
• Have you protected or will you protect this result before disclosing it?
• Processing technology and surface treatment
• How?
• International patents (PCT)
• When?
• Dec 2015, April 2016
ER 3
Describe the type of result and the resulting innovation
• Applicability of the production method for Ti- and Ni-based alloys, ferrites (mag- netic
material), alloys with complicated microstructures (e.g. where longer diffusion processes
and or liquid phase sintering required)
Potential customers
• Medical (Ti-Alloys)
• Automotive, Aerospace (Ni-based alloys)
• Tooling industry (hardened low alloy steels with better crack-stability)
Customer Benefits
• Tailored microstructures
• Tailored surface features
• Better mechanical and thermal stability
ER 3
Technological Readiness Level
•5
Milestones in the TRL progression up to TRL9
• Setup of demonstrator toolings (12/2016)
• Complete qualification of the process (12/2017)
Main technical challenges in this result
• Timeline
Time to market (Mth/yr): Dec 2017
ER 3
IPRs
• Have you protected or will you protect this result before disclosing it?
• Yes, see ER 1 and 2
• How?
• International patents (PCT)
• When?
• Dec 2015, April 2016
Expressions of Interest
Expressions of interest in the results of the other projects
M1-US-QuesTek
ER2
Commercial availability of one of QuesTek Innovations’ new Ti 6-4 Mod alloys
that has greater strength and toughness vs traditional Ti-6-4 used in AM, with
a stretch goal of meeting or exceeding the properties of wrought Ti-6-4.
ER3
Design of a new Co, Ni or other alloy tailored specifically for AM that can be
applied to a range of industries such as medical, aerospace and heavy industry.
It is readily agreed upon that the use of existing “off-the-shelf” alloys for
additive manufacturing poses a number of manufacturing and material
performance issues, and new materials designed to the unique processing of
AM need to be invented.
Expressions of Interest
Expressions of interest in the results of the other projects
M1-US-EXOVA
ER1
ER2
ER3
Design allowables of 3D printed materials for product designers to
exploit the introduction of new materials in critical applications.
Development of standard test and qualification protocols for raw
material qualification/verification, process and machine qualifications,
and product qualification and quality control.
Development of adequate surface finish to produce net shape parts and
avoid machining or other expensive finishing processes.
Expressions of Interest
Expressions of interest in the results of the other projects
M13-EU-AATID
ER1
ER2
ER3
Optimal processes for printing, welding and post-processing of Ti printed
parts.
Selection of the most appropriate (powder bed) printer and most
worthwhile parts to be printed @ specific technology.
Design rules of bionic parts based on topology optimization combined with
printing technologies limitations.
Expressions of Interest
Expressions of interest in the results of the other projects
M14-EU-Nanotuned
ER1
Develop a raw material (metal powder) to be processed by additive
manufacturing techniques (with powder bed fusion –selective laser
melting (SLM) and electron beam melting (EBM))- based on a
nanomodified Ti6Al4V alloy with enhanced structural performance
versus standard alloy (tensile properties 30-40% better; hardness,
fatigue and wear properties enhanced 20-30%,
Expressions of Interest
Expressions of interest in the results of the other projects
M6-SA-MEDAERO
ER1
ER2
ER3
Proven methodology for characterising Ti6Al4V powder and parts
produced (through selective laser melting) with a view on qualification of
materials and AM processes.
Validated post-processing treatments required to enhance the
microstructure and mechanical properties (of selective laser melting)
Ti6Al4V parts to comply with standard specifications for the wrought alloy.
Qualified process chains for producing Ti6Al4V medical implants and
structural aerospace components (through selective laser melting)