Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Additively manufactured component surrounded by loose metal powder
RESULT – Resource efficiency in laser beam melting through powder recovery
In short
A new dry separation process from Ruwac Industriesauger GmbH and Fraunhofer IPA enables the safe recovery of reactive metal powders without liquid. The aim is to conserve resources, reduce material costs and make additive manufacturing more efficient.
In detail
Beim additiven Fertigungsverfahren Laserstrahlschmelzen können hochkomplexe Bauteile schichtweise gefertigt werden. Nach dem Fertigungsprozess muss das überschüssige Pulver aus dem Bauraum und von den Bauteilen entfernt werden.
With the additive manufacturing process of laser beam melting, highly complex components can be produced layer by layer. After the manufacturing process, the powder must be removed from the process chamber and from the manufactured components.
Challenge: Reusing reactive metal powder
Suction devices are typically used for this, but so far without the possibility of reusing the extracted metal powder. The reactivity of the metal powder has so far made wetting the metal powder with liquid necessary. This changes the material properties so that reuse for laser beam melting is not possible.
Solution approach: dry separation for recovery
Together with Fraunhofer IPA, Ruwac Industriesauger GmbH has developed an innovative dry separation process based on a high-speed cyclone. The institute advised in particular on issues of occupational safety and the potential and necessity of dry pre-separation of reactive metal powders. The process enables efficient recovery of reactive metal powders. Initial tests carried out by Fraunhofer IPA with TiAl6V4 show a separation rate of over 98 %. Further tests with industrially relevant metal powders are already underway. The aim is to further develop the process and significantly improve resource efficiency and cost-effectiveness in additive manufacturing.
