Developments in Net Additive Manufacturing and Advanced Alloys

Our first ever Additive Manufacturing was a complete success. With bookings flying in up until the very last minute, we had over 60 delegates attend including ALFED members, students & apprentices. We had speakers from Sheffield University, EOS, Meterion, Renishaw, Fronius, TWI, DMG Mori & Wolverhampton University and an hours tour of the facility at the University of Wolverhampton, Telford Campus.

Speakers

Paul Unwin, Additive Manufacturing UK
Industrial Chair of the Additive Manufacturing Strategy Steering Group

“The UK’s high value manufacturing sector creates substantial wealth for the nation and the further adoption and industrial commercialisation of additive manufacturing is a key to unlocking significant potential benefits.

Additive Manufacturing (AM) is a disruptive and transformational cross-sectoral technology impacting design, manufacturing, infrastructure and business models. It is revolutionising businesses by providing a radically new method of production that enables new, functionally superior designs to be realised at lower cost with enhanced function, productivity and greater sustainability. It is transforming supply chains and the way businesses compete by introducing revolutionary new business models which take advantage of this fully digitally enabled process.”

Dr. Russell Goodall, University of Sheffield

High Entropy Alloys and Alloy Design
A new approach in alloying, termed High Entropy Alloys (HEAs), may allow us to reach new performance levels, or create materials adapted to the needs of new processing routes, such as additive manufacture. These alloys are often unusual, complex compositions, and present challenges for conventional methods of alloy development; the presentation shown alternative strategies, and examples of their application to the design of new alloys.

Stuart Godfrey, Materion AMC

For the last 25 years Materion have been producing aluminium silicon carbide reinforced metal matrix composites (MMCs) via a unique powder metallurgy process from its Farnborough facility.
These MMC materials are used in a range of industries including performance automotive, commercial automotive, space and defence, niche engineering and consumer electronics.
The presentation summarised the production, mechanical properties and application of these materials.

Stuart Jackson, Renishaw plc

Multi-Laser Metal Additive Manufacturing – The road to economic AM Production
Renishaw have developed and released to market amid-size multi laser metal AM machine. With their feet firmly on the ground it is their first move towards bringing affordable AM product to market. The presentation shown the production rate gains achieved by applying multiple lasers into a bed area previously processed with one laser and the effects on cost-per-part with the focus on Aluminium alloys.”

Valerion Carollo, TWI – The Welding Institute

The presentation provided an overview on the numerical modelling strategies for the simulation of additive manufacturing processes. The overview is based on applications of aluminium additively manufactured parts and included: models for the prediction of residual stresses and distortions, microstructure and mechanical properties, and design optimisation.

John Robinson, Senior Engineering Technician, University of Wolverhampton

ALM activity at the University and more specifically the research being done involving aluminium.

Garth Stevenson, Area Sales Manager UK & Ireland
EOS – Electro Optical Systems Ltd

Aluminium – Additive Manufacturing at scale
Size, volume and cost. Does AM compare with conventional casting?
“I hope to convey a message that advancements, are allowing serious consideration for AM to be part of a conventional supply chain.”

Richard Kellett, DMG Mori

DMG MORI are a global leading and established supplier of machine tool technologies, and have in recent years developed an innovate additive manufacturing portfolio including directed energy deposition as a hybrid solution within 5 axis mill turn platforms, and highly flexible powder bed SLM systems.

Paul Conquest, Fronius UK

Fronius CMT single wire & twin wire process for additive Manufacturing