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 Monday, 11 December, 2017

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DMST

MANUFACTURING CHALLENGE

Ever increasing performance requirements of components demand higher performance from materials. Materials such as Ni, Co or Ti alloys are well known for their high temperature properties and excellent wear/corrosion resistance. Building a whole part with such expensive alloys may be cost prohibitive. Traditional coating technologies have metallurgical limitations when costing these alloys onto low cost substrates. The following summarizes some of the challenges:

  • Cost of materials
  • Metallurgical bonding
  • Coating thickness

DMST SOLUTION

With its closed loop feedback system and five-axis deposition capability, the DMST process can coat expensive metals onto low cost substrates of different geometries. Further, it creates a metallurgical bond and can be applied up to millimeters thick. Coating parts with expensive but high performance materials offers a cost effective solution to the material challenges. This allows great savings on material costs while still providing performance functionality of the parts.

 

CAPABILITIES

  • Apply wear and/or corrosion resistant coatings

  • Coating thickness can range from microns to millimeters
  • Metallurgically bonded DMST coatings do not spall or peel off like mechanically bonded coatings

  • Small heat affected zone (HAZ) between coating and part gives better coating integrity (unlike PTA/TIG)
  • Patented closed loop control reduces part distortion
  • Coating on 3D surfaces with 5-axis motion system
  • Selective area coating possible without any masking
  • Part sizes can vary from a few centimeters to a few meters

  • Wide variety of coating materials including high hardness steels (RC65) to stainless steels, Stellites, Inconels and cermets (ceramic metal composites)

APPLICATIONS

  • Automotive wear components, such as pistons, piston rings, valves, breaks, etc.
  • Cutting implements, such as knives for forestry, agricultural industry, book bindery, etc.
  • Perishable tools in forging, stamping, metal forming and other industries



 
 
 
 
 
 


DM3R

MANUFACTURING CHALLENGE

Demands for longer life and higher efficiency results in higher wear and tear of components requiring better methods for repairing and re-manufacturing. The need for high performance components for sustainable operations, coupled with the ever increasing cost of materials, has intensified the search for re-manufacturing technologies that offer better quality and a near net shape finish. Some of the challenges for successful re-manufacturing are:

  • Part distortion

  • Large Heat Affected Zone (HAZ)
  • Integrity of repair

DM3R SOLUTION

Direct Metal Deposition (DMD) is an advanced additive manufacturing technology that offers an excellent solution to the challenges above. DM3R uses the DMD process to repair and rebuild worn/damaged components that are hard to weld. This additive metal technology can also reconfigure parts to accommodate design changes which saves and reduces lead time.

 

CAPABILITIES

  • Add metal on a 3D surface with a 5-axis motion system
  • DMDCAM software for precision & quick toolpathing

  • DM3R ranges from a few microns to several millimeters depth
  • Metallurgically bonded DM3R yields longer life to repaired part
  • Small heat affected zone (HAZ) (8-10 x shorter than PTA/TIG)
  • Part sizes can vary from a few centimeters to a few meters
  • Wide variety of material capability including steels, stainless steel, Stellite, Inconel, Titanium alloys, etc.
  • Deposit superior material so DM3R parts are often better than new parts

APPLICATIONS

  • Turbine components, such as vanes, blades, knife edges, seals, etc.

  • Automotive components, such as engine heads, engine blocks, transmission parts, etc.
  • Wear components for agricultural, construction and heavy equipment industries

  • Oil and gas industry components

  • High value tools



 
 
 
 

DM3D

MANUFACTURING CHALLENGE

Additive Manufacturing (AM) is a group of emerging technologies that create objects from the bottom up by adding material one cross section layer at a time. AM is great for design freedom and building complex geometries; however, as a means for fabricating end-use components, it was limited by the following:

  • Material selection such as plastics or polymers
  • Part density

  • Only small parts available

DM3D SOLUTION

DM3D is a 3D Printing (aka Free Form Fabrication) application which is not new to our organization. Direct Metal Deposition (DMD) has long been the leader in additive metal technology. DMD is a laser-based, additive fabrication technology which can create fully dense larger parts from various metals and alloys.

CAPABILITIES

  • Builds fully dense functional metal parts (not sintered parts)
  • No post-deposition sintering or metal infiltration is needed
  • 5-axis deposition capability allows building features/flanges/ bosses on existing parts
  • Additive DMDCAM software allows precision & quick toolpathing for part build up

  • Patented closed loop control results in better part quality
  • Part sizes can vary from a few centimeters to a few meters
  • Significantly higher build rate than Powder Bed Fusion technologies
  • Wide variety of material capability including steels, stainless steels, Stellite, Inconel, Titanium alloys, etc.

APPLICATIONS

  • High value aerospace components, such as turbine casings and components, structural components, seals, lattice structures, etc.
  • Feature addition on existing components, such as flanges, bosses, etc. on casings
  • Oil & gas industry components

  • High performance tooling components

 

 
 
 
 

Mult-Material Manufacturing

MANUFACTURING CHALLENGE

Higher performing materials are necessary to meet the demand of technological advances. The difficulty has been to combine two or more materials with distinct properties into a single component for enhanced product performance. One such difficulty is the fabrication of components that combine a high conductivity core (heat transfer) with a high durability surface (strength or hardness) for a variety of manufacturing applications. The challenges of developing such multi-material components are:

  • Joining dissimilar metals/alloys
  • Part distortion during fabrication

SOLUTION

DMD can add a variety of materials precisely at select locations on the part which allows for fabricating multi-material components with functional properties. This innovative solution eliminates the need for assembling multiple parts with different metals which saves cost and reduces manufacturing time.

 

CAPABILITIES

  • Dual hopper capability allows controlled deposition of multiple materials

  • Additive DMDCAM software helps toolpathing and recipe selection for different metals
  • Proprietary recipes help to add dissimilar metals on a single part

  • 5-axis motion system aids precision deposition of different metals at different locations
  • Parts are fully dense and functional (unlike sintered parts)

  • Patented closed loop control helps to minimize dilution of metals and mantains dimensional integrity
  • Part sizes can vary from a few centimeters to a few meters
  • Wide variety of material capability including steels, stainless steels, Stellite, Inconel, Titanium alloys, etc.

APPLICATIONS

  • Automotive applications, such as valve seat cladding

  • High productivity tooling for injection molding & die casting
  • High toughness tooling for forging industry