IMTS 2022 Conference: Overcoming the Challenges of New Designs, New Materials, and New Printers with X-Ray CT

This presentation addresses the successes and failures of 3D printing a topology optimized heat exchanger with a new alloy, Aluminum F357, that hadn’t been printed on a Xline 1000 printer before this project. Using X-ray computer tomography (CT), new print parameters were developed in one build and the redesigned heat exchangers printed in the next. Some background will be given on X-ray CT and the parameter selection method created and the positives/negatives of this method. Upon inspection of the printed parts, our workflow generated unexpected gaps in the parts. CT scanning the printed parts allowed us to determine the size of the internal gap and adjust the models accordingly. Updating a set of complicated heat exchanger models while changing the material and the 3D printer can be a daunting task. However, X-ray CT can give you confidence when selecting new print parameters and inspecting printed parts. X-ray CT allows rapid feedback when printing a design of experiments (DOE) of parameters and can inspect hard to reach regions such as internal channels. This presentation showcases the successes and setbacks we’re able to overcome while improving a set of heat exchangers.

Registration
Powered by AMT and managed by GIE Media, The IMTS 2022 Conference features 69 different sessions you won’t want to miss so register today. Focused on a range of topics that include process innovation, plant operations, quality/inspection, and automation, The IMTS 2022 Conference addresses improving productivity; improving part quality; and developing a stable, competent workforce to lower the cost of manufacturing in the United States and create new levels of market demand.

Meet your presenter
Curtis Frederick is an additive manufacturing (AM) application scientist with Carl Zeiss and is positioned at the manufacturing demonstration facility within Oak Ridge National Laboratory (ORNL) to support the CRADA between ZEISS and ORNL. Frederick researched parameter development for grain control using electron beam AM of Ni-based superalloys during his graduate studies. He also worked on alloy development of high temperature Al-based alloys for laser powder bed fusion at the production scale. He is currently developing workflows for linking defects in printed parts to properties of the powder feedstock for multiple powder bed AM processes. He received his Ph.D. in material science and engineering at the University of Tennessee, Knoxville in 2018.

About the company
ZEISS develops, produces, and distributes innovative solutions for industrial metrology and quality assurance, microscopy solutions for the life sciences and materials research, and medical technology solutions for diagnostics and treatment in ophthalmology and microsurgery. The name ZEISS is also synonymous with lithography optics, used by the chip industry to manufacture semiconductor components. ZEISS consists of four segments: semiconductor manufacturing technology, industrial quality and research, medical technology, and consumer markets.