Advanced Manufacturing & Remanufacturing and the Use of Direct Deposition and Its Applications
okay a very good afternoon again ladies and gentlemen uh my name is and i'll be your host today uh we'll present live on facebook uh some additional information about our direct deposition 3d printing for manufacturing and remanufacturing force organized by a star this uh live transmission is made possible through joint efforts from advanced manufacturing and technology center and singapore institute of manufacturing technology through their knowledge through our knowledge transfer office uh i have together with me online uh two colleagues miss grace day and dr davide they are going to introduce themselves uh when it comes to the content of today's webinar we'll have a first part by miss gray state who's going to talk to you a bit more about who advancement manufacturing and technology center is and then dr verdi is going to give you more details about what exactly this training is about and what's in you'll have the opportunity to ask questions and i'll make sure i manage them all the easiest way is to type them in the chat window the other way is to raise your hand during the q a session and i will invite you to to ask the questions why so without any additional waste time let's invite miss to tell us a bit more about who advanced manufacturing and technology is and how does this fit in the bigger picture of manufacturing it's mistake thank you allen so hi everyone good afternoon my name is grace um so i'll be giving you a first introduction to firstly our organization advanced remanufacturing and technology center a part of uh a start of the introduction also on what manufacturing and remanufacturing is before diving into direct deposition and its applications after which i'll pass on the ball to my colleague dr davide verdi will share more in detail about the course as alin has mentioned so firstly a little bit about myself so i'm currently a senior development engineer and team lead at drtc under the advanced remanufacturing group i graduated with a bachelor's degree in aerospace engineering from ntu uh prior to joining artsc in 2014 so since then i've been working on additive manufacturing technologies focusing uh on laser powder balloon direct deposition so we i've been doing this for a good seven years currently the team leader in this area i'm helping to drive developments in the technology especially towards the next generation of manufacturing and remanufacturing where some of the big concepts include sustainability and digitalization so we do work a lot on developing such application solutions across various industries okay so before we go into direct deposition and 3d printing uh just to give an overview about what manufacturing and more importantly what remanufacturing is because i believe that remanufacturing is a term that people would be more unfamiliar with so here is a slide showing the different key differences between the two in terms of how a typical cycle for manufacturing and remanufacturing looks like so for manufacturing it starts with extracting the raw materials before you actually process the part put the parts together in what we call the assembly stage after which you know the parts are distributed and sold before going into service so at the end of its life the parts are typically uh wasted by disposal so what remanufacturing hopes to do is at stage number six for parts that are defective for damage we actually look into uh repairing the part but that of course comes firstly with uh key processes like this assembly to disassemble the component which will have many more low parts which we then inspect and then before we do the repair and prior to putting it back there's always going to be a assembly stage and then do the final testing and putting it back in service so the key difference comes in terms of the material usage because at the in manufacturing basically you are throwing away the components and buying new ones it's going to be a high volume of materials and parts as well as the energy and carbon dioxide that comes um that comes into play whereas if you're remanufacturing and reusing parts that are already uh having a first life cycle you can imagine the amount of savings that you can achieve so a quick example here of a life cycle and this is done uh by by by rit so this is a study done on mid-sized gas powered car engines so on average it's been found that in terms of energy remanufacturing actually saved 68 to 93 for carbon emissions it's 73 to 87 and especially if you look at raw materials it's a good 90 so there's a lot going into sustainability a lot of material a lot of energy can be saved by remanufacturing in any case in both whether it be manufacturing remanufacturing direct deposition and additive manufacturing have very critical roles to play okay so moving on before i dive into um the technology of am itself uh as well as direct deposition i'll just give an overview about our organization first especially since the training that we will be providing will be hosted and facilitated here so to give everyone uh an idea of what our environment is like and what our overall goals are so the altc is institute under a asa so currently we are the leading public private partnership research center in southeast asia so our mission is really to develop and deploy advanced manufacturing solutions as well as to upskill the workforce one of the reasons why we are offering the course so ultimately we are hoping to drive local industry competitive competitiveness so we are um also uh collaborating a lot with educational institutes hence we are sort of bridging the gap between research and industry where we receive problem statements from the industry we do projects of the industry but we are strongly supported by educational institutes as well so ultimately in the entire ecosystem we are serving and empowering not just the mncs but also the local smes as well as lles so in arcc there are six big technology groups as you can see so the first one being additive manufacturing industrialization where you have a lot of the 3d printing technologies and not just polymers that you see in many commercial platforms but largely looking into metal printing as well because that's where the industry is looking for for par for parts so in the second technology group we have advantage manufacturing and this is where we have not just direct deposition which looks at doing repair restoration but we also are coupled with some other sub teams that looks into masking and automation intelligent machining as well as looking at the entire remanufacturing process and how we actually do industrialization in that areas so we we have robotic applications advanced robotic applications as a technology group so this is where we look to robotize many industrial operations that are conventionally manual so the fourth group data service data driven service enhancement this is where the group and the teams look into various ways um to to to support manufacturing and remanufacturing looking into technology for surface prep and finishing surface enhancements as well as coatings so for the fifth group intelligent product verification this is where the metrology aspects as well as the inspection processes come into play the the group develops and looks into new ways to inspect components many times in a non-disruptive manner and lastly moving towards industry 4.0 we now also have a smart manufacturing group that looks into virtual virtual manufacturing as well as digital manufacturing so looking a lot into digitalization supply chain and also making use of the latest augmented reality technologies to optimize manufacturing and remanufacturing workflows so in general as an overview artc is comprised of groups that tries to cover the entire manufacturing and remanufacturing spectrum so just to touch a little bit and i mentioned before we are playing in the middle trying to bridge uh research and and production so we are in a prime position where we do projects that will infuse research and deep knowledge coupled with operating the machines and developing the processes so here we are actually exposed and we will be able to expose people who partake in our course with a very good knowledge from both ends so a little bit sharing about achievement so far so as you can see as mentioned we are the leading public private partnership research center we have a good number of staffs here it says more than 305 although the number is close to 400 right now so we are also supported by a good number of students interns and even trainees so uh the ecosystem here is it is it's very good for learning so as of this current time we do have a good number of over 80 industry members with good global presence so later in the next couple of slides we will show who some of these companies are so lastly over the course of uh seven eight years we do we have actually achieved more than 500 and closing 600 or even 700 industrial projects delivered so we do have a good base of knowledge supported by people um so as mentioned um here is an overview of some of the members member companies that is in the artc consortium we do on the consulting model so you can see big names such as halliburton ihi rolls royce shell and siemens so we have actually done projects for them so we receive direct industry problem statements and many times our applications and knowledge are based on what these industry players need so now going to additive manufacturing here's a framework that shows how it's um it can be categorized because there are many types of additive manufacturing even if it's one term so uh in general they they can be known as seven families of adhesive manufacturing coupled with a hybrid category where it it basically couples a little manufacturing with subtractive and you combine the two processes many times on the same machine so um the directed energy deposition that we will be introducing to you is only one of it's one of the families here so compared to some of the other families where for example powder bait technologies is more widely known character energy deposition really looks into a different kind of am in here at artc it's what we call powder blown so rather than the powder being swept a layer by layer on the powder bit powder is being blown out of a nozzle and a laser comes in to fuse the materials to create a layer of deposition and this can be easily shown and can be seen in the schematic that is shown on the slide so um to introduce what direct directed energy deposition is or direct deposition laser is used as an energy source and you can have powder or wire as the feedstock material here powder is underlined because we have been working and we do have mostly powder capabilities the the technology can be used for generative and regenerative applications so by regenerating if you mean repair for example uh and there are many terminologies that are associated with direct deposition so as you probably heard me saying directed energy deposition dev that's one of it other common names are laser metal deposition is a cladding direct laser deposition laser engineered net shape so these are very common terms that are interchangeably used many a times so some of the advantages of direct deposition and here we are comparing really to conventional welding because many times applications are similar you're either putting on material repairing material or sometimes even joining material the reference here is looking at welding so with laser as energy source you get a low heat affected zone a controllable heat distribution good consistent overall process control and overall this will allow us to get very controllably possible near net shape geometries okay so now sharing here some of the typical direct deposition applications so i mentioned generative and regenerative so the pictures over here can give you a good idea of what these look like so a new part large format fabrication these are building or rather generative applications where you can build new parts from scratch and with the build volumes of some of the systems that we have on which are on industrial scale you can achieve very small parts um that can have very fine features uh two very big parts uh and which can be built very very quickly uh the the second category will be feature edition so also on the generative aspect it's where you can actually selectively and very locally put on a feature onto an existing component so that in itself has economic benefits if you compare to the conventional cast forge and then machine to get out very localized features so there's a lot of cost savings that you can already imagine by only putting on what you want versus machining out what you do not need so lastly repair coding and hard phasing this is where we go into the many a times a regenerative category where we are firstly prior to repair we dig out or we remove the defects and we put back the material so that it can be put back into service so that's repaired so coating hard facing is where you can actually put on material that can enhance the part performance for example to achieve wear and corrosion resistance uh where the original parent material may not perform to what you desirably need okay so um without further ado um i will pass the ball to my colleague dr dave to explain and elaborate more about the training that we can offer at the artc on this technology thank you thank you very much grace uh thank you for the introduction into what your research center is and what this technology is about just to make sure i understood correctly to me it looks like it's it's a much better way of having a welding type of process deployed in uh in the field so not only you can you can weld two parts together but you can add material far from the original surface and uh and build new things not only repair did i understand correct that's correct allen the the range of applications is indeed broad and flexible thank you thank you again grace so let's move now into the deeper content of this course that verdi is going to to tell us a bit more about what's what's planned for for this training dr verdi hello hi everybody thank you ali for the introduction thank you grace for the your part as well uh i'm gonna talk to you about uh the training that we are offering that will offer to you uh on direct the position for manufacturing and the manufacturing before this just a quick introduction of myself i am actually a scientist and a technical lead in a direct very pleasant deposition in rtc i joined ntc in 2017 and i'm working on these depositions since i started my my phd back in 2011 so almost i was traveling and working in different countries in europe spain france and then i moved here to singapore so the training we are going to offer is fully developed by artc as also grace mentioned uh before in uh in our presentation and it's based on a previous offer that we we gave to one of our industry members in ftc and to build their local capability on laser deposition the target audience and objective is uh is the training is target for uh organizations and individuals that are looking for a first understanding of this technology but also to uh dip more on and develop their own capabilities with a goal for sure on for manufacturing and manufacturing application for sure then the typical candidates for this kind of training are for example process technicians or engineer uh production supervisor so manager and quality control manager and engineer for this for example i call your attention to the picture on the bottom right corner it's a picture of us of uh i think a couple of years ago now in front of one of our machine rpc with some of the guys that participated the training and among them there are from our technician to our manager to our quality control engineer and all of them enjoy in a different way the training that we provide them the format uh is intellectually divided into parts uh a theory uh part in which for sure we need to give you some basic concepts uh on uh what is the laser deposition um the the materials etc and a better understanding of all these all these concepts and then for sure a practical part in which you can ever first touch our end zone on on the process with one of our machines available in rtc so the objectives the key learnings outcomes that uh the participant to this training will uh will bring home uh uh basically these are listed in these slides so you will understand the fundamentals of laser blown powder dark deposition so from the process technology itself including some element safety aspects such as the licenses and the holes that you need to operate this kind of process in your in your company here in singapore then for sure you will understand the key uh inputs of this process and the outputs and especially try to connect them to understand their relationship relationship so i modify this input i guess this outputs y etc so you will also be able to create like a plan of a systematic strategy for the for process parameter development so uh as i mentioned before i modify this parameter i obtain this output so instead of just a triangle maybe you can you can find a way to overly do a research of this parameter to achieve the output that you are looking for you will be able then to identify typical system architecture of the dark deposition technology toy the different components of the machines uh kind of understand if there is a um something that is not working properly how to act for example so some general understanding of the maintenance also the of this complex equipment uh you will establish also a typical uh lbp process flow so essentially basically is from uh before what to do before uh the deposition deposit process itself so how to monitor it and then uh how to check so that the process is correct what you achieve is what you want and also some understanding of some example of post processing so additional technologies that you can uh or processes that you can do on the parts that you repair through that position or you manufacture for direct deposition you will also understand and learn a bit on process codes and programming so for cad cam or create basically the tool path that will uh serve to generate the component and as i mentioned also before uh perform basic on-site uh post build evaluation so some amazon on these parts the training will be divided mainly in four uh four parts four chapters let's say the first one is the introduction to attack deposition while we again into the the technology and the safety aspects second one is the focus on understanding of later laser uh powder bloom processing technology so understanding all the different concepts and architecture of the machines the third one on the programming so fundamentals of programming and how to achieve a proper tool path and the last one will be on uh basically the flow of the entire process from pre-processed impulses monitoring and post process activities i will go through now quickly on each of these four points just to give you a a bit more again of understanding so for the first one for the introduction uh here i report an image of the process on board so you can see the uh the powder being heated uh by the laser and be deposited on the surface all for to if this process basically you need a lot of input okay for sure you need a laser and i put the laser i put also this this logo that is the laser safety logo basically to also remember that there are some safety aspects correlated to the use of these these technologies for sure you need a material a feedstock material as grace mentioned before we are focusing more on powder blonde so i put a couple of images also to need to be able to characterize this material and identify when a material is a good quality or maybe lesser with quality also you need gas gas is used for care release powder and to shield the deposition itself remember that is this technology comes from welding kept on technology so the material will be melt and will solidify very fast and you need a shielding to protect it to avoid oxidation and other defense usually you need a controller so a part of the machine is be able to pitch the machine tell the machine what you need what the machine have to do to achieve your your final goal i put here an image of a nozzle a nozzle is a part of the of the machine that literally helps to deliver the powder in the melt pool generated by the laser so also this is very important we'll discuss more on this and help you to understand the differences between different nozzles different applications etc here is to understand that you need to recipe so when you do the process you need to input a lot a lot of parameters that you slowly understand we our goal will also help you to understand the effects of each of them on the quality of your path and on the bottom side of the slide i report uh two very important uh points then one the safety aspects all the uh dangers related to the process itself dangers that are mitigated and is very reduced to zero when you follow uh proper opel rules of the behavior basically uh and for sure the an example of the laser license that you must have if you want to operate a machine in your in your facility so all these will be introduced in the first part of the training the second one we focus on the uh the architecture let's say of the their deposition and here we report for the four machines that we have in a in rpc uh we have a machine from thrones uh one from beam and two from dmg morning every one of them with different different characteristics that make them different one from each other for example the the truth machine is probably the bigger one that we have is a machine laser machine used not only for laser deposition but also for cutting and welding and the cnc machine is a seven axis so it's very flexible and we have a variable spot size so we will teach you what does it mean but it means quickly that you can do very near net shapes applications to the position of very big parts or coatings in a short time let's say if they are big machine that is the characteristic to be equipped with a control atmosphere means that the machine can be sealed and filled with an inert gas usually argon and it is possible to uh to run deport the the process in this inner atmosphere to avoid for example the oxidation of the parts so this part this is mainly done for example for materials like the animal noise the two on the bottoms are from the mgmoria hybrid machines so additive and subtractives are machines that have both the laser deposition but also the machining are also machining centers in this case the one on the left is for milling the one on the right for turning we will in this part of the of the training will go in details and let's explain the different components of the machines you want some and so on some more understanding of the parcel uh what is a uh deposition machine basically in the third part we will go in the programming for direct deposition in particular we'll we focus on uh cad cam in which basically you can literally drawing uh draw your parts and simulate the tool path so the the the path that the laser will follow to deposit to create your parts for sure to understand properly this part will need to give you some understanding of the codes that this cad cam software generates so what each line means and we'll also provide an understanding of other ways to create this tool path for example through manual teaching or for example directly direct writing of of the course depends uh depends a lot on the application and the kind of geometries that you're gonna do finally the the last one will be to make you understand more on the entire flow of the um of the position from the process in which for example we will check the quality of the powder of the laser doing measurements like how much powder we need doing setups on on the machine in process in which we will employ for example external sensors or internal to the machines to assure that the quality of the process is maintained throughout the entire duration of the of the process itself and finally some understanding of post-processing from for example 3d scanning of the paths to assure that the entire the material that you add for example repairing application is enough uh microstructure to assure that there are no defects for example mechanical properties from hardness etc to understand the behavior of the component that was manufactured in treatment so we'll give you some idea of typically treatments that are done made by that deposition and for example some understanding also on machining or other post-deposition treatments this is a key for part of the of the training i will conclude with these slides that basically show you a bit on the capabilities that we have in uh in rtc and that will support the the training so from material characterization equipment for a simple preparation or microscopy analysis also the the machine that i showed you before for that deposition toolpath generation we have three software at least for for this job and for sure other auxiliaries equipment that serve to produce samples or prepare the powder etc with this i conclude my my presentation i passed back to ali and thank you very much for your attention uh thank you very much dr verdi for for this thorough description of the content of the course uh before we go into the next session which is going to be q a i just want to make sure i understood clearly from my position as a host your intention and final outcome of the course is to equip the learners with almost everything they are going to need in order to make sure they can consider this technology for deployment in in their own company what is needed in order to embark uh into the use of this technology what kind of outcomes one should expect and so on did they understand correct your presentation perfect correct everything you said is correct so this is the key outcome that we are aiming to achieve and this is what we want to to give to the to the people that will sign for for this training okay so thank you very much again thanks so uh with this two two parts of our webinar completed with the introduction in the technology as well as a thorough discussion of what's intended to be in the course we're moving now towards the the final part hopefully the most interesting one for you uh to answer whatever questions you may have while considering questions uh you can also have another look at your screen there is a wide range of additional materials which can be downloaded if you scan those qr codes but now let's move to the to the q a section and i already see a question posted in the chat what dd machines uh is the rtc using for remanufacturing grace i think you you you would be able to answer that sure so uh davide could you help me go up to the slides on the four machines so thank you davide so as you can see here these are the four uh main machines that we have in artc and they are all powder blown although srvda has already very uh you know specifically indicates that the differences of the four machines we do have a typical open uh atmosphere system in the trunk uh although it's the most flexible in terms of the spot size and then we have a designated and specialized uh closed atmosphere system that is really primed to work on radioactive materials and that's the beam modulo 400 and then we have two hybrid machines which combines additive and subtractive uh uh processing all on the same machine just that the laser 65 this is attack 65 uh in terms of the machining is more of a milling operation compared to the lt the lasertec 1400 which is a much bigger machine but but which is meant to uh process and turn by turning operation larger parts uh usually uh cylindrical so these are the four dv machines that we have in ertc and in the training we will introduce you to all of them however for the specific training modules we will use one of them as a demonstrator okay thank you grace i guess this answers that question thoroughly but for my curiosity why did you feel the need to invest in four different machines from three different manufacturers okay so thanks alan for the question uh i think we can now try to recall that we do work with a very wide range of uh industry uh customers and companies so the reason for looking at all four uh very unique types of machine is really to so it's really so that we can uh meet the very different needs of the of the industry uh we have people from aerospace we where we sometimes look at very fine and intricate kind of a repair and that's where if you have a machine such as the chrome with a spot sizes that can go down to 0.18 or even the beam you know which has both sizes can go down to 0.8 these are machines that will be primed for such operations whereas if you go to the oil and gas industry or marine for example where you have much larger components you could be looking at the larger system such as the lt4300 and then as mentioned just now if you work with reactive materials let's say titanium then for sure the the first choice to look at would be the beam machine so um the different range of machines and also from different brands is firstly to look at the capabilities of the equipment guided by the needs of our industry partners okay thank you very much grace i i guess that answers this even more thoroughly while we'll be looking to take additional questions uh our colleagues from kto are going to share with you a link to uh an online forum an online survey in which you'll be asked whether this uh this webinar is of interest for you you'll see the actual content there so please while you think uh what what additional questions you meant to ask already see one popping up please also consider giving some quick answers to the to the online form which our colleagues are going to share with you uh very soon and while we while they do that the question which appeared there just now any prototype product development boom to be i can approach for medical products grace or davide who wants to take this question okay so i see also a forward to send mr arum the context for the below email well i'll say it depends on the specifications and even the geometry of the component so medical products uh you know uh not to say that we cannot do on the machines we can but first it depends as mentioned on the the part to to to to be uh to be built uh let's say if it's titanium we do have machines that can process titanium however in many cases we can look to our our um sort of colleagues in the additive manufacturing department they have the powder bed systems which could be better used for medical prototyping medical product prototyping so we do work hand in hand very closely with them and sometimes the component may even be uh developed or prototyped by the two technologies so uh we are in research and we are more than willing to explore different ways of doing things yeah so i hope that answers your question and we will look into your request as well thank you very much grace uh indeed it is capabilities from rtc not just from this group which is dealing with powder blown it could be capabilities from uh from the other groups in rtc we could also look at additional capabilities across the whole a star starting with our colleagues from simtech so i'm pretty sure there's going to be a solution to any problem which is uh being drawn to us am i right to say that grace yes that's right thank you again uh our colleagues from kiki already shared the link in if you open the chat box you're going to see there a hyperlink to the online form so please go online quickly i i think it's it's a pretty simple form with just some yes no uh no persons so go there give us your feedback because we want to make this useful for for for you as well it is for us to to understand what is needed out there and how we can we can make things better and why we do that we we still have plenty of time to take additional questions so feel free to to ask feel free to put anything you would be interested in in the chat box and we'll try to the best of our capability answer them live now if if it's something beyond what we can uh what we can discuss during the time we have in hand we will come back to you with uh with additional uh explanations and information offline via so anyway thank you mr arun for for this uh link which are going to establish with uh with your colleagues from uh from italy we were more than happy to to establish collaborations across the world let's see exactly what the problem is and how we can fit our solutions into the actual problem in a better way thank you very much again gentlemen again ladies and gentlemen it's it's it's a good opportunity for you to ask like our specialists in the process and the ones who are actually going to conduct the actual training in order to to to see exactly what's in for you and uh how how you can make better use of this training for your company for your career progression or for any other purposes you you may have in mind if you prefer to ask just raise your your hand using the tools which which zoom puts at your disposal there is a raised hand button at the bottom of your screen just press it and [Music] will unmute you to ask your question live all right we'll wait for a few more seconds if there's no other further questions we'll end this webinar for today well i guess there is nothing much left for today again additional materials are available just scan those qr codes go online and you are going to to find additional information about the course about how to register for these courses as well as the web page of the knowledge transfer office where you may find additional courses of interest for you uh you have already the the the means to contact the knowledge transfer office the speakers for the day feel free to do so if you have additional questions later and with one more attempt if if there is any additional question at this moment doesn't look like ladies and gentlemen thank you very much again for your time i i hope we could give you a proper picture of what we are trying to do through this training through this course feel free to contact the speakers later if if you need to do so and with this these this webinar should be considered closed from my side thank you again for your time i wish you a great weekend and goodbye
2021-07-21 08:09
