Technical Sheet: Controlling temperature and pressure during hot isostatic pressing (HIP)

In this special, we introduce our newest offering – Powder Metallurgy. Using our methods, we are able to produce semi-finished products by combining several interesting technologies including can manufacture, encapsulation, welding, vacuum, hot isostatic pressing (HIP) as well as CNC machining. This allows us to produce parts and material combinations that would not be possible using conventional manufacturing methods. But why do we do this? Having conversed with a multitude of customers from a variety of markets, we established that the ability to produce semi-finished products using a combination of these technologies, isn’t widely known. When presenting the idea of encapsulation via powder metallurgy, our clients already have suitable ideas and products in mind, but very few options to obtain all of the necessary technologies from one supplier. OWLHIP-PM can improve the quality of your products, reduce cost per piece (depending on the lot size to be produced), and decrease delivery times, whilst producing parts and material combinations which traditionally would have been deemed impossible. The OWLHIP-PM production chain, showing the steps which occur after powder selection and can manufacture, is as follows: First step: Powder Sourcing – Many different powders exist on the market and many of them can be used to produce OWLHIP-PM products. There are numerous combinations of suitable powders available, as well as conventional stainless, tooling, cold-working, high speed and wear-resistant steels and Fe-based alloys; further Ni, Al, Ti, and Co-based alloys. Mixing different types of powder is possible and is indeed often used to adjust and optimise the characteristics of the semi-finished product. We assist in the selection of the right powder for your product. Due to our strong network and relationship with powder manufacturers, we are also able to support you from initial prototypes through to serial production. Second step: Can Manufacture (Design/Bending/Bordering/Welding the Can) – This is naturally one of the most important steps in the process. The design of the can needs to be calculated correctly to allow for the expected shrinkage during the HIP process. Our knowledge includes the design of the can dimensions before and after HIP to use as little raw materials as possible. The can could be a simple tube, a square or even a very complex 3D structure. There are almost no limits. The welding needs to be 100% gas-tight, in order to avoid inclusions which will result in scrap parts. For this reason, every can produced with our OWLHIP-PM process is tested with a gas leakage system in order to avoid defective parts even entering the HIP process. Every can produced and supplied by OWL comes with a certificate, showing that the welding was checked according to our internal process standards. Third step: Filling – This requires knowledge about the powder, its tap density, as well as its floating behaviour. The optimum vibration frequency is used to densify the powder and provides the best possible conditions for obtaining a homogeneous semi-finished part after HIP. Fourth step: Vacuum degassing and Closing – The can is filled with powder prior to evacuation. This step will define if the powder is sintered perfectly together during the HIP process. Based on our internal process standards and the material(s) being evacuated, we apply an optimal evacuation time, according to the needs of the material. After the final vacuum level is reached, the can is closed. Fifth step: HIP Process (Hot Isostatic Pressing) - When components are treated with the Hot Isostatic Pressing (HIP) process - simultaneous application of elevated heat and pressure within an inert gas atmosphere - internal cavities and micro-porosities are eliminated through a combination of plastic deformation, flow, and diffusion bonding of the material. This section of the process is where the powder in the can transforms into a solid material. Our equipment and standards of processing are in line with leading aerospace standards, where we also hold AS/EN9100 and ISO9001 accreditations. Sixth Step: CNC Machining – The product is now suitable for almost any type of machining method suited to its final design. Quality control - Our OWLHIP-PM internal standards ensure the best quality possible. Every production step is controlled by the highest standards. Advantages of using OWLHIP-PM: Isotropic material properties Production of complex, Near-Net-Shape (NNS) parts Less subsequent CNC machining due to NNS Significantly reduced lead-times Capacity availability and continual capacity investments Optimal and significantly reduced use of raw materials International supplier network for the full array of powder needs Possibility to produce parts made from materials that are only available in powder form Production of multi-material parts is possible; to include suitable bimetallic combinations To optimise your current product portfolio, reduce usage of raw materials, or even produce parts and applications which were not possible before, please contact Daniel Guizard (dgu@owl-am.com) or David Loughlin (dlo@owl-am.com)

We did it again! Last week, 24th of May, we successfully passed the surveillance audit of our Aerospace Quality Management System EN9100 (equivalent to AS9100) also maintaining our ISO9001 status. Thanks to TÜV SÜD for this very professional audit. Excellence in Quality, through stable processes and customer orientation, have been the basis for our successes to date. It was a pleasure to have this verified externally over the course of the audit.

We offer weekly shared direct transport: UK to Germany to UK In support of our growing UK customer base, OWL AM are now offering a weekly direct shared transport service to and from our plant in Aachen, Germany. We have committed to sending a vehicle from the UK to Aachen on a fixed day each week, for the shared use of our customers. With the added foresight of the pending processing requirements, we are able to even more quickly and efficiently process your order within either the pre-booked cycle slot, or within one of our new ‘OWLHIP’ shared cycles. The parts are then quickly sent back to your site on the next available shared use direct vehicle. To book your space on the next available transport or to find out more, contact David Loughlin (dlo@owl-am.com)

OWL AM Additive Manufacturing, in the next phase of its development for Hot Isostatic Pressing (HIP) services, would like to introduce the ‘OWLHIP’ range. These processes are dedicated to support the needs of customers who require shared HIP cycles. The market has for many years been asking for a simpler, more cost-effective way of obtaining shared HIP cycles. Sending parts for a shared HIP cycle, only for them to be processed several weeks later against no guaranteed schedule, is impossible to work with. The ‘OWLHIP’ range of processes delivers against all of these needs and more. Benefits of the ‘OWLHIP’ range include: The most cost effective HIP solution for ‘small’ batch sizes – where the cost of a dedicated cycle can be prohibitive Easier to specify your processing needs – simply refer to the programme name below, no complex parameters Guaranteed lead-times Highest standards of customer service EN9100 certified Quality Management System. The OWLHIP range of processes, dedicated to shared HIP cycles: ‘OWLHIP13’ - process for the HIP densification needs of most Aluminium alloys ‘OWLHIP22’ – process for the HIP densification needs of most Titanium alloys ‘OWLHIP26’ - process for the HIP densification needs of most Steel alloys ‘OWLHIP27’ - process for the HIP densification needs of typical Cobalt alloys ‘OWLHIP28’ - process for the HIP densification needs of most Nickel alloys. To find out more, or to book your parts into our next shared HIP cycle, please either use the contact form on our website or write to us by email contact@owl-am.com