ProgramPROGRAM

AM Process Session

Understanding and improving laser-material interactions in LPBF through imaging and modelling

We present results from our visualisation studies of atmospheric effects during laser powder bed fusion (LPBF). The interactions between the laser, metallic vapour, particles, and gas cross-flow are analysed both experimentally and through multiphysics modelling. We examine the production of process by-products, characterise their extraction and highlight the most important factors. Additionally, we explore the effects of increasing or reducing the atmospheric pressure, investigating the feasibility of LPBF under such conditions. Finally, simultaneous synchrotron x-ray and schlieren imaging experiments give insight into the joint behaviour of the melt pool, laser plume, and powder particles. The interconnected dynamics of the vapour and liquid phases are explored under varying energy input. Image processing and analysis aid in relating our observations to process stability. Ioannis Bitharas, Heriot Watt University, A.J. Ross, K. Perkins, A.J. Moore

Physical analysis, process monitoring and new developments on the LPBF process.

A new insight was put on the analysis of the LPBF process, with the combined use of instrumented set-up, dedicated diagnostics (high speed imaging, absorptance measurements …) and numerical simulation. The LPBF process was considered at two different scales : a mesoscale including melt-pool monitoring and a more macroscopic scale corresponding to cm-like 3D parts. A specific focus was put on the detection of geometric defects and the influence of the gas shielding (Ar, N₂ or He). Patrice Peyre, ENSAM/GIS/AFH. S. Traore*, Y. Mayi**, I. Koutiri, M. Schneider, M. Dal, C. Dupuy and F. Coste, Colin and J.D. Bartout. PIMM Laboratory, Arts et Métiers Institute of Technology, CNRS, CNAM, HESAM University 151 Bd de l’Hôpital, 75013 PARIS. Centre des Matériaux, Mines Paris-Tech, CNRS UMR 7633, 63-65 Rue Henri Auguste Desbruères, BP 87, 91003 Evry Cedex *Currently at CETIM, Additive Factory Hub, Saclay, France **Currently at Safran Additive Manufacturing Campus, Bordeaux, France    

Recent developments on monitoring solutions for DED processes, Towards a closed loop control of the processes

Geometry and temperature of the melt pool are key metrics that have to be controlled during DED processes. First the link between these metrics and the residual state of Al 5356 parts manufactured by WAAM is shown. Then a low-cost monitoring solution based on a simple RGB CMOS camera is presented. A bichromatic radiometric model is first calibrated on a black body. The proposed methodology is applied to LMD-p and WAAM processes. It enables to acquire the thermal map of the melt pool and the solid phase surrounding the melt pool without any knowledge of the heterogeneous emissivity map. Nicolas Tardif²³⁴, Nicolas Beraud¹, Thomas Elguedj², Joel Lachambre², Maxime Limousin¹, François Villeneuve¹, Frederic Vignat¹,1 G-SCOP, 2 LAMCOS, 3 INSA Lyon, 4 Initiative 3D

Optimization of mechanical part's quality based on a manufacturing strategy in WAAM process

Wire Arc Additive Manufacturing (WAAM) process recently attracted strong interest within different industrial fields because of its capabilities to produce large metal parts dedicated to aeronautics, automotive or energy domain. Xavier Lorang, IRT SystemX/AFH. Chetra MANG1, Ramdane TAMI1

L-PBF process monitoring

Benjamin Vayre, Add-Up

Coffee Break

Progress on L-PBF instrumentation and prospects for in-situ monitoring

The Laser Powder Bed Fusion AM process enables manufacturing components with complex geometries. Proposed solutions to address the quality control of the produced parts include the use of in-situ monitoring to obtain data while the process is running. We will present the in-situ monitoring approaches, current progress and perspectives. Florian Le Bourdais¹, P. Lapouge². ¹Université Paris-Saclay, CEA, List, F-91120, Palaiseau, France.² PIMM, Arts Et Métiers Institute of Technology, CNRS, CNAM, HESAM University, 75013 Paris, France.

In situ monitoring of melt pool for Wire Arc Additive Manufacturing

In this presentation, we present specific data acquisition for welding process and Wire Arc Additive Manufacturing to monitor the liquid metal. Then, specific treatments of images are presented in order to investigate the dynamic of the weld pool that drive the heat transfer during the manufacturing. These treatments offers nice perspectives to control on line wire arc additive manufacturing. Cyril Bordreuil, Université de Montpellier. F.Soulié, Ch.Hacquard, F.Deschaux-Beaume.

Post-Processing Session

Improving the corrosion properties of the 17-4PH martensitic stainless steel using additive manufacturing process – focus on laser beam melted specimens

Our two PhD theses explored different aspects of the corrosion behaviour, the susceptibility to stress corrosion cracking and hydrogen embrittlement of 17-4PH LBM MSS parts in relation with their microstructure and in comparison with those of the conventional counterpart. Adrien Barroux^1,2, Nizar Guennouni^1,3, Nadège Ducommun², Eric Nivet², Christophe Grosjean³, Daniel Maisonnette³, Julien Delgado⁴, Lydia Laffont¹, Eric Andrieu¹, Dominique Poquillon¹, Christine Blanc¹ 1 CIRIMAT, Université de Toulouse, CNRS, Toulouse, France.2 Cetim, Pôle Matériaux Métalliques et Surfaces, Nantes, France.3 Cetim, Pôle Matériaux Métalliques et Surfaces, Saint-Etienne, France. 4 Cetim, Pôle Matériaux Métalliques et Surfaces, Senlis, France.

Impact of heat treatments on alloy IN718 produced by SLM process

Bertrand Max, IRT Saint-Exupéry/Addim Alliance

Lunch

Mechanical and thermal treatment for additive manufactured components optimization

Christophe Desrayaud, LGF/MINES STE/Initiative 3D. J. Favre, G. Kermouche, F. Christien: LGF. J. Rech, P. Bertrand, E. Cabrol, H. Si-Mohand: LTDS

A first industrial feedback for the management of surface and internal states of WAAM made components

Amongst different AM solutions for Metallic Materials, the WAAM (Wire Arc Additive Manufacturing) process has been chosen by Naval Group for the fabrication of large, complex and critical components such as propellers, structure parts, fittings. This presentation delivers an industrial feedback based on Naval Group’s experience. Guillaume Rückert, Anne-Sophie Thorr, Naval Group

Design & Applications Session

How Design for Additive Manufacturing has created new product design opportunities ?

Additive Manufacturing (AM) brings new freedoms in terms of the product shapes that can be built and the ability to create multiple product versions. Increasingly, product designers and engineers are finding new ways to take advantage of these opportunities to create novel products, that would previously have been too difficult or too expensive to produce. Ian Campbell, Loughborough University.

Effect of process induced defects on the fatigue behavior of AS7G06 alloy obtained by SLM process

The prediction of the fatigue resistance of parts produced with Additive Manufacturing (AM) is a current issue for the materials and process qualification in aerospace industry. Despite a continuous improvement of AM process, the presence of defects cannot yet be completely avoided, and the latter are still one of the main causes of fatigue damage in AM materials. Thus, the impact of defects on the fatigue resistance has to be quantified in order to provide a proper assessment of fatigue strength. In this framework, the present work focused on the influence of defects on the fatigue behavior of AlSi7Mg0.6 alloys produced by Selective Laser Melting (SLM) submitted to T6 heat treatment. The fatigue behavior is assessed for uniaxial and torsion loadings. The variability of the material integrity is characterized by X-ray microtomography. Specimens containing CAD defects, allowing the control of the maximum defect size, are also studied. Results of fatigue tests are then analyzed through Crossland and Kitagawa diagrams. Benoit Tranchand, IRT / Addim Alliance. Mathieu Bonneric, Antonio Castro-Moreno, Charles Brugger, Nicolas  Saintier– Collab I2M/IRT

Coffee Break

Fatigue behavior of lattices structures obtained by Additive Manufacturing

Nicolas Saintier, I2M / Arts et Métiers ParisTech /Addim Alliance. E. Charkaluk, C. Brugger, A. Constantiniescu, J.J. Blandin 

Decarbonization acceleration through Additive Manufacturing

Additive Manufacturing is a key for aeronautical decarbonization due to the highly mass-optimized parts it allows. Nevertheless mastering this technology in industrial environment will require to address key characteristics of this process: material soundness and durability, geometrical conformance, ability of parts to be finished with classical industrial processes… Safran group chose to launch Safran Additive Manufacturing Campus in Le Haillan, to accelerate the development of additive manufacturing in aeronautics, by combining physical and digital data for fostering material, design and production Clara Moriconi , Safran 

Application of L-PBF technology to heat pipes production through optimization of process parameters.

Heat pipes are thermal exchange devices. In this work, a new approach to produce them is presented, by means of L-PBF additive manufacturing. In addition, the complex-shaped internal load is integrated into the structure by tuning operative parameters of powder sintering process. Luis Suarez Rios , IDONIAL

Closing Statement

Philippe Lubineau , Director R&D Programs, Cetim