Inside GKN Powder Metallurgy’s Acquisition of Forecast 3D

January 27, 2020 / AEROSPACE HEAT TREAT NEWS, FEATURED NEWS, MEDICAL HEAT TREAT, MEDICAL HEAT TREAT NEWS, SINTERING POWDER METAL NEWS

Picture two men sitting at a bar table watching a video on a smartphone. As they enthuse about how much they love it, a bystander might be tempted to think they’re just killing time goofing off. “It’s fantastic technology,” the man with the phone, Forecast 3D founder and CEO Corey Weber, says of the Multi Jet Fusion (MJF) process featured in the time-lapse video that shows a Californian facility in the dead of night illuminated only by the passing of a dozen lights flashing over a dozen powder beds through until the morning. As he pulls back his smartphone, he and Guido Degen, GKN Powder Metallurgy’s President of Additive Manufacturing, look pleased with both the technology and themselves.

Corey and Donovan Weber, Forecast 3D, and Guido Degen, GKN

GKN Powder Metallurgy’s acquisition of Forecast 3D appears to be natural synergy. Much of Forecast 3D’s expertise exists in polymer 3D printing, serving the aerospace and medical markets on the West Coast. GKN’s focus is metal parts, the bulk of which is for the automotive market in Central Europe and the Midwest of the United States. When GKN highlighted the contrasting technological expertise that exists in both companies, the figureheads at Forecast were on the same wavelength.

Corey and Donovan Weber, the two brothers who founded Forecast 3D, shown in 2017 at their 3D Manufacturing Facility in Carlsbad, California.

“We knew that the opportunity is much bigger than the size of our pockets,” Weber acknowledges. “We needed resources and our goal was to get someone that shared our vision. We found those with GKN. . . . And, honestly, it’s kind of a relief because now we can really focus on polymers and let them handle metals.”

To read more from the original article, click here: https://www.tctmagazine.com/3d-printing-news/gkn-powder-metallurgy-forecast-acquisition-deal/

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Titanium-Copper Alloy May Improve 3D Process for Medical, Aerospace Applications

December 19, 2019 / ALLOY FABRICATIONS NEWS, FEATURED NEWS, MEDICAL HEAT TREAT, MEDICAL HEAT TREAT NEWS, TITANIUM PROCESSING TECHNICAL CONTENT

Source: Today’s Medical Developments

A new category of high-performance titanium-copper alloys for 3D printing is being considered for medical device, aerospace, and defense applications, and heat-treating may improve the process further.

In a collaborative project, leading researchers from RMIT University, CSIRO, the University of Queensland, and The Ohio State University studied the problem of titanium alloys being prone to cracking or distortion due to cooling and bonding together in column-shaped crystals during the 3D printing process. But a titanium-copper alloy developed by the research team seems to have solved this dilemma.

“Of particular note was its fully equiaxed grain structure,” said Professor Mark Easton from RMIT University’s School of Engineering in Today’s Medical Developments. “This means the crystal grains had grown equally in all directions to form a strong bond, instead of in columns, which can lead to weak points liable to cracking. Alloys with this microstructure can withstand much higher forces and will be much less likely to have defects, such as cracking or distortion, during manufacture.”

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CSIRO Senior Principal Research Scientist, Dr. Mark Gibson, says their findings also suggest similar metal systems could be treated in the same way to improve their properties.

“Titanium-copper alloys are one option, particularly if the use of other additional alloying elements or heat treatments can be employed to improve the properties further,” Gibson says. “But there are also a number of other alloying elements that are likely to have similar effects. These could all have applications in the aerospace and biomedical industries.”

Main photo credit / caption: RMIT University / 3D-printed titanium-copper bars with titanium powder and copper powder.

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Tungsten Metal 3D Printing Focus of Collaboration

November 20, 2019 / ENERGY HEAT TREAT, FEATURED NEWS

A 3D equipment and materials supplier recently announced a collaboration agreement to develop advanced tungsten-based metal 3D printing using binder jetting that focuses on two metal matrix composites.

Deborah West, vice-president of Business Unit Refractory & Specialty Powders, GTP

Global Tungsten & Powders Corp, a global manufacturer of tungsten and metal powders, and The ExOne Company, which manufactures industrial sand and metal 3D printers using binder jetting technology, have entered into this collaborative partnership to focus on tungsten-copper (W-Cu), used in high-voltage electrical applications, and cemented carbide (WC-Co), used in cutting tools and wear-resistant parts.

GTP uses the ExOne® Innovent®, an advanced and compact binder jet 3D printer, to manufacture parts in tungsten carbide and other tungsten composites. Binder jetting is a 3D printing process that uses a digital file to inkjet a bonding agent into a bed of powder particles, creating a solid part one layer at a time. Compared to other 3D printing processes, binder jetting delivers precision parts at a high rate of speed, making it an ideal approach for serial production.

The new ExOne-GTP collaboration focuses on the development of two metal matrix composites:

cemented carbide (WC-Co), a material with very high hardness and toughness that is widely used for the production of cutting tools and wear-resistant parts
Tim Pierce, ExOne Vice President of Metal Commercial Products
copper-tungsten (CuW), which is used in applications where high heat resistance, high electrical and thermal conductivity, and low thermal expansion are needed

“Binder jetting is the 3D printing method of choice for serial production of hard metal parts,” said Deborah West, vice-president of Business Unit Refractory & Specialty Powders, GTP. “Traditionally, tungsten carbide powder is pressed into the desired shape and then sintered to give it strength and density. Instead of costly and timely mold construction, the parts now can be printed directly in the desired shape, still using sintering technology to achieve the final strength. As a market leader in the development and production of high-quality tungsten powders, GTP always stays on top of the latest technology. We are excited to work with ExOne in the development of cutting-edge technology for the additive manufacturing industry.”

“Metal 3D printing using our exclusive approach to binder jetting has exciting and significant consequences for a variety of manufacturers, including those who make parts with cemented carbide and other tungsten composites,” said Tim Pierce, ExOne Vice President of Metal Commercial Products. “Our latest development collaboration with GTP will help advance the materials necessary to deliver on the vision of producing these parts faster, with less waste and more geometric design freedom.”

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U.S. Army Research Lab Invests to Develop Powerful Metal Powder 3D Printer

August 23, 2019 / MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS, SINTERING POWDER METAL NEWS

The Combat Capabilities Development Command Army Research Laboratory, also known as ARL, recently awarded a 3D engineering and manufacturing company a $15 million contract to create a metal 3D printer that it intends to be the world’s largest, fastest, and most precise.

3D Systems and the National Center for Manufacturing Sciences (NCMS) were awarded funding to create this printer and will partner with ARL and the Advanced Manufacturing, Materials, and Processes (AMMP) Program to advance the leadership and innovation. This printer will impact key supply chains associated with long-range munitions, next-generation combat vehicles, helicopters, and air and missile defense capabilities.

“The Army is increasing readiness by strengthening its relationships and interoperability with business partners, like 3D Systems, who advance warfighter requirements at the best value to the taxpayer,” said Dr. Joseph South, ARL’s program manager for Science of Additive Manufacturing for Next Generation Munitions. “Up until now, powder bed laser 3D printers have been too small, too slow, and too imprecise to produce major ground combat subsystems at scale. Our goal is to tackle this issue head-on with the support of allies and partners who aid the Army in executing security cooperation activities in support of common national interests, and who help enable new capabilities for critical national security supply chains.”

According to the U.S. Army Additive Manufacturing Implementation Plan, the Army has been using additive manufacturing (AM) for two decades to refurbish worn parts and create custom tools. Once developed, the Army will leverage its manufacturing experience by placing the new large-scale systems in its depots and labs. Subsequently, 3D Systems and its partners plan to make the new 3D printer technology available to leading aerospace and defense suppliers for development of futuristic Army platforms.

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HRL Laboratories Registers New 3D-Printed Aluminum Alloy

May 20, 2019 / ALLOY FABRICATIONS NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT NEWS

Aluminum Association Creates Registration System for Additive Alloys Beginning with HRL’s First-Ever 3D-Printed High-Strength Aluminum

HRL Laboratories, LLC, is commercializing its additively manufactured (3D-printed) high-strength aluminum, which has obtained the first ever registration of an additive alloy from the Aluminum Association. HRL will be granted registration number 7A77.50 for the aluminum powder used to additively manufacture the alloy, and number 7A77.60L for the printed alloy.

The Aluminum Association oversees alloy registration and product standards used throughout industry. The association’s new additive alloy registration system was launched in February 2019 in response to a growing number of additively manufactured alloys. The first to be registered was HRL Laboratories’ high-strength aluminum, the first alloy of its kind to be printable. (This breakthrough discovery was published in the journal Nature in September 2017.)

“Essentially, this will connect us to this particular alloy composition forever,” said Hunter Martin, the lead scientist on the HRL team that created the alloy. “These alloy numbers will always be trackable back to HRL, like a DNA signature. When I first contacted the Aluminum Association about registering our alloy, they did not have a way to register alloys printed from powders, so they decided to create a new system for registration of additively manufactured materials – a first in the materials space.”

Zak Eckel, another HRL team member said, “We’re in the process of commercializing this material, which is already in high demand. As we scale up to commercial levels, AA registration validates our product. Companies who want the powder for their 3D printers can ask for its specific number, and it becomes a true commercial alloy.”

As the aluminum industry’s leading voice in the United States, the Aluminum Association provides global standards, statistics, and expert knowledge to manufacturers and policy makers. Alloy and temper designations, chemical composition limits, and registered properties in North America adhere to those standards. The association also provides business intelligence, sustainability research, and industry expertise and is committed to environmental considerations while advancing aluminum as the sustainable material of choice around the world.

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Heat Treatment of FDM Parts to Determine Effect on 3D Printing: UT-Arlington Study

April 18, 2019 / FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Source: 3DPrint.com

A University of Texas at Arlington thesis student recently investigated thermal annealing to determine how to increase inter-bead bond strength overall in 3D printing processes.

Rhugdhrivya Rane tackled the dilemma of weak tensile strength in FDM parts and whether parameters chosen by the user — such as temperature ranges and pressure gradients — can affect an increase in inter-bead bond strength. The researcher used thermal annealing, and thermal annealing with unidirectional mechanical pressure in the Z direction, 3D printing a variety of specimens in ABS. The method of 3D printing was chosen due to its increased popularity in mainstream manufacturing.

“The parts were printed using two different sets of print parameters: high and low settings, to investigate the effect of heat treatment on both sets of print parameters. The values of temperature, time and applied pressure during heat treatment were varied to obtain a detailed comparative study and the correlation between the given variables and the increase in ultimate tensile strength.” ~ Rane

The discovery was that “higher temperatures and longer exposure to heat produced better tensile strength, along with increased ductility.”

“Though thermal annealing and uniaxial pressure cause an increase in the strength of the parts, the print parameters play a vital role in determining the initial mechanical properties of the parts. When the parts are fabricated with a higher value of flow rate and extrusion temperature, they exhibit significantly higher mechanical properties as compared to parts printed with substandard setting,” concluded the researchers. “Thus, by controlling the print parameters and using the right values of temperature and pressure we can see substantial increase in strength of FDM parts.”

Photo credit/caption: via UTA / “Tensile testing of dogbone specimens”

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3D-Printed, Robot-Built Bridge Traversed by Pedestrians in Test, Next Stop: Spanning a Canal in Amsterdam

December 12, 2018 / MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Source: ThomasNet.com

At 41 feet long and 21 feet wide, weighing in at nearly 10,000 pounds, the world’s first 3D-printed bridge has been approved and tested for pedestrian traffic in Eindhoven, in the Netherlands, approximately 90 minutes south of where it was constructed by four robots in Amsterdam.

MX3D, in partnership with more than 30 global industrial partners, completed the final deck and structural tests and finalized the sensor design earlier this year. In October, at Dutch Design Week, visitors provided the foot traffic needed to generate the first data set from the sensing system. The next phase will be to use the sensor data to build a digital twin model to monitor foot traffic in real-time, then installation over a canal in Amsterdam.

The structure is a testament to the possibilities of large-scale 3D printing, but this is just the tip of the iceberg. ~ ThomasNet.com

Photo credit: video still, Thomas Net.com

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First Titanium Wheel Created with 3D Unveiled in California

November 28, 2018 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, TITANIUM PROCESSING TECHNICAL CONTENT

The first titanium wheel created using EBM technology was recently unveiled during the official announcement of a partnership agreement between the two companies responsible for its design and manufacture.

HRE Wheels, headquartered in Vista, California, and GE Additive launched the new technology, which is a type of 3D printing to test the capabilities of additive manufacturing in a practical application and to create a highly-sophisticated wheel design with an elusive material like titanium. The new prototype wheel is known as “HRE3D+”.

With a traditional aluminum Monoblok wheel, 80% of material is removed from a 100-pound forged block of aluminum to create the final product. With additive manufacturing, only 5% of the material is removed and recycled, making the process far more efficient. Titanium also has a much higher specific strength than aluminum and is corrosion resistant, allowing it to be extremely lightweight and to be shown in its raw finish.

There was an intensive design collaboration between the Vista, California-based, team at HRE and the GE AddWorks team out of Ohio. Using design queues from two existing models of HRE wheels, the two companies worked together to create a stunning example of what is possible with additive manufacturing.

The wheel was produced on two Arcam EBM machines – Q20 and a Q10 in five separate sections, then combined using a custom center section and titanium fasteners.

“This is an incredibly exciting and important project for us as we get a glimpse into what the future of wheel design holds,” said HRE President Alan Peltier. “Working with GE Additive’s AddWorks team gave us access to the latest additive technology and an amazing team of engineers, allowing us to push the boundaries of wheel design beyond anything possible with current methods. To HRE, this partnership with GE Additive moves us into the future.”

Robert Hanet, senior design engineer, GE Additive AddWorks

“HRE prides itself on its commitment to excellence and superior quality in the marketplace. It was a natural fit for AddWorks to work on this project with them and really revolutionize the way wheels can be designed and manufactured,” said Robert Hanet, senior design engineer, GE Additive AddWorks.

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Agreement Reached to Initiate Titanium 3D Printing for Boeing 787

September 19, 2018 / AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FEATURED NEWS, TITANIUM PROCESSING NEWS

A Wichita, Kansas-based, manufacturer of fabricated parts for the aerospace industry recently announced its partnership with the world’s pioneering supplier of aerospace-grade, additive-manufactured, structural titanium components to initiate qualification of parts for the Boeing 787.

Spirit AeroSystems and Norsk Titanium US Inc. have reached an agreement to initiate qualification of Spirit’s first additive-manufactured, titanium, structural component for the Boeing aircraft.

Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management

This qualification will validate NTi’s production and industrialization processes, integrate Spirit’s work scope of machining final parts from additively manufactured near-net shapes, and verify material and final part conformity to requirements.

“Spirit has had a comprehensive and long relationship with Norsk Titanium, and this part will be our first additive structural titanium component incorporated into a commercial airplane program,” said Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management.

NTi is the world’s first FAA-approved, OEM qualified, supplier of additive-manufactured, structural titanium components. NTi’s proprietary Rapid Plasma Deposition™ (RPD™) process has been in serial production of Boeing 787 titanium components since April 2017.

“I am very proud of the Norsk Titanium team and this accomplishment. It represents years of technology development,” said Mike Canario, CEO of Norsk Titanium. “I also would also like to thank Spirit for this vote of confidence in the Norsk RPD™ process and capability.”

NTi’s Plattsburgh, N.Y., facility was recently added to Spirit’s Approved Supplier List (ASL) and Boeing’s Qualified Producer’s List (QPL). Spirit and NTi have had an ongoing technology collaboration for more than nine years. In 2017, both companies signed a Master Procurement Agreement (MPA) for qualification and production activities. The first commercial aircraft part will begin serial production later this year.

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Grant Awarded for “Super Finishing” 3D Lab, Builds on Existing Thermal Processing Technology Research

July 25, 2018 / AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS

Ed DeMeter, a professor in the Harold and Inge Marcus Department of Industrial and Manufacturing Engineering, is the lead on the research project.

Source: Penn State News

A state-of-the-art “super finishing” lab for 3D-printed metal parts at Penn State University has received grant funding of $535,000 and will complement existing subtractive processing technology, including heat treating systems, as part of the one-year project, titled “Super Finishing of Printed Metallic Parts for High-Performance Naval Systems.” The grant has been awarded by the Defense University Research Instrumentation Program, which operates through the Department of Defense’s Office of Naval Research.

“The Navy has a strong interest in identifying and researching the technical issues of using 3D-printed metal parts for naval applications now and in the future,” said Ed De Meter, a professor in the Harold and Inge Marcus Department of Industrial and Manufacturing Engineering, is the principal investigator on the project. “They want to better understand how to design parts while identifying potential barriers and also benefits that may arise between the metal printing process and any secondary processing that is done to smooth out the surface texture of these parts.”

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