The document provides a progress update on Work Package 1. It discusses two Bachelor's projects conducted at NLR that studied the effects of process parameters on metal additive manufacturing. The first project analyzed how layer thickness influences the properties of Inconel 718 parts produced by SLM, finding differences in microstructure and hardness between 30μm and 50μm layers. The second project examined how metal powders absorb moisture in humid environments, determining moisture uptake and identifying chemical composition changes using XPS analysis. The results provide insights to improve AM part quality and guide further research on post-processing techniques.

1. PROGRESS UPDATE WORK PACKAGE 1
LAURA CORDOVA GONZALEZ

2. AGENDA
1. INTRODUCTION
2. RESEARCH PLANNING
3. BSc. PROJECTS AT NLR - RESULTS

3. AGENDA
1. INTRODUCTION
2. RESEARCH PLANNING
3. BSc. PROJECTS AT NLR - RESULTS

4. 4
INTRODUCTION
CONNECTION BETWEEN THE WORKING PACKAGES
WP1
WP3WP2
• Feasibility of part production on location
• Failure behavior & life prediction
• Update in development of technology
• Maintainability (& repair)
• Supply chain network design
• Facility location & shipping
• (Re)design stage impact
• Scoring method
• Part consolidation
• Resource pooling
l.cordovagonzalez@utwente.nl 13/12/2016
Bram Westerweel Nils Knofius
Laura Cordova

5. AGENDA
1. INTRODUCTION
2. RESEARCH PLANNING
3. BSc. PROJECTS AT NLR - RESULTS

6. 6
RESEARCH METHODOLOGY
Base powders
properties and
influence on
material behavior
Technology,
process
parameters and
post-processing
Maintainability (&
repairing)
l.cordovagonzalez@utwente.nl 13/12/2016

7. 7
RESEARCH TOPIC I: PRODUCING ON LOCATION
MOISTURE INFLUENCE FOR AM METAL POWDERS
Characterization of metal
powder for AM
• Moisture influence on
mechanical performance
(Layer deposition in SLM and
powder flow)
• Rheological properties
• Chemical reaction
(irreversible effect) – (XPS /
LECO)
Influence of drying process and
moisture on quality / properties
• Analysis of builds with as-
received and dried powders
• Porosity / CT-Scanning
• Density
• Hardness
• Microstructure
l.cordovagonzalez@utwente.nl 13/12/2016

8. 13/12/2016 8
RESEARCH TOPIC II & III: SELECTING THE CORRECT PATH
POTENTIAL OF AM IN PRODUCING METAL PARTS
II: Selection of suitable AM
techniques
Post processing
Materials selection
Maintenance
RepairingPrinting new parts
III: Study of post-processing
techniques to optimize the
life prediction and
preventive maintenance
Cases studies in industry of different type of parts to evaluate performance of
developed approach

9. 13/12/2016 9
CASE STUDIES
PARTNERS INVOLVEMENT
• What type of parts can be selected?
• Which are the important properties to fulfill the requirements?
• Is there the possibility of printing on location?
• What AM technique and post-processing?
• Can be printed in the same materials? And design?
• What is the result in terms of performance and economical benefits?
• Is there a quantifiable impact in the maintenance actions?

10. AGENDA
1. INTRODUCTION
2. RESEARCH PLANNING
3. BSc. PROJECTS AT NLR - RESULTS

11. 11
BSc. PROJECTS I – STEFAN SMIT
MOTIVATION
I- Effect of layer thickness on Inconel 718 manufactured with SLM:
 Influence of process parameters (layer thickness) when producing SLM parts
with optimized conditions
 Measurement of properties such as: porosity level, microstructure and melt
pool size, hardness and density
13/12/2016
Sample preparation

12. 12
BSc. PROJECTS I – STEFAN SMIT
Effect of layer thickness on Inconel 718 manufactured with SLM:
30μm 50μm
- Melt pool size
 Microstructure  Hardness
Microstructure with Kalling’s reagent no. 2
l.cordovagonzalez@utwente.nl 13/12/2016

13. 13
BSc. PROJECTS I – STEFAN SMIT
Effect of layer thickness on Inconel 718 manufactured with SLM:
 Density  Porosity
l.cordovagonzalez@utwente.nl 13/12/2016

14. 14
BSc. PROJECTS II – STEFAN SMIT
CONCLUSIONS
I- Effect of layer thickness on Inconel 718 manufactured with SLM:
 Comparable density and porosity
 Differences in microstructure -> hardness
 Next steps -> study post-processing techniques
l.cordovagonzalez@utwente.nl 13/12/2016

15. 15
BSc. PROJECTS II – NIELS VLUTTERT
MOTIVATION
II- The absorption of moisture by metal powder in a humid
environment:
 Impact of environmental conditions in the quality of metal powders for AM
 Measurement of moisture content in three different alloys
 Study of chemical composition of the most critical alloy in terms of reaction to
humidity
l.cordovagonzalez@utwente.nl 13/12/2016
Humidity 90%
Time in chamber 8 weeks
Time testing 45 min
Temperature 150C

16. 16
BSc. PROJECTS II – NIELS VLUTTERT
The absorption of moisture by metal powder in a humid environment:
Moisturecontent
 Moisture analysis
0,186%
Material Starting w % moist. % n mois.
AlSi10Mg 5,7255 0,1869% 0,5099%
Ti6Al4V 9,6952 0,1031% 0,1662%
Inc718 15,6232 0,0499% 0,0499%
Inconel Titanium
Aluminum
l.cordovagonzalez@utwente.nl 13/12/2016
Mass (g)
Time (min)

17. 17
BSc. PROJECTS II – NIELS VLUTTERT
The absorption of moisture by metal powder in a humid environment:
 Composition analysis with XPS
l.cordovagonzalez@utwente.nl 13/12/2016
Oxygen

18. 18
BSc. PROJECTS II – NIELS VLUTTERT
CONCLUSIONS
II- The absorption of moisture by metal powder in a humid
environment:
 Moisture content is difficult to measure in metal powder by thermo-
gravimetrical analysis (low accuracy)
 Variability in particles chemical composition
 Next steps -> analyze builds
l.cordovagonzalez@utwente.nl 13/12/2016

19. THANK YOU
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