“Our unique advantage in the additive manufacturing industry allows Roush to provide seamlessly integrated services like no one else can.” “Roush is a single-source product development supplier for customers,” said Brandy Badami, business development manager, additive manufacturing for Roush. Increasing these additive manufacturing capabilities and topology optimization technologies complement other Roush offerings, such as performance testing, product design and advanced engineering. The company’s services that support additive manufacturing capabilities include 3D scanning metallurgical testing and inspection machining, fabrication and assembly and full-spectrum design engineering. Roush’s latest investment adds new fused deposition modeling with large-frame machines from Stratasys direct metal laser melting equipment from EOS and capabilities in design for additive and topology optimization to its existing stereolithography, selective laser sintering and rapid prototyping services. Roush has been providing additive manufacturing and rapid prototyping services, commonly known as 3D printing, for more than 15 years. “Investing in the latest additive manufacturing technology continues our commitment to innovative, high-performance solutions - from concept maturation and optimization, all the way through to hardware integration and development.” “During the past year, Roush has invested millions of dollars in new additive manufacturing equipment to expand our reach into more industries,” said Dean Massab, executive vice president of business development for Roush Enterprises.
The company has expanded its additive manufacturing capabilities with equipment to benefit multiple industries, including aerospace, automotive, defense, energy, entertainment, medical and consumer products.
The machine includes a rotating platform that allows two build modules to be used reciprocally. Acquired by GE Additive in 2016, the Xline 2000R from Concept Laser has a build envelope of 800 x 400 x 500 mm for large-scale production, such as engine blocks. Roush has purchased the Xline 2000R, the largest powderbed metal additive system in the world. Additive manufacturing is a process that creates a physical object from a digital design. Results of the XPS and STEM-EDX analysis of oxide composition are shown to be in agreement with the thermodynamic calculations confirming that oxide scale on sputter particles is formed by MgAl 2O 4 spinel and Al 2O 3 (corundum) oxides.Today Roush is the first service supplier in North America with the largest metal additive manufacturing system of its kind. Columnar oxide scale formation on spatter particles was revealed as well, reaching up to 125 nm in thickness measured using STEM. Analysis of the oxide characteristics were consistent with the observed oxygen content in the sampled powder. XPS analysis of the powder surface chemistry indicates that powder particles are covered by uniform oxide layer, formed by Mg- and Al-based oxides, average thickness of which increased from ~4 nm in case of the virgin powder up to about 38 nm in case of the reused for about 30 month powder, established by XPS. The results show an increase in volume fraction of heavily oxidized spatter particles up to 3% in 30 months. Thereby, detailed analysis of the powder morphology, microstructure and surface chemistry was performed by SEM, TEM and XPS.
AlSi10Mg powder degradation in Concept Laser XLINE 2000R machine over the total period of 30 months was analyzed in order to understand the extent and mechanism affecting powder aging. Knowledge concerning powder degradation during additive manufacturing (AM) processing is essential to improve the reusability of the powder in AM and hence maximize feedstock powder reuse and economy of the process.
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