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Laser powder bed fusion (PBF-LB) + Powder atomization and analysis

L-PBF device: SLM®280 2.0 Dual

Selected features:

  • State of the art dual laser machine (700 W / 1000 W)
  • Maximum build envelope: 280 x 280 x 365 mm3
  • High-temperature build envelope (550 °C) for improved processing of a wide range of weldable and less weldable alloys
  • Layer-by-layer monitoring system and open software platform (further monitoring systems can be connected)

L-PBF device: SLM®250HL

Selected features:

  • High power fiber laser for the processing of a wide range of alloys (400 W)
  • Maximum build envelope: 250 x 250 x 280 mm3
  • High-temperature build envelope (650 °C) and NuPure filter system for residual oxygen reduction
  • Fully flexible machine with low setup times, low powder consumption and open software platform

L-PBF device: Realizer SLM®50

Selected features:

  • Desktop machine for material qualification (Fe-, Ti-alloys, metallic glasses, Co-alloys) and the processing of precious metals
  • Fiber laser with a maximum laser power of 120 W
  • Build envelope: 70 mm diameter (X/Y), 80 mm height (Z)
  • Fully flexible machine with lowest setup times and low powder consumption

Metal powder atomization system: ATO Lab Plus

Selected features:

  • Compact ultrasonic atomizer for a wide range of metal alloys including Ti-based or other reactive metal materials
  • Highly spherical metal powders suitable for material development in the field of additive manufacturing (powder bed fusion, deposition welding)
  • Flexible machine setup for the atomization of wire or bulk (rods, several millimeters diameter)
  • Low operating costs and high efficiency

Powder analyzer: Camsizer X2

Selected features:

  • Dynamic picture analysis of powders and loose bulk solids (granules, fibers)
  • Robust and reliable device for precise and quick measurements (several thousand to millions of particles)
  • Particle size analysis from 1 µm to several millimeters
  • Detailed 2D-analysis of shape characteristics (anisotropy, sphericity, symmetry)

Powder flow analyzer: GranuDrum

Selected features:

  • Automated powder flowability measurement device based on a rotating drum principle
  • Dynamic measurement principle with adjustable rotating speeds for the detection of the air/powder interface relations
  • Characterization of flowing angle and cohesive index
  • Reduction cell for the analysis of small powder volumes

Photos: M. Otto, T.Gustmann / IFW Dresden

Developed and processed alloys at Leibniz IFW Dresden

Al-based

  • binary Al-xCu/xSi alloys
  • Al-3.5Cu-1.5Mg-1Si + hard materials
  • quasicrystalline Al-based composites

Fe-based

  • 316L + hard materials
  • biodegradable FeMn-based alloys
  • FeCrVC-based tool steels (patented compositions)

Ti-based

  • Titanium aluminides
  • Ti-5Al-5V-5Mo-3Cr (Ti-5553)
  • Ti-6Al-2Sn-4Zr-2Mo-Si (Ti-6242)
  • Ti-45Nb
  • Ti-35Nb-7Zr-5Ta
  • Ti-24Nb-4Zr-8Sn
  • Ti-13Nb-13Zr
  • Ti + hard materials

Special functional and structural alloys

  • bulk metallic glasses (Cu-, Fe-, Ti- and Zr-based alloys)
  • Cu-based shape memory alloys (-30 °C < transformation temperatures < 200 °C)
  • magnetocaloric La(Fe, Co, Si)13

Conventional processable powders for SLM devices

Al-based

  • AlSi10Mg
  • AlSi12
  • AlSi7Mg0.6
  • AlSi9Cu3

Co-based

  • CoCr28Mo6
  • SLM® MediDent (Co-Cr-Mo-W)

Cu-based

  • Tin bronze (CuSn10)
  • low alloyed Copper (CuNi2SiCr)

Fe-based

  • 316L (1.4404)
  • 15-5PH (1.4545)
  • 17-4PH (1.4542)
  • Heat resistant tool steel (1.2709 und 1.2344)
  • Invar 36® (Fe-Ni)

Ni-based

  • HX
  • IN625
  • IN718
  • IN939

Ti-based

  • Commercial pure Titanium (Grade 2)
  • Ti-6Al-4V ELI (Grade 23)
  • Titanium (near-alpha) alloy TA 15 (Ti-Al-Zr-Mo-V)