The primary advantage to DMLS is that you can create parts with incredibly complex geometries, such as honeycombs and mesh-like structures. Instead of a wide range of different products optimised for each market sector, we just have one. Is This the End of Different Fluid Power Products for Different Markets? Stress-bearing members may have to be solid due to the manufacturing process, when a lighter hollow structure would be preferable. These problems become more severe as part complexity rises. By choosing the alloy with the highest specific strength, whatever its density, we can build the lightest part. DMLS is an additive manufacturing process. Get a realistic snapshot of the surface finishes that are possible on machined plastic and metal parts. Both these factors favour steel. The aluminum alloy used in the DMLS process adds silicon and magnesium, building parts with material properties exceeding their die-cast counterparts. ductile determine brittle steel whether breaking material without heavier magnet titanium amagnetic stick aluminum similar than So, the cost of an AM part made from maraging steel will be lower than that of a part of similar mass made from titanium. For others, space and weight are not at a premium, and cost is the prime driver. And added bonus? In some market sectors, cost is the driver and not weight. We created a detailed guide to resin substitutes for ABS, PC, PP, and other commonly molded thermoplastics. Thanks, Richard C.. My goal with this article was to get people thinking - there are many ways to be successful with AM. Indeed, if we plot the specific strengths of each material, we can see this clearly: So, it looks as though maraging steel could be used successfully in light-weight parts, but for this to work, it is vital that part volume is minimised. Furthermore, limitations in where cutting tools can reach often mean that material is too expensive to remove, and so it remains on the component, adding unwelcome mass. This may have knock-on benefits in the rest of the product, enabling that to be smaller and lighter too. Readers may also find the following articles useful: To view or add a comment, sign in Refer to Is This the End of Different Fluid Power Products for Different Markets? Image above - production build of servo valve bodies produced on RenAM 500Q industrial AM machine. Using 3D printing or CNC machining, these two metals have proven to be incredibly versatile for parts across a range of industries. The big difference between your two choices for machining aluminum has to do with the amount of copper in the alloy. However, if we select a cost-effective material such as maraging steel, use a productive AM machine and minimise post-processing, then our cost-v-mass curve shifts. But when we look at a wider selection of materials, we see some potential rivals. Titanium parts have additional cost implications because they are difficult to machine. So, a maraging steel part can be smaller and cheaper than an equivalent titanium part. AM should be seen as mainstream manufacturing process and not just an alternative for complex metal cutting pricess. One of titaniums pluses is low thermal expansion. If they replace the same subtractive steel part with an AM steel part, they might achieve a 60% reduction in weight: a 400g steel part. The properties of 3D-printed aluminum exceed its die-cast counterpart except for lower elongation at break. Many conventional manufacturing processes are limited in the intricacy and detail of what they can produce, and so they cannot always be used to produce the most weight-efficient designs. Innovation in alloys that deliver even higher performance than the current exotics, or strong properties at a lower cost point, will open up even more possibilities. We've added GD&T to our in-house first article inspections (FAIs) and process capability studies to give you an even more complete set of dimensional verification options. This saves assembly time and reduces your Bill of Materials (BOM). Ti needs AM, the reverse is not true. We can compare the suitability of these alloys for use in light-weight, high-strength applications by assessing their specific strength. If you need a prototype part quickly, aluminum stands out for its low cost and high quality. Nice article Marc! It is now possible to optimise the part design to suit our chosen alloy, using just the amount of material that we need. Contact UsProto Labs, Inc. 5540 Pioneer Creek Dr. It also offers excellent corrosion resistance and equally poor electrical conductor. Post-processing costs also have a role to play. The right material for a subtractive manufactured part is not necessarily the best choice for an AM part. The second element is processing costs, driven largely by the build time. So, if our conventional part has to be bulkier than we would like it to be, then a low-density material is a must. The idea of using a denser material to meet specifications while still maintaining required strength and cost effectiveness through AM redesign is well explained. One advantage of 3D printing titanium that you might not have thought of has to do with titaniums cost. Another insightful article Marc, often materials are said to be X many times stronger then steel. The cost of mass comprises two elements, the first of which is the raw material cost. If the forming process demands a volume that is larger than the ideal size, then this favours low-density materials over their stronger but denser counterparts. How does this affect our material choice? Not necessarily. The material cost of maraging steels has a fair way to fall as well, while the intrinsic cost of titanium will keep the price of those alloys high. However, machining is somewhat limited in terms of geometries, so extremely complex designs require a different solution such as DMLS, no matter what material you choose. Moreover, while manufacturing costs are somewhat higher using DMLS, the parts deliver value through the combination of strength and weight reduction. Simplistically, if one replaces a 1kg steel part like-for-like with Ti they can achieve a 40% reduction in weight: a 600g Ti part. Steel really can be as light as titanium, and the compact, cost-effective AM products made from it could be even more disruptive. Domin has chosen maraging steel to produce innovative valve bodies and spools that are able to withstand high hydraulic pressure in an ultra-compact package. Its often used for casting and is most similar to a 3000 series alloy, given the addition of magnesium as the principal alloying element. Similarly, the productivity and automation of our AM machine will govern how long it takes to build the part, whilst the purchase and running costs of the equipment will determine how much this time costs us, once again affecting the cost-v-mass curve. For more details refer to Is This the End of Different Fluid Power Products for Different Markets? steel pots backpacking stainless cook pot titanium aluminum pros If we work really hard on our product design and find more weight savings, then it might even be possible to move to a point where our ultra-lightweight product matches the minimum cost conventional product. Aluminums low specific gravity (2.7 g/cm3) means that its considerably lighter than counterparts such as steel, which is about three times as heavy. But this is likely to leave a lot of extra material on the part, and so the material cost starts to become more significant. DMLS lets you combine separate parts of assemblies into a single, strong part. To the left we see the low-density aluminium alloys, including the widely-used AlSi10Mg as well as higher strength formulations such as A20X and Scandium-Aluminium. But is it always the right material when we want to build high-strength parts with minimal mass? Boosting AM adoption - the next phase of market growth. We can place material just where we need it to fulfil the component's function, and we can omit it from areas where we don't. Now, switching to a Ti AM part vs the same steel AM part, the 40% weight saving represents just 160g extra vs the AM only 600g saving. Parts can be multi-functional so that joints are eliminated and products can be made more compact. With a melting point of about 3,000 degrees F (1,660 degrees C), when exposed to heat, it maintains its form better. Titanium is often the material of choice for light-weight structural additive manufacturing (AM) components. But if we could make really light-weight parts out of a relatively inexpensive metal, then it might be possible to serve all market sectors with a single product. It has a long history in cast, wrought and forged forms, and so manufacturers have confidence in its suitability for a wide range of demanding applications. This guide includes high-quality photos of your surface finish options at Protolabs. Domin Fluid Power is a company that has put all of these principles into practice. We are starting to use AM to make the metal parts. This chart provides a technical overview of the types of aluminum and titanium we offer for DMLS and machining. Struggling with thermoplastic material shortages? Points along this line exhibit an equal ratio of strength to density. In terms of appearance, titaniums color varies depending on how much it has been altered. Aluminum and titanium are both light, but for different reasons. While aluminum generally doesnt react to acids, it does tend to corrode in alkaline (basic) environments. It has developed a range of direct drive servo valves that are lighter than the best conventional products, and inexpensive enough to satisfy even the most cost-sensitive sectors. Using a fusing laser to weld powdered metal together, it forms parts, layer by layer. Get this quick reference guide to explore your surface finish options across our six 3D printing technologies. 
Denser materials generally require more energy to melt each layer and so volume build rates can be slower, but the mass build rates of denser materials are generally higher. Maraging steel's high specific strength, high density and low cost makes it particularly attractive. For instance, aerospace customers will be looking for weight reduction and they attach a certain value to weight, so if we can make an AM part that falls into the blue region in the diagram below, then it should be attractive to them. for how this applies to the market for hydraulic servo valves. The titanium used in our DMLS process is Ti 6Al4V, more commonly referred to as Ti 6-4. Image above - factors affecting the cost-v-mass curve for an AM part. A part built from 316L will be both larger and heavier than a equivalent titanium part. CNC milling and turning are time-tested ways to manufacture aluminum and titanium parts. rfs riko Additive manufacturing opens up new possibilities, making it possible to realise near-ideal part designs. It has mechanical properties similar to Ti grade 23 annealed and has exceptional tensile strength. It combines high strength with low density, making it invaluable for long-life, high-stress applications where weight is critical. If we can streamline or eliminate downstream finishing, assembly, inspection and testing processes, then this also moves the curve. And if youre looking for a good electrical conductor, aluminum can do that. Definitely an area to watch in the coming years. In fact, you need a fraction of the amount of titanium to get the same physical strength you would get with aluminum. Plus, it provides a compelling blend of properties. To view or add a comment, sign in, Excellent post as usual Mr Saunders. It gets more and more expensive to shave off each last gram of material. So, titanium has a lot to recommend it. With a tensile strength that can exceed 1,000 MPa after heat treatment, it is actually significantly stronger than austenitic stainless steels such as 316L, and yet it is roughly half as dense. When you think of a dream team of material characteristics for parts, light weight and strength come to mind. Spoiler alert: the answer is 'yes', but it may not be the steel that you're thinking of. At the other extreme, minimal processing will produce a heavier part, so material costs will rise.
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