DR.HORST HILL face to face with...
Advances in 3D printing have benefited many industries, but when they involve powdered metals, the uses appear endless. We spoke to DEW’s Head of Special Materials
POWTECH WORLD MAGAZINE: The layering process has obvious creative advantages, that must put pressure on the component elements. Just how important is precision in powder quality in this? HORST HILL: The powder quality and correct specification is a major factor for producing an ambitious part with the help of a 3D-printer. Flowability is very important to ensure we have a homogeneous distribution of the powder. Then there is the question of fine or coarse powder: the grain size of distribution must match the layer thickness, otherwise, it can lead to defects in the printed part because of the unevenly distributed metal powder. If you expect a smooth surface, you will have to choose fine powder, but if you want maximum cost-effectiveness, you need coarser powder as it accelerates the process, to a certain extent. Then there is the purity of the chemical composition. The alloy elements have a huge influence on the final properties. On one hand, a high amount of minor alloy elements such as oxygen, sulphur or phosphor could reduce the quality. On the other, the main elements like chromium are important to assure the quality. Now, it becomes complicated if you keep in mind that none of these topics are independent of the printer and the printing parameters. Therefore - and very importantly -
it will always be the combination of the 3D-printer,
the metal powder and the chemical composition which lead to a successful part.
PW: Your AM journey follows your work in powder production for the likes of build-up welding. How did that background shape what you do? HH: On first view you may get the impression that it is not important because, typically, you use different alloying systems for build- up welding and 3D-printing. But, with a closer look, I am convinced it helps a lot. Let me explain: My background in powder production for welding has given me a broad overview of various alloy systems for use in different applications. We use this experience strongly for the development of new materials. On the way we try to facilitate
property profiles not currently available, such as high hardness and wear resistance in the case of tool steels.
PW: The AM process can appear far more complex than those used in traditional manufacturing, yet there are economies? How are they achieved? HH: You are right, the complexity of the printed parts is one of the big advantages. We have already said that by applying 3D-printing you get the “complexity for free”.
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