Solutions for coating, repair and additive manufacturing of high performance components - ponticon GmbH Alte Schmelze 20, 65201 Wiesbaden ...
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Solutions for coating, repair and
additive manufacturing of high
performance components
ponticon GmbH
Alte Schmelze 20, 65201 Wiesbaden
www.ponticon.de
PONTICON: AT A GLANCE
WHAT WE DO
Ponticon develops solutions for coating, repair and additive manufacturing of high-performance
components
Based on 3D-EHLA technology, we enable significantly faster development of innovative alloy systems
WHY IT IS UNIQUE
Utilized process principle allows for unprecedented material combinations on 3D surfaces
New performance levels thanks to kinematics designed for highly dynamic machine movement
Application & materials knowhow combined with awareness for industrial challenges
WHO WE ARE
Team of passionate engineers, bold entrepreneurs and experienced strategists
Embedded in strong networks of academic and industrial end-users
WWW.PONTICON.DE 2
3D METAL PARTS: FAST, PRECISE, FLEXIBLE
FAST
The highly dynamic kinematics of the pE3D machines enables surface rates up
to 500 cm²/min and build-up rates up to 600 cm³/h
PRECISE
Reproducible production of filigree 3D-structures with a minimum wall
thickness of 300 μm and roughness of about 10 μm.
FLEXIBLE
Processing and combination of diverse alloy systems and elementary metals
with nozzle-based powder supply.
pontiCOAT pontiBUILD
Durable coatings for higher Additive manufacturing of
productivity and lifetime functionally enhanced parts
PONTICON TECHNOLOGIES
pontiFIX pontiMAT
Repair of delicate high- Rapid alloy development
value components with unlimited possibilities
WWW.PONTICON.DE Image Sources: Fraunhofer ILT 3
DRAWBACKS OF EXISTING TECHNOLOGY
Laser Material Deposition (LMD) allows for combination of hard-to-weld alloys,
creation of graded materials and processing of freeform 3D surfaces.
The process is well-established and used on an industrial scale.
LMD Process Characteristics
Powder or wire is molten on the surface of the substrate
3 – 5 axis, gantry or robot kinematics
Typical
Kinematic Systems
Feed rates from 0.5 to 5 m/min
LMD Challenges
High energy input leads to undesired manipulation of microstructure
Deformations results in low dimensional accuracy
Layer thickness from 0.5 to 2 mm requires rework
WWW.PONTICON.DE Image Sources: Fraunhofer ILT, DMG Mori,, Trumpf, BeAM 4
PUSHING COATINGS, REPAIR & AM TO THE NEXT LEVEL: 3D-EHLA
Extreme high-speed laser cladding (EHLA) is successfully industrialized for coating of brake discs,
rollers, shafts and hydraulic cylinders:
Only applicable on rotational symmetric geometries
No repair or additive manufacturing
Limited possibilities when developing new alloy systems
Ponticon offers an innovative system to untap the potential of EHLA in three dimensions
pontiCOAT
Advantages of 3D-EHLA process:
Surface roughness
pE3D SYSTEM:
ENABLING 3D-EHLA TECHNOLOGY
Tripod kinematic system for workpiece movement, stationary optics & nozzle
Optional tilt-turn axis for advanced geometric freedom
Granite for maximum stiffness and precision
State-of-the art industrial controls available (Siemens, Beckhoff, Bosch, …)
Sophisticated CAM module for easy programming
Easily adaptable to conventional wire- or powder-based DED processes
Recovery of overspray powder
Suitable clamping system R&D Topics
Parameter database
TECHNICAL SPECS:
Wide range of feed rates: 1 to 200 m/min* for smooth surfaces, high
accuracy and high productivity
Max. acceleration: 5G* for maximum powder efficiency
Up to 4 powder feeders and 8 hoppers for material flexibility
Build envelope: D700 x 800 mm³ for highest flexibility
Up to 12 kW laser power for future-proof operation
* up to 25 kg payload
WWW.PONTICON.DE 6
HIGH-PERFORMANCE COATINGS ENABLED BY pontiCOAT
Advantages of pontiCOAT compared to existing coating technologies:
No need for hazardous chemicals
Significant reduction of material and energy consumption
Increased layer adhesion
Increased corrosion resistance
Shorter process chains
Highest material flexibility
! Surface technology accounts for 3 – 7 % of overall product cost
! Wear and corrosion of industrial goods results in significant economic loss in developed countries
(3 – 4 % of GNP in Germany, approx. 110 – 140 billion € in 2019)
Despite mitigating economical risks, an increased life cycle of industrial goods largely contributes to sustainability
End-users benefit from innovative coatings which are composed of application-specific materials and hence
increase part functionality:
USP in a competitive, global landscape
Top and bottom-line impact (more revenue due to better coatings, less
production cost due to efficient manufacturing process)
WWW.PONTICON.DE Image Source: Corrosionpedia, https://doi.org/10.1016/j.engfailanal.2015.11.057 7
MULTIMATERIAL: TAILORED TO APPLICATION REQUIREMENTS
Being able to individually combine materials according to application requirements
is a value-add enabled by laser-based metal deposition. In an integrated approach,
ponticon facilitates multimaterial processing for industrial coating, repair and
additive manufacturing processes.
Nozzle-based processes enable in-situ mixture of powders:
IN718
IN718 316L Unique possibilities regarding material composition
CuCrZn IN718 Vast portfolio of available powder materials
V2A No pre-alloying or dry-mixing required
Challenges
IN625 + WC Ensure homogenous mixture of base powders
Tune process for desired composition and microstructure
316L
Creation of database with feasible recipes
WWW.PONTICON.DE Image Sources: RWTH Aachen DAP, Fraunhofer ILT 8
pontiMAT: RAPID ALLOY DEVELOPMENT FOR EVERYONE
Advanced materials are of utmost importance for meeting future challenges:
More durable (reduced abrasion and corrosion)
Tailored to application (more resource-efficient)
Sustainable (more environmental-friendly)
Conventional casting procedures are inflexible, unproductive and limited in terms
of feasible material combinations
pontiMAT is the only technology that enables significant
acceleration of alloy development:
Ponticon supports your Rapid Alloy Development process with
suitable equipment, EHLA-specific knowhow and metallurgical
expertise.
WWW.PONTICON.DE Image Sources: RWTH Aachen DAP, Fraunhofer ILT 9
pontiMAT: RAPID ALLOY DEVELOPMENT FOR EVERYONE
Economic try & error approach for promising alloy systems in short timeframes
Low-effort validation of simulation results
Transferability of findings to other AM processes such as LPBF and Binder Jetting
Analysis of Target chemical Lowest effort in mixing powder materials in any ratio
specimen properties composition
Adjustable melting and solidification process (heat input, duration)
pontiMAT Intuitive, fully integrated software system supporting the development process
3D-EHLA of Systematic variation
test specimens workflow of composition
What used to take years or months is now achievable in weeks
Automated machine Assignment of pontiMAT is the fastest, most precise and most flexible solution for alloy development.
code generation process parameters
WWW.PONTICON.DE Image Sources: RWTH Aachen DAP 10FLEXIBLE pE3D SYSTEM:
SCIENTIFIC PROGRESS AT YOUR FINGERTIPS
pE3D allows you to focus on your R&D endeavours:
Software toolbox for simplified material development
Modular CAM system to avoid inefficient G-Code programming
Up to 8 powder hoppers for highest material flexibility
All DED technologies are integrated into pE3D:
3D-EHLA with highly dynamic 3 or 5 axis operation mode
EHLA with fast turning axis
Conventional LMD (powder and wire) with 3 or 5 axis operation mode
pE3D is the most powerful tool to push your DED and material-related
R&D activities to the next level
WWW.PONTICON.DE Image Sources: RWTH Aachen DAP 11PONTICON REFERENCES: ACADEMIC USERS OF 3D-EHLA TECHNOLOGY
DR. THOMAS SCHOPPHOVEN
Fraunhofer Institute for Laser Technology ILT, Aachen, Head of Business Unit LMD
"With the pE3D system from ponticon, we are able to use the Extreme High Speed Laser Cladding EHLA
process developed and patented at Fraunhofer ILT for coating, repair and additive manufacturing of three-
dimensional components for the first time.“
PROF. DR. JOHANNES HENRICH SCHLEIFENBAUM
RWTH Aachen University Digital Additive Production DAP, Head of Institute
"Agile, digital materials research is the foundation for innovation in countless industries. EHLA 3D and the
pE3D system from ponticon will help us to significantly advance and shape the topic of Rapid Alloy
Development (RAD) in the future.”
WWW.PONTICON.DE 12EQUIPMENT:
pE3D machine
Periphery (powder feeders & handling, sensors)
Powder material INDIVIDUAL SOLUTIONS:
PONTICON PRODUCTS AND SERVICES
APPLICATION & ALLOY DEVELOPMENT:
Feasibility studies
Process parameters & database Ponticon realizes innovative solutions in the field
Material analytics of coating, repair and additive manufacturing of
metallic components.
MANUFACTURING SERVICES: By using these processes, our customers benefit
Support during ramp-up from new possibilities when developing and
On-demand production of parts manufacturing their products.
Full-service provider for coatings and repair
We accompany them with our know-how from
the first idea, process and alloy development to
ENGINEERING: industrial application.
Tailored pE3D machine
Individual CAM modules
Re-design of customer parts
WWW.PONTICON.DE 13APPLICATION EXAMPLES: PROVIDING OEMS & SUPPLIERS WITH INDUSTRY-SPECIFIC SOLUTIONS
MINING TURBOMACHINERY AEROSPACE
Coating of drills and conveyor components Coating of turbine blades AM of structural components
Repair of mission-critical high-value parts Repair of turbine blades Coating of propulsion components
Increased wear resistance for longer lifetime Avoid costly replacement & increase lifetime Weight reduction through material-enabled
Higher productivity due to higher durability Enable higher operating efficiency lightweight constructions
Better thermal management
TOOLING OIL & GAS AUTOMOTIVE
Repair of worn-out inserts, hot runners etc. Coating of subsea and fracking Coating of powertrain components
Coating of newly manufactured molds components for fluid handling AM for local stiffness increase chassis and
AM of hybrid tools AM of downhole tools structural parts
Longer lifetime of components Longer lifetime of components Improved mechanical properties
Reduced cycle times Better performance of AM parts Lightweight potential through reduced
material utilization
WWW.PONTICON.DE 14Our Approach:
Solving Customer Challenges
1 Identification of customer challenge: How could the product be
improved? What are the pain points with current production method?
2 Part analysis with regard to desired functionality and geometry
(support with redesign if necessary)
3 Identification of suitable alloy system
4 Preliminary estimate of economic and technical impact
5 Feasibility study
Combination of identified alloy system with base material and subsequent analysis of properties (density, surface roughness, mechanical
properties, microstructure, chemical composition, corrosion & wear resistance, powder efficiency, productivity etc.)
Transfer of results to actual geometry (repeat tests from previous step and check for dimensional accuracy)
6 Technical and commercial negotiations:
Deriving a suitable machine configuration (considering hardware and software)
Identify individual concept of use (machine acquisition, manufacturing-as-a-service etc.)
7 Industrial implementation:
Machine and process setup
Training for end user
WWW.PONTICON.DE 15FEASIBILITY STUDIES
DEMONSTRATORS
pontiCOAT of St37 mild steel with 316L stainless steel
Applicable for coating of parts used in corrosive environments
One layer, height 200 µm
Processing time 3 minutes @ 80 m/min feed rate (~600 cm²/min)
Smooth surfaces, low dilution & heat input
pontiCOAT of V2A stainless steel with tungsten carbides embedded in Inconel 625 matrix
Applicable for coating of parts used in abrasive and corrosive environments (Mining,
Oil&Gas, Excavation)
Ten layers, total height 1.8 mm
Processing time 2.5 minutes @ 50 m/min feed rate (~100 cm²/min)
Variable tungsten carbide content in each layer
WWW.PONTICON.DE 16FEASIBILITY STUDIES
DEMONSTRATORS
pontiBUILD of thin-walled AlSi7Mg aluminum structures
Alternative to time-consuming laser powder bed fusion process
Smooth surfaces even with overhangs
Build-up time approx. 2 minutes for overhang structure, 5 minutes for blade profile
pontiBUILD of AlSi7Mg aluminum 3D geometries
Applicable for function enhancement of conventionally
manufactured aluminum parts
Processing time 3 minutes for 15 mm height and 2 mm
wall thickness
Smooth surfaces, no distortions, no hot-cracking
WWW.PONTICON.DE 17FEASIBILITY STUDIES
DEMONSTRATORS
pontiCOAT of copper substrate with IN718 nickel-base alloy
No dilution and strong adhesion
Surface rate of 120 cm²/min @ 180 µm layer thickness
Alternative to CGS process
High thermal conductivity, strength and corrosion resistance enables applications
requiring highest heat flux
WWW.PONTICON.DE 18FEASIBILITY STUDIES
DEMONSTRATORS
pontiCOAT of conductive metal layers on Al2O3 ceramic components
Applicable for local, targeted functionalization of ceramic components
Firm bond between metal and ceramic substrate
Various materials may significantly improve the properties of ceramics:
Titanium for tunable electric resistors and high-temp environments
Copper for highest heat and electrical conductivity
Tungsten for improved mechanical properties of the ceramic
components (fracture strength, toughness, thermal shock resistance
and creep resistance)
WWW.PONTICON.DE 19Solutions for coating, repair and
additive manufacturing of high
performance components YOUR CONTACT
Tobias Stittgen, M.Sc.
ponticon GmbH Managing Director
Alte Schmelze 20, 65201 Wiesbaden +49 174 7496055
stittgen.tobias@ponticon.de
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