At Mizar Additive we have three techniques used for this technology: SLS (Selective Laser Sintering), DMLS/SLM (Direct Metal Laser Sintering) and EBM (Electron Beam Melting). One of the main features of this technique is the possibility of producing components in titanium or nickel metal alloys. In addition, it also offers advantages in producing parts with a very consistent internal structure. In addition, it also offers advantages in producing parts with a very consistent internal structure.
This is a process, especially in the case of metals, where the cost of powder can account for up to a third of the total production cost of the final component. Commercial viability, therefore, depends on a strong supply chain and effective metal dust recycling strategies. In addition, the chemical and physical properties of the metal powder directly affect the manufacturing process and the final quality of the component. To maintain process robustness and consistency, these properties must be controlled and optimized.
For this purpose, it is necessary to characterise the properties of the powder at the different stages of the supply chain, from the development of new alloys or polymers to the recycling of the powder.
There are four key analytical techniques commonly used to characterize additive manufacturing powders:
- Laser diffraction
- Automated image analysis
- X-ray fluorescence
- X-ray diffraction
These four techniques are used for the following purposes:
To know the particle size
Particle size distribution is critical to PBF additive manufacturing processes as it affects the packing and flowability of the powder bed, which in turn affects the build quality and final component properties.
To measure the particle size distribution of metallic, ceramic and polymeric powders, laser diffraction is used. It is a technique used by powder producers, component manufacturers and machine builders around the world to qualify and optimize powder properties.
To study the shape of particles
The density of the powder bed and the fluidity of the powder are directly influenced by the size and shape of the particles.
The shape of particles is therefore another important metric for PBF technology and is studied through automated image analysis. Smooth particles and regular-shaped particles are preferable because they can flow and pack more easily than those with a rough surface and irregular shape.
To analyze the elemental composition
Elemental composition is particularly important for metal alloys, as small variations in the concentration of alloying elements can affect chemical and physical properties such as strength, hardness, fatigue life and chemical resistance.
In order to detect these variations, contaminants or inclusions and to determine the elemental composition of these metallic alloys and ceramics, X-ray fluorescence (XRF) systems are commonly used.
To determine microstructure
Microstructural characteristics such as phase composition, residual stress, grain size and grain distribution (texture) are of vital importance for additive manufacturing of metals as they can affect the chemical and mechanical properties of a fabricated component.
Bench-top X-ray diffraction (XRD) systems are used to analyse these microstructural features and to control the properties of the final component.
Types of PBF
Depending on the source of energy used to melt the material, Mizar has two types of PBF technology:
- Laser fusion which, in turn, has two techniques:
- SLS (Selective Laser Sintering)
- DLMS/SLM (Direct Laser Metal Sintering)
- The electron beam fusion which has a technology:
- EBN (Electron Beam Melting)
Possible applications of the technique
The PBF makes it possible to obtain components in metal alloys and thermoplastic polymers. Due to the possibilities, it offers for the production of parts in metals with added characteristics, the most advanced applications tend to be in metal parts. Thus, this technology is mainly used in the industrial and aerospace sectors to obtain titanium or nickel components, as mentioned above.
At Mizar, we produce, by means of this technique, components for turbomachinery such as centrifugal compression rotors and other elements such as lifting fittings for the industrial sector.
If you want to know more about our capabilities to manufacture components with Powder Bed Fusion technology, contact us and we will help you.
