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Home HIP Technology HIP Techniques Additive Manufacturing



ADDITIVE MANUFACTURING (AM)

Additive Manufacturing (AM) is a manufacturing process that encompasses various
techniques that have the production of three-dimensional components from a
previous CAD design in common, based on the addition of layers or
two-dimensional elements. This form of manufacture allows for greater design
freedom as it is not limited by conventional manufacturing techniques. Additive
Manufacturing is also known as 3D printing or rapid prototyping.

Hiperbaric's Hot Isostatic Pressing (HIP) technology improves the properties of
the metal parts manufactured by different AM processes, giving them more added
value and making them suitable for a larger number of applications by providing
them with the necessary functionalities.

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SYNERGIES AND BENEFITS OF ADDITIVE MANUFACTURING WITH THE APPLICATION OF HIP


Nowadays, as the various AM techniques achieve greater reliability and
robustness, this form of manufacturing is moving away from validation
prototypes, which were possible until now, to become a way of manufacturing
components in batches in a viable manner. Alongside this growth, HIP technology
has become established as a key post-processing tool to ensure the quality of
these components, as its application has numerous benefits, such as the
following:

 * Elimination of porosity and densification of the material.
 * Possibility of combined heat treatment with HIP, saving time and cost.
 * Improvement of mechanical properties such as ductility, resilience and
   fatigue life.
 * Reparation of defects and therefore reduction of the number of failures.
 * Cost reduction by reducing the number of non-destructive tests required.

 

Typical examples of HIP and AM combinations:

As Additive Manufacturing techniques evolve and the number of studies supporting
the benefits of combining them with Hot Isostatic Pressing processes increases,
examples of combining the two technologies continue to grow. Some of the best
known examples include the following:

 * In the aerospace sector, fuel injectors and other CoCr components
   manufactured by L-PBF (Laser - Powder Bed Fusion).
 * Also in the aerospace sector, turbine blades in aircraft engines,
   manufactured from nickel superalloys using the L-PBF technique.
 * In the field of medical implants, hip and knee prostheses manufactured using
   L-PBF and EBM (Electron Beam Melting) from titanium alloys.
 * In the automotive sector, thanks to HIP, the prototypes and parts
   manufactured by Additive Manufacturing (AM) can be used with total
   confidence, as they obtain greater reliability and better properties.

 


METAL ADDITIVE MANUFACTURING TECHNIQUES


The various Additive Manufacturing techniques differ in the way the
two-dimensional layer is created, and the way each layer attaches to the
previous layers. This defines the required precision, materials and
post-processes, as well as times and costs of each AM method making some more
suitable than others depending on the application.

Additive Manufacturing - Powder Bed Fusion (PBF)

Selective Laser Melting (SLM), also known as Selective Laser Sintering (SLS), or
DSL or EBM (Electron Beam Melting)

This is one of the most established AM techniques. The piece is created from
layers of metal powder spread evenly and welded to the previous layer with a
power source. The power source can be either L-PBF/SLM laser or an E-PBF/EBM
electron beam. Thus, layer by layer, the part is produced. Since it is a spot
welding process, defects and porosities are relatively frequent depending on the
material and processing parameters. HIP technology helps to overcome these
problems.

 




Additive Manufacturing - Binder Jetting

The Binder Jetting technology is based on a patent from MIT (Massachusetts
Institute of Technology). Here, after a layer of powdered material has been
applied, binder drops (liquid adhesive) are applied to hold the powder particles
together, as well as to the previous layer. Due to the nature of the process, a
part is obtained that is joined by a binder, called "green", which must be
sintered in order to be used. During the subsequent sintering stage, the binder
is removed (it can also be removed in a previous stage).

The sintering process binds the powder particles by reducing their surface
energy. Total densification is not achieved after sintering, for this reason,
HIP technology is applied for components that require high mechanical properties
and full density.

 



Additive Manufacturing - Directed Energy Deposition

This additive manufacturing process applies a source of energy while adding the
material that forms a part of the part. As in Bed-Fusion processes, the energy
source can be either a laser or an electron beam. The added material can also be
supplied in the form of powder or wire through a concentric cone to the energy
source.

This AM process has a very high output but lower geometric accuracy and is
intended for repairs, coatings or large parts. Pressing these parts with HIP
substantially improves their performance.




Wire Arc Additive Manufacturing (WAAM)

This technique is similar to DED in that the material and power source act
together to create material. The process is essentially MIG/MAG welding. A wire
made of metallic material serves as an electrode as well as a filler material.
The material is deposited (sprayed) on the weld pool.

This AM process has a very high output and low geometrical quality, and is
intended for repairs, coatings or large parts.

 



Additive Manufacturing - Material Extrusion

It is an Additive Manufacturing Technique based on the extrusion of a plastic
material that flows and attaches itself to the substrate on which it is
deposited. The extruded material can be a mixture of plastic Binder and metal
particles.

After printing, a green piece is obtained which is then sintered to achieve a
specific density and consistency. As with binder jetting, these parts can
undergo HIP to achieve the maximum theoretical density.

 

 




Additive Manufacturing - Material Jetting (MJ)

Includes MJ, NPJ, DOD

The evolution of the conventional printing industry towards Additive
Manufacturing has led to the development of Material Jetting (MJ) technology.
This is a technology in which inkjet-like print heads inject material onto a
previous substrate creating, layer by layer, the 3D print. In the beginning this
technology was limited to wax-like materials.

More recently, some manufacturers have developed technology where a liquid
binder carrying nano metal particles is injected, creating a green part that is
subsequently sintered and whose properties can be enhanced by the use of HIP.

 

 


OTHER HIP MANUFACTURING TECHNIQUES


Casting
Metal Injection Molding
Powder Metallurgy
Diffusion Bonding

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The pasteurizing effect of high pressure was recognized in the 19th century,
when in 1899 Hite discovered the shelf life extension in milk using this
process. However, it was not until the 1990s, that the first HPP products began
to be marketed in Japan and Europe. In 2000, 10 years later, this technology
became a recognized alternative to traditional food processing (thermal or
chemical). The commercial success of this process was due to the design of
equipment better adapted to industrial requirements, such as its horizontal
layout and the growing demand by consumers for safe and more natural products.

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From a legal point of view, high pressure processing technology is recognized by
the main food authorities in the United States, Canada, Europe, Australia…

In the United States, the FDA (Food and Drug Administration) published a
document in 2000 prepared by the IFT (Institute of Food Technologists) that
endorsed HPP technology as an alternative to classic food preservation
processes. Later, the USDA (US Department of Agriculture) published in 2003 the
first document recognizing the efficacy of high pressures for the elimination of
Listeria monocytogenes in a packaged meat product ready for consumption.

In Europe, the EC (European Commission) gave its first approval in 2001 for the
marketing of HPP fruit products. In 2018, they published a document in which
declared that “high pressure processing is a food transformation technology by
which solid or liquid foods are subjected to high pressures to improve their
safety and, in some cases, their quality and organoleptic characteristics”.

In Canada, Health Canada issued a statement in 2016 authorizing the marketing of
HPP products without prior notification to the national health authority.

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