InssTek

The precision of powder feeding is directly influenced by the physical properties of the input metal powder, such as its inherent particle size distribution, morphology, and flowability. The Insstek system maintains stable precision throughout the entire process by combining a powder profiling step, which pre-verifies powder behavior before entry into the process, with a real-time feedback function that measures and corrects feeding errors in real time during processing.

The total estimated powder consumption for processing must be calculated in the software, and the internal capacity of the powder hopper must be sufficiently filled in advance. Additionally, it is essential to perform feeder/splitter validation to check in advance the error between the actual flow rate sprayed through the nozzle and the set value . Since the detailed specifications of the monitoring function that detects powder shortages in real time during the process vary depending on the selected equipment model and options, prior verification is required.

By applying the PCM-Multi Feeder configuration, up to six mutually independent powder hopper channels can be expanded. By simultaneously controlling the discharge flow rate of each channel in real time, precise material composition gradients required for Functional Material Gradient (FGM), High Entropy Alloy (HEA), and In-situ Alloying processes can be achieved, and the actual number of hoppers that can be installed is determined by the basic class of the equipment.

The powder supply lines connecting to the hoppers and head nozzles for each material are composed of physically independent hoppers and powder lines, reducing the possibility of cross-contamination. Additionally, it supports a dedicated 'Powder Cleaning Mode ' that discharges fine powder remaining inside the supply lines at high pressure after material switching or processing is complete , ensuring process stability and material purity.

For Insstek Variable Flow Direct Energy Irradiation (LP-DED) process, the use of spherical metal powders with a size range of generally 45 to 150 μm is recommended to ensure stable powder flow and melting reactions. For smooth process implementation, flowability meeting standard specifications must be ensured in addition to particle size, and thorough temperature and moisture control management must be implemented during storage and input.

The InssTek LP-DED system is fundamentally designed for metal additive manufacturing. Therefore, it does not support the additive manufacturing of single pure ceramics. However, for the R&D process of metal matrix composites ( MMC ) in which ceramic particles are uniformly dispersed and mixed within a specific metal matrix for additive manufacturing, test printing can be performed after reviewing the feasibility based on the thermal and material properties of the input materials.

When applying new materials not found in the database, we first conduct a comprehensive preliminary analysis of the relevant metal material's melting point, laser absorption rate, sensitivity to thermal deformation/cracking in quenching environments, and powder physical fluidity. Subsequently, to secure basic physical properties, we sequentially perform coupon tests, bead-on-plate tests, and wall tests. During this process, we organically adjust data regarding laser output, beam size, nozzle travel speed, powder feed rate, and laser layer height to establish optimal dedicated process parameters. (※ For customers introducing the equipment, a database of process parameters for approximately 20 types of standard metal materials, whose reliability has been verified through years of accumulated data by Insstek, is provided as a standard feature.)

Through high-power fiber lasers and precision control hardware, we can successfully conduct research on the processing of high-melting-point alloys, superalloys , and special composites, including C103 ( niobium -based alloy), which are widely required in the aerospace sector. However, since controlling internal crack sensitivity or residual stress can be extremely challenging for these high-melting-point and difficult-to-process materials due to their inherent properties, we recommend conducting a feasibility test before establishing the process.

The heating plate option preheats and maintains the temperature of the substrate area where additive manufacturing takes place at a constant level, mitigating local thermal gradients caused by rapid laser irradiation . This significantly reduces residual stress accumulated internally as the metal solidifies, making it highly effective in suppressing the risk of macroscopic distortion in parts or microcracking in crack-sensitive alloys. It is an essential option to consider when researching high-strength special alloys or non-fusible metals that are susceptible to cracking.

When processing reactive metals that react violently with oxygen O_2at high temperatures, such as titanium alloys, the process is carried out in a fully enclosed argon chamber environment combined with a gas purification system. Sensors mounted inside the system measure oxygen ( ) and moisture ( H_2 O) concentrations in real-time in ppm units, and through a circulating purification filter, the oxygen concentration inside the titanium standard processing chamber is precisely controlled to an ultra-low oxygen state of 50 ppm or less, thereby preventing oxidation defects at the source.