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Granutools is a Belgian company specializing in powder flow characterization. Granutools improves the understanding of powder by providing leading physical characterization instruments and related services. Leibniz IFW Dresden is a legally independent non-university research institution and a member of the Leibniz Association.
Dr.-Ing. Tobias Gustmann, Head of Additive Manufacturing (AM) Technology (Alloy Design and Processing Department), gave an in-depth introduction to the processes and challenges associated with metal AM research.
The use of additive manufacturing technology in the field of metal materials science has a long tradition in our institute. As one of the earliest research institutions in Germany, we began to study this technology and its effect on solidification and material properties as early as 2009. Our first laser powder bed fusion machine was SLM250HL from MTT Technologies GmbH-now called SLM Solutions Group AG globally.
In my academic career, I have not even heard of this particular type of manufacturing process. I was studying at the Freiberg University of Technology. I am keen to use high energy beam technology to treat the surface of metal alloys, however, I quickly became fascinated by this topic.
SLM250HL is still running in our laboratory, allowing us to execute unique methods and act as a test bed for our own process solutions. Stay true to the motto: Oldie but Goldie.
The characteristics of the powder are very important to the characteristics of the process and the final part. Since we usually don't cycle powders for a long time (we test multiple alloys every year, usually related to the project), one might think that we don't need to pay special attention to powder behavior.
Knowing the state of the powder at any time, such as the influence of chemical composition and process on the characteristics of the powder, or being able to quickly measure it under dynamic conditions, is our main focus, and we have strengthened our capabilities in this regard. Thanks to Granutools, there are powerful devices on the market that are easy to use and ready in minutes. GranuDrum is an important part of our laboratory and a tool that we cannot do without.
First, the main challenge in powder characterization is the handling of the material itself. It starts with obtaining the material itself. You need a strategy to prepare representative powder samples. In my opinion, this is not trivial.
Another challenge is to adjust the measurement to allow transfer of process-related conditions to the measurement equipment-flexibility is the key. The static observation of the powder is of course important, but it is not enough to understand the relationship between recoating and the material, and why the powder flow will vary according to your process settings or changes in the manufacturing process.
Third, even if we perform multiple measurements on a material, we cannot draw conclusions about the correct process strategy and whether the material needs to be re-screened, tried or further pre-treated.
Figure 1. Powder recoating selected after GranuDrum measurement (left), PBF-LB in progress (right). Image source: Granutools
The more powder measured and the larger the data set, the easier it is to understand the behavior of the powder. Here, improved measurement tools are very important for quickly collecting results. Having the right benchmark or reference material is also very helpful, especially if you can guide millions of particles.
There is no perfect material for all methods. This is why we need to perform powder analysis and share expertise with others around the world.
To answer this question, I would like to introduce the GranuDrum instrument. I started operating this machine at the end of 2020, and it has become one of my most popular measuring devices. Its independent characteristics, robustness and versatility combined with self-developed and user-friendly software is a great help.
Figure 2. The GranuDrum instrument evaluates powder characteristics, such as cohesion, based on drum measurements. Image source: Granutools
When printing samples for material analysis, I can set up and run measurements at any time (within a few minutes). The depth of the results and the tunability of the measurement are also some of the key advantages of this instrument.
Most importantly, there is a great team behind the scenes who listen to customers and lend a helping hand when needed. If I fail on something, I know there will be someone in Belgium who can apply my ideas.
The upgrade of Metal AM is a never-ending story. The development trend of parameters to increase the accumulation rate is also the direct manufacturing technology (laser powder bed fusion) that we are studying in depth.
The point here is to understand how well you can still determine the material properties far beyond the standard configuration (beam shape or profile, energy input for very high-level thickness) and the established particle size range. The use of intensified melting to speed up the process usually results in more pronounced powder aging. However, it also allows you to use powder more flexibly. Wider PSDs and even non-gas atomized powders may be used to further improve sustainability and industrialization.
For us, another important topic is the development of new alloys, ideally, such as casting and AM can benefit from it. We currently do have a closed material process chain, starting from alloy synthesis, casting and/or forging, atomizing by ultrasonic excitation, and finally additive manufacturing before the start of "real fun" (material science).
If you start producing your own powders, you want to study powder science more deeply. Only time will tell how this will develop in Leibniz IFW Dresden.
Tobias Gustmann graduated from Technische Universität Bergakademie Freiberg in Materials Science and Engineering. During his main study period and as a diploma student, he focused on the application of thermal electron beam technology in aluminum-based alloy surface modification and multi-material joint welding.
From 2013 to 2020, he has been a research scientist in the field of additive manufacturing (AM) at Leibniz IFW Dresden and Fraunhofer. . IWU). His research covers multiple topics in the field of metal additive manufacturing and materials science, namely. Laser powder bed fusion (LPBF) of Cu-based shape memory alloys was also his main topic during his PhD. student. Therefore, he graduated from the Dresden University of Technology in Materials Science (Dr.-Ing.) in August 2018.
Dr. Gustmann is currently the technical manager of additive manufacturing technology at Leibniz IFW Dresden, focusing on studying the influence of the LBPF process on the characteristics of the corresponding materials: from raw materials to powders and process optimization to final products. The fundamental basis is his passion for material development in the manufacturing process and the in-situ operation of alloys during the manufacturing process.
This information is derived from materials provided by Granutools and has been reviewed and adapted.
For more information on this source, please visit Granutools.
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