SENAI Innovation Institutes

Joinville-Santa Catarina

Joinville, 2017.

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SENAI Innovation Institutes – National Network

Creation of the National Network

of SENAI Innovation Institutes
As a Structuring Action from the SENAI Program for
Supporting Brazilian Industrial Competitiveness

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Simplified Scenario of National Innovation Systems
Comparison between German and Brazilian Models – FUTURE BR

R&D&I Institute Government Industry (BMSMEs)

Universities, STIs Funding Agencies Startup Communities

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Location and Technical Field of SENAI Innovation Institutes

PA: Mineral Technologies CE: Constructive

Technologies RN: Renewable Energies

AM: Microelectronics
PE: Information and
1 1 Communication Technology

1 1
TOTAL 1 BA: Forming and Materials Union
26 3
BA: Production Automation
BA: Logistics
MG: Surface Engineering
MG: Metalurgy and Special Alloys
LEGEND:
4 MG: Mineral Processing
Planning MS: Biomass 1 3 MG: Extra High Electric Power
Implementation
4 RJ: Virtual Production Systems
PR: Electrochemistry
Inaugurated
1 RJ: Applied Chemistry
SC: Laser
3 RJ: Biosynthetics
SC: Embedded Systems
SP: Micromanufacturing and Nanometrology
SC: Manufacturing Systems 2
SP: Ceramics Engineering
RS: Polymer Engineering SP: Biotechnology
RS: Integrated Solutions in Metalmechanics SP: Defense

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Location and Technical Field of SENAI Innovation Institutes at SC

Laser
TOTAL
Manufacturing Systems
3

Embedded Systems

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SENAI Innovation Institute in ISI Phase:
OPERATIONAL
MANUFACTURING SYSTEMS

Modelling, simulation e manufacturing for systems requiring high production precision

 Strategic Markets Segments
– Metalworking
– Metallurgy
– Oil & Gas
– Energy
– Biomedical
– Aeroespace
– Automotive
– Naval and Defense

 Service Portfolio/ Technology Platforms

– Development of Machining Processes
– Development of products and Automatic Machines
– Materials Technology applied to Machining Processses

Investment >> DR: R$ 5.707.991,85 | BNDES: R$ 6.764.478,07 | TOTAL: R$ 12.472.469,92

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SENAI Innovation Institute in ISI Phase:
OPERATIONAL
LASER

Solutions for laser applications in several fields of scientific and technological knowledge
 Strategic Market Segments
– Oil & Gas
– Naval
– Energy
– Metalworking
– Aeroespace
– Automotive
– Biomedical
– Defense

 Service Portfolio / Technology Platforms

– Additive Manufacturing
– Laser Surface Treatment
– Laser Welding and Cutting

Investment >> DR: R$ 364.766,58 | BNDES: R$ 33.697.057,50 | TOTAL: R$ 34.061.824,08

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SENAI Innovation Institutes in Joinville-SC
Industry partners with applied research projects

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SENAI Innovation Institutes in Joinville-SC
Infrastructure – Materials processing

5-axis machining centre Multi-axes CNC Turning centre 3-axis milling centre 5-axis micro-milling and grinding FDM 3D Printer
Hermle C42U ROMI E320 Discovery 560 Kern Piramyd Nano Stratasys BST 768 e Elite

Micro injection moulding machine Die sinking EDM Wire EDM Hole drilling EDM Glove box
Arburg 270 A Agie Charmilles SP 1U Agie Charmilles CUT 20 P Agie Charmilles DRILL 20

Selective Laser Melting Selective Laser Melting Hybrid laser welding, heat Laser Metal Laser Texturing – ns Laser Texturing – ps
ConceptLaser M2 Cusing SLM Solutions 125HL treatment and cladding Deposition Welle Laser LS3000 Oxford Laser MJ Series
machine RPMI 535
PRECO SL8600

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SENAI Innovation Institutes in Joinville-SC
Infrastructure – Materials characterization

Scanning Electronic Microscope Ion milling Optical Microscope Confocal laser scanning X-Ray Difractometer X-Ray Fluorescence
Zeiss Supra55 Cross Polisher JEOL ZEISS microscope Panalytical Empyrean Spectrometer
ZEISS LSM 700 Panalytical AXIOS Max

Carbon and Sulfur Analyzer Inductively coupled plasma Optical emission Salt spray chamber Humidity Chamber
Quimitron QCS-2010 mass spectrometer spectrometer EQUILAM EQUILAM
Agilent 700 ICP – OES Oxford Foundry-Master Pro

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 SENAI Innovation Institutes in Joinville-SC
Infrastructure – Materials characterization

Laser interferometer Ball-Bar Multicomponent Dynamometer Ultrasonic flaw detectors Infrared camera Power quality and
Renishaw Renishaw Triaxial Force Sensor Phasor XS GE Irisys IRI 4030 energy analyzer
Kistler 9256, 9257 e 9272 Fluke 435

Coordinate Measuring Machine Surface Profiliometer Roundness and cylindricity CNC Vision System Profile projector Portable coordinate
Mitutoyo Strato Apex Taylor Hobson Form Talysurf measuring machine Starret AV300 Mitutoyo PJ-A3000 measuring machine
Taylor Hobson Talyrond 565 (Measurement Arm)

Static testing machine Dynamic testing machine Torsion tester Impact testing machine Microhardness Hardness
INSTRON 5988 - 400 kN INSTRON 8801- 100 kN Instron MT2-E1 Charpy Instron SI-1D3 Wilson 402MVD Heckert

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SENAI Innovation Institutes in Joinville-SC
INMETRO Certified Tests (Certification number 1011)

Mechanical Testing Chemical Analysis

 Tensile tests  Optical espectrometry chemical analysis of

low alloy and stainless steel
 Vickers, Brinell and Rockwell Hardness
 Impact testing

 Welds tensile tests

 Welds bending tests

Metalography Analysis

 Inclusion level analysis

 Grain Size
 Graphite Classification
 Microsctructure characterization

 Screw thread discontinuity

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 Additive Manufacturing Infrastructure

 Concept Laser M2 Cusing - Selective Laser Melting Process;

 SLM Solutions 125HL - Selective Laser Melting Process;

 RPM Innovations 535 – Laser Metal Deposition Process.

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Selective Laser Melting at SENAI
Concept Laser M2 Cusing

Specifications
Laser power [W] 400
Scanning speed [mm/s] máx. 7000
Laser beam spot size [µm] 150
Layer thickness [µm] 20-100
Common roughness (Ra) [µm] 5-20
Approximate precision [µm] 50-200

Succesful Cases Process Architecture

Stator stage Conformal cooling
Ti6Al4V Maraging 300

15 mm 20 mm

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Selective Laser Melting at SENAI
SLM Solutions 125HL

Specifications Process Architecture

Laser power [W] 400

Scanning speed [mm/s] max. 10.000
Laser beam spot size [µm] 70-100
Layer thickness [µm] 20-75
Common roughness (Ra) [µm] 5-20
Approximate precision [µm] 20
Substrate-plate Heating [°C] max. 200

Succesful Cases
Design Driven by Topology Optimization and Additive Manufacturing
Ti6Al4V

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Laser Metal Deposition at SENAI
RPM Innovations 535

Specifications
Laser power [W] 3000
Maximum building volume [mm3] 1524x914x1524
O2 purged atmosphere concetration [ppm] <10
Number of controllable axis 5
Scanning speed [mm/s] máx. 42,3
Laser beam spot size [mm] 1-3,6
Layer thickness [mm] 0,25-0,76
Common roughness (Ra) [µm] 25-100
Volume building up capacity [cm3/h] 5-50
Internal deposition head
Maximum length [mm] 1000
Minimum diameter [mm] 57

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Laser Welding at SENAI
Preco SL8600

Specifications
Preco – SL8600 Laser Power (Disc / Diode) [W] 10000 / 6000
Work volume [mm3] 1200x2438x787
Number of axes 5
Velocity X/Y [mm/s] max. 338,6
Velocity Z [mm/s] max. 84,6
Beam diameter on focus (Disc / Diode) [mm] 0,6 / 2
Maximal current MIG [A] 800

 Conduction mode laser welding;

Laser brazing
 Penetration mode laser welding;
Hybrid welding  Hybrid laser-arc welding;

 Weld brazing;

 Narrow-groove laser welding.

Conduction mode
Penetration
mode
Narrow-Groove

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Laser surface texturing and nanoparticle fabrication at SENAI
Welle Laser LS3000 e Oxford Lasers MJ-Series

Specifications
Radiation wavelength UV, Vis, IR
Average Power 4-70 W
Maximum pulse energy 20-1000 µJ
Pulse duration 9 ns – 10 ps
Repetition rate 1 Hz – 500 kHz
Maximum scanning speed 5 m/s
Laser beam spot size 60-100 µm

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 Additive Manufacturing in
Oil&Gas Industry
Potential Developments

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Additive Manufacturing in Oil&Gas Industry

 The application of additive manufacture in the Oil&Gas

industry is little explored in the literature;

 Shortage of documents, cases and specific

information with focus in the Oil&Gas industry;

 Excellent development potential;

 SENAI's infrastructure is enabled to work in the Laser

Metal Deposition (LMD) and Selective Laser Melting

(SLM) processes of large and small structures.

Search: SmarTech 2016.

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Advantages of the Additive Manufacturing Applications

 Possibility of producing extremely complex

geometries, impossible to obtain with conventional

manufacturing processes;

 It allows the reduction of mass with the construction of

components with the optimized topology;

 In some cases, shorter manufacturing times;

 Flexibility of production (it does not require serial

production to compensate the use);

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 Potential Developments in the Valve Designs and Optimal Duct Layout

 Possibility of producing extremely complex geometries, impossible to obtain with

conventional manufacturing processes

52% reduction in part volume and a 60% increase in flow efficiency.

60% of Mass Reduction.

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Potential Developments in the Design of Heat Exchangers
“Metal additive manufacturing enables lean, green heat exchanger”
“The real benefit of additive manufacturing came when the students started
experimenting with the design freedom of the technology.”
“The project clearly shows the benefits and opportunities of using additive
manufacturing for intercoolers used in the automotive sector and the
motorsports subsector. Both industries are moving towards the use of
smaller, turbocharged engines that mean reduced carbon emissions,
while increasing power outputs.”
Search: http://www.renishaw.com/en/additive-manufacturing-crosses-the-
finishing-line--38971
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“Complex internal channels sometimes impossible to obtain by
conventional manufacturing processes.”
“Metal additive manufacturing enables lean, green heat exchanger”
Original Design Additive Manufactured Design
“Design algorithms create unique shapes for tubes
and fins in heat exchangers. The goal is to reach
an optimal air-side thermal resistance and
minimize the size and weight of the heat
exchangers.”
Search: http://www.makepartsfast.com/metal-
additive-manufacturing-enables-lean-green-heat-
exchanger/
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 Potential Developments in the Design of Complex Mechanisms

Exploration of Applications of Metalic Additive Manufacturing for Oil and Gas Industry

“The mechanism was produced as a form and fit prototype in a 3D printing laboratory to reduce the
project timeline.”

“The mechanism consist of 12 sets of small moving plates that are hinged in three locations, a ball-
and-socket joint at top and bottom, and a pin connecting the middle of each plate pair.”

Additive manufactured plate prototypes for full functional testing. The final fit/functional prototype is shown in the OPEN
and CLOSED position.
Search: Offshore Technology Conference 2017, Exploration of Applications of Metalic Additive Manufacturing for Oil and Gas Industry.
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 Potential Developments in the Functionally Graded Materials
“Multi-Alloy LMD: Develop tri-alloy impeller for advanced turboshaft
engines.”

A)
. Impact: Conventional Ti Alloy (Ti 6-2-4-2);

B) LC Fatigue: Orthorhomic Ti Alloy (Ti 22-23);

C) Creep: Gamma Ti-Aluminide (Ti 48-2-2).

“Binary Ti–xMo alloys samples were deposited from

“Aerofoil with multi alloy deposition (Inconel-Haynes-Inconel using LMD
technology from RPM Innovations, USA) for testing and evaluation of
application of laser metal deposition (LMD).”
Search: In book: Advances in 3D Printing and Additive Manufacturing Technologies.
elemental Ti to Ti–25at-% Mo within a 25 mm length part
using LMD. The microstructures across the graded alloy
correspond to those typically observed in α/β Ti alloys, but
the microstructural scale is significantly refined. Interesting
microstructure gradients are tailored across the alloy.”
Search: Collins PC, Banerjee R, Banerjee S et al (2003) Laser
deposition of compositionally graded titanium-vanadium and
titanium-molybdenum alloys. Mater Sci Eng A 352(1/2):118–128.

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 Potential Developments in the Design for Hybrid Manufacturing
“The NextGen spaceframe nodes can be configured to be highly functionally
integrated thanks to additive manufacturing.”
“Laser-additive manufacturing has been linked to the profiling and bending
and end processing of profiles by laser.”
“The focus is on joining individual components to create a hybrid structure
to produce topologically optimised spaceframes that are simply not
possible using existing technology.”
“Laser welding is used as the joining method, characterised by precisely
welded seams and low thermal input.”
Search: Metal AM in the automotive industry: New vehicle structures, series
components for the luxury market and beyond, Concept-laser, 2016.
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“GE announces first FAA approved 3D-printed
engine part”
“This method has a number of advantages. The part can be
made lighter and extremely complex shapes can be
made in a single piece, instead of several fitted together.
This allows for designs that were previously impossible,
much faster turnaround times from design to finished
product, and much lower manufacturing costs with very little
waste.”
Search: http://newatlas.com/ge-faa-3d-printing-aircraft-engine-
part/37018/
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Applications of Additive Manufacturing in Oil & Gas Industry

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Applications of Additive Manufacturing in Oil & Gas Industry

http://www.geadditive.com/
http://www.industrial-lasers.com/articles/2016/06/ge-oil-gas-to-use-additive-manufacturing-for-printing-metal-parts-and-materials.html
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Additive Manufacturing Infrastructure of SENAI

Laser Metal Deposition (LMD)

Selective Laser Melting (SLM)

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 Thank you very much!

Henrique Rodrigues Oliveira

Henrique.oliveira@sc.senai.br
(47) 3441-7745
André Marcon ZAnatta
andre.zanatta@sc.senai.br
(47) 3441-7775

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