A few days ago, British metal powder developer, manufacturer and supplier LPWTechnology found that even a slight powder contamination could destroy a metal 3D print by investigating a cracked 3D printed part. It is important to strictly follow the powder maintenance procedure. Such contamination is likely to occur if the operation is improper during material replacement.
Recently, British metal powder developer, manufacturer and supplier LPWTechnology investigated a cracked 3D printed part and found that powder contamination caused cracking. LPW says this is a good example of the “complexity of the AM process†and the importance of adhering to the powder maintenance program, reminding people that even minor mistakes can ruin 3D printed parts.
According to reports, a US customer of LPW recently sent it a SLM3D printing industrial gas turbine component with AlSi10Mg aluminum, which showed some cracks. The task of LPW is to find the cause of the crack.
To this end, LPW tested a sample in the customer's order. After conducting a comprehensive chemical and dimensional analysis of the sample with its state-of-the-art equipment, LPW found the powder delivered to the customer and was contaminated. Methods for testing metal powders are scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX).
Next, LPW investigated the powder samples sent by the customer and the 3D print itself. After the test, LPW found that the aluminum powder was actually contaminated, and the EDX test showed that the foreign powder of Inconel 625 (a nickel alloy) was dispersed in the aluminum powder. This granule has a "very limited solubility" in aluminum powder, with a higher concentration in some areas and a specific gravity of over 40%. It is in these areas that parts have the most cracks and damage.
This contamination has proven to occur during the material change process of the SLM 3D printer . LPW customers realized that the material on their SLM printers had recently been replaced by AlSi10Mg, formerly Inconel625. However, due to the operator's “less experienceâ€, the equipment was not properly cleaned.
From the beginning of the investigation to the final finding, LPW spent a total of four days. The metal powder supplier said it provides survey services to all customers as long as there are defects caused by materials.
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