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Layered Print Defects/Cracks (Machine (Verified CX material parameters…
Layered Print Defects/Cracks
Man
Training
Verified Magics/EOSPRINT1.9 process viaTEAMS meeting w/ Bonn
Operator
Machine
Overtemp Fault (build plate) - DAN
Machine Calibration (Dec 2019 - both machines)
Grid nozzle verified ok - EOS Vince
EOS version number same as other GKN sites?
verifying
Magics parameters same as other GKN sites
confirmed
EOSPRINT hatching evaluation does not match laser pattern on machine (02Mar2020) - see pics/email
Verified Magics parameters
Verified CX material parameters same as DAN (2x), Bonn (3x), CIN (1x)
New RAC file for AUB for Monday, 3/9/2020
Materials
Humidity
Verified w/ meter/flow test
large bags desiccant, confirmed dry
Purchaced humidity meter (
(verified dry, verified same as 316L)
Temperature (cold powder), multiple days?
1x Batch (serial numbers)
CX Stainless Steel
Measurements
Density (7.68-7.69g/cm3 vs target 7.65 g/cm3 min; 99.8% vs target 99.6%)
Surface Roughness (Ra 5.89-6.04 um vs target Ra 7.5 um)
Evaluated "Bad" builds for defects using height gauge
Defect height/part by position does not appear to be a pattern
Environment
Ambient Humidity (16%)
Cleanliness of Machine
Prior Materials = 316L Stainless, cleaned machine
Added ~120kg of new material
Verified CX material humidity (meter and flow test vs. 316L in stock)
Methods
Verified Root
.stl File:
6796.5000.a00-AM6-med4-magics*
received AM6.stl from Bonn/China to ensure AUB file not corrupt
Received labeled core slice data provided from Bonn
Setup
Location on Build Plate(Parts, Density Cubes & Tensile Bars)
re-positioned cores, tensile bars, and density cubes
slice files received from Bonn
Hardness, Tensile strength, density testing as expected
Parameter verification conducted side-by-side comparison AUB to DAN-China
EOS & Rami (GKN Radevormwald) verified *.jz file has hatch lines throughout, should print
Dosing
%/ Coverage - all pictures indicate sufficient layer coverage
EOS/Materialise = Feb 28/29 Root Cause meeting & Feb 29
anotherbadprint
ideas
add new/separate part?
Added to no labeling build
print base parts, no labeling
2 of 2 successful so far (printing complete 3/7/2020 and 3/12/2020)
Send base AM6 and *.platform Good/Bad files to Materialise and EOS for analysis.
No issue found
Send
.eosjz Good/Bad files to EOS for analysis - Tom found no issues (again - Al investigated previously) and also ran RP tools on
AM6.stl and found nothing out of the ordinary - 03Mar2020
EOS to watch label and setup from base AM6 to export to printer
Complete - no issue found
EOSPRINT 2.5?
spaces, dashes, and decimal points? (ok to use unders
score
)
Mar 2 EOS on site
EOSPRINT exposure strategy does not match the machine (pics and EOSPRINT hatching analysis at layers)
Request to contact EOS machine and software experts for brainstorm ideas
Does EOS have capacity to print a "bad" print? to verify if this is an AUB issue or does defect transfer as a corrupt file?
