Titanium Demand on Rise for Additive Manufacturing Printing: How it’s Made? Titanium Plasma Atomization

                                                                                                                                      Link to oxygen sensors
Plasma atomization is used in many applications, including 3D printing. First developed in 1998, this technique has risen to become the industry standard process for creating reactive metal powders suitable for 3D printing. Learn how plasma atomization works and why you need an oxygen monitor to stay safe with plasma atomization. 

How Plasma Atomization Works

Plasma atomization is used not only in 3D printing, but in any circumstance where powder metallurgy is needed. Other uses include spray coating, cold spray, and metal injection molding. 
To pulverize metal, wire is fed through a tube, then hit by three plasma torches capable of reaching temperatures of 10,000 degrees Celsius. As the wire liquefies and melts, individual droplets shear off and fall into a chamber filled with argon gas and cooled by water. When the drops of metal hit the argon, they solidify into spherical droplets. This process produces a fine, uniform metal powder. After the wire has been transformed into droplets, the powder is sieved to ensure uniformity. This is key to the success of the 3D printing process, which relies upon fine grade, uniform powder. 

Titanium (Ti), Nitinol, Niobium, Aluminum, and other reactive metals and their alloys can all successfully be atomized through this process. Variables in the plasma atomization process allow workers to create droplets of different sizes, for different end uses.  

PureAire offers an oxygen analyzer, which many 3D printing manufacturers utilize. This device helps monitor the levels of oxygen in ppm, from 0 to 1000, while the atomization process takes place. 
It's important to keep oxygen levels low while the Ti and other base metals are being turned into powder, as this ensures the purity of the final product. Oxygen analyzers provide a continuous readout of oxygen levels inside the chamber, so your workers can ensure the highest levels of purity at a glance. 

Argon gas is used during plasma atomization because it helps ensure the purity of the powdered metal by reducing the chance for chemical reactions that might happen if oxygen interacted with the metal during the atomization. As long as the argon gas remains in the chamber where the aluminum or titanium powder is being made, plasma atomization is quite safe. Like other inert gases, argon depletes oxygen from the atmosphere. Were the argon gas to leak out of the plasma atomization chamber, employees' wellbeing could be at risk. 

Why You Need an Oxygen Monitor with Plasma Atomization

When argon escapes into the environment, it displaces oxygen molecules. Since the gas is both odorless and colorless, there is no way to detect an argon leak by sight or smell. If there are several atomization stations creating Ti or titanium powder at once, the risk increases exponentially. 
Once oxygen levels begin to drop, worker safety becomes a concern. If oxygen levels fall below the minimum set by OSHA, workers can suffer respiratory and cognitive impairment. Symptoms include dizziness, confusion, fatigue, and shortness of breath. Even a brief exposure to an oxygen deficient environment can prove deadly. 

Fortunately, an oxygen deficiency monitor can continually weigh oxygen present in the room, alerting staff before oxygen levels plunge below the OSHA threshold. This provides sufficient notification via flashing lights and loud alarms for staff to exit the room to safety. 

PureAire offers an oxygen monitor with a zirconium sensor. Unlike other sensors, this lasts with no maintenance and no calibration once the O₂ monitor is installed. The O₂ monitor and oxygen analyzer, when used together, allow for precise manufacturing of powdered metals with low risk to workers. Businesses prefer PureAire products, which are low-maintenance, cost-effective, and reliable for 10+ years. Visit www.pureairemonitoring.com to learn more about our oxygen analyzers and monitors. 

 

PureAire Oxygen Analyzer for 3D Printers: How Argon is used and Why O2 Detection is Required

Thanks to new technologies, the 3D printers that have been used to create plastic three-dimensional objects can now print metal. Titanium 3D printing is possible thanks to a technique called DMLS, or Direct Metal Laser Sintering. While the potential to use titanium 3D printing is groundbreaking for many industries, the new advances could pose a health hazard if volatile gases used in the printing process are not contained. Learn more about the role of argon in 3D printing and how an oxygen analyzer can safeguard your employing while printing. 

What Happens in Direct Metal Laser Sintering? 

3D printing of plastics uses an additive process in which objects are constructed layer by layer or fused together cross section by cross section. These basic techniques need rethinking for titanium 3D printing. With Direct Metal Laser Sintering, a laser follows a computer-aided design (CAD) file to melt titanium powder, rendering the object. The process is similar to sculpture, in which pieces of the raw material are carved away to create or reveal a three-dimensional object or figure. 

Because titanium is such a strong metal, the resulting objects are highly durable. For something like medical devices or three-dimensional replacement joints or bones, this means that individuals can get greater use out of the replacement part. Aviation professionals greet these new developments, estimating that titanium parts can cut the weight of an airplane by as much as 1,000 pounds, saving fuel on every flight. 

Since the titanium powder (Or other metal powders) used in this additive manufacturing process is created from manufacturing remnants, the materials are highly cost-effective. 

What are the Risks of 3D Printing? 

The 3D printer operates in an inert environment, where argon prevents any unwanted chemical reactions from taking place and maintains the purity of components. The inert environment in the 3D printing machine keeps the oxygen content low, to reduce oxidization in the manufactured part. It also reduces the fire hazard by rendering combustible dust inert. Since thermal stress is controlled and titanium powder clumping is reduced, the argon improves the consistency of the final product and reduces deformities. 

While there are many benefits to using argon in the printing process, and argon is harmless when contained, it does pose a health risk should the argon escape the additive manufacturing environment. 

Argon is known as an oxygen displacer. This means that when argon gas leaks into the air, it physically displaces the levels of oxygen in the air. In extreme cases, staff can asphyxiate due to the lack of oxygen in the environment. 

This gas is colorless, tasteless, and odorless. Were argon to leak out of the 3D printer, staff would be unable to see or smell it. As soon as oxygen begins to deplete from the room, it cause symptoms including dizziness, shortness of breath, and confusion. Even if staff suspect that something is wrong, they may be unable to escape from the area before it is too late. 

When you have a poorly ventilated manufacturing space with several 3D printers going at once, the potential for oxygen displacement by argon gas increases.

How Can an O₂ Analyzer Reduce Risks? 

An O₂ Analyzer helps keep levels inside the 3D printing environment low, to ensure the printer works optimally. Without the analyzer, there would be no way to ensure that the ppm concentration of oxygen remained at a steady state for the duration of the printing process. The oxygen analyzer checks levels of oxygen ranging from 0 to 1,000 parts per million (ppm). 3D printers using the DMLS process need to keep the oxygen under 1% or less for product manufacturing. A 0 to 25% oxygen range detector is also available. The oxygen analyzer can make sure that the air inside the chamber meets the low levels needed. Meanwhile the air outside is safe for staff to breath. PureAire's oxygen analyzers are easy to install and easy to use. Once set up, they require no maintenance and will work as promised for a set period of time.

At PureAire, we have just developed a new oxygen analyzer that works with 3D printers. To learn more about our new oxygen analyzer, please visit www.pureairemonitoring.com or send an email to info@pureaire.net. 

Source

http://nj.gov/health/eoh/rtkweb/documents/fs/0151.pdf

http://3d-printing-titanium.com/titanium-3d-printer-everything-you-need-to-know/

Additive Manufacturing 3D Printing: The Growth Progress and Need for Safety Monitors

 

3D printing is officially skyrocketing, with industrial applications in medical, biotech, aerospace, defense, and consumer electronics industries growing daily. At the heart of this acceleration is the additive manufacturing or AM process, which allows for easy printing from computer-aided design templates. As this new technology reaches its tipping point, review what the growth process says about the safety of 3D printing. 

3D Printing: Additive Manufacturing at a Tipping Point

No longer solely the terrain of artists and inventors making one-off products, 3D printing is finally going mainstream: Major companies including GE, Boeing, Lockheed Martin, NASA and Google have adopted 3D printing as of 2014. This widespread adoption heralds the move of 3D printing away from niche technology and toward a mainstream staple of next-generation manufacturing.
In the 3D printing process, the printer deposits layers one at a time, essentially building up the prototype before bonds the layers together. In the laser sintering process, a special laser melts and fuses the layers together, to bring the design to life. Because employees can make changes to the prototype between items, it is relatively easy to make changes to the item color, size, or shape from one printed item to the next. This makes it possible for individual medical devices or accessories to be printed from a select stock of computer-aided design (CAD) templates. 

Major companies like those mentioned above can afford to make the investment in 3D printing and AM because they have the funds to purchase the costly equipment needed for the initial foray. While 3D printers have become more widespread, they are not cheap. Compared with other types of manufacturing, it costs a lot to make something like an airplane part or a dental device using 3D printing over traditional printing. 

However, the initial expenses in 3D printing represents the peak costs to the business. After the device or the part is perfected, the company can utilize the same equipment and printing patterns to effectively mass produce the unit. Aside from ongoing expenses for printing supplies, the cost to produce subsequent parts is quite low. 

The competitive advantage of being able to offer something like a personalized medical device is well worth the initial cost of 3D printing. As printable materials continue to expand, more companies will invest in 3D printing to develop niche-appropriate custom products and solutions. This is not without its dangers to the business and its employees. Protect yourself by learning more.  

The Hidden Dangers of 3D Printing

While it may seem like a safe process -- and, indeed, the end result is quite safe -- 3D printing does utilize some potentially dangerous materials. Argon gas is particularly common in certain types of 3D printing. In the printing process, the 3D printer deposits thin layers of powder to effectively build the form that is being produced. The argon gas allows the different layers of powder to fuse together during the laser sintering, bringing the product to life in three dimensions. 

Argon is relatively inexpensive and highly effective at this task, which accounts for its widespread use in this new niche. However, argon is also a dense gas that is naturally heavier than oxygen. Were argon to escape from the 3D printing environment and enter the workshop or manufacturing floor, it would deplete the oxygen in the room. Any staff working there would thus face death by asphyxiation. Since argon is colorless and odorless, there is no easy way for staff to tell there is a problem. 

As 3D printing becomes more widespread, businesses must take the appropriate safety measures to ensure a safe working environment. They must inspect printing equipment to ensure that it is functioning properly and argon will remain contained in the printer. They must also introduce safeguards to protect staff in case of a malfunction. 

One simple and cost-effective solution is to install an oxygen monitor, which is also known as an O2 monitor. This type of sensor continually monitors the levels of oxygen in the room. If oxygen levels falls below the critical safety levels, such that employee health would be threatened, the oxygen monitor sounds an alarm to alert staff to the health threat. Staff can then evacuate immediately, and appropriate measures can be taken to secure the workplace environment and protect the printing technology.

PureAire offers sophisticated O2 monitors, which use a 10+ year no calibration sensor to offer durable everyday protection. PureAire's sensors are the perfect choice for 3D printing environment protection. To learn more about PureAire's lineup of oxygen monitor for argon gas detection, please visit http://www.pureaire.net or email us at info@pureaire.net.

Source

https://hbr.org/2015/05/the-3-d-printing-revolution

http://www.pureairemonitoring.com/argon-gas-3d-printing-stay-safe/

Argon Gas, 3D Printing, and How to Stay Safe

For the average person, Argon gas is not a topic of daily conversation, or, for that matter, any conversation, ever. It may be surprising to learn that argon is the third most common gas in the earth’s atmosphere, though most people know little about it. The word argon itself comes from a Greek word meaning ‘inactive’ because of its lack of chemical reactions. Argon is colorless, odorless, tasteless, and non-toxic, but this doesn’t mean it is completely harmless. Because it is 38% denser than air, it can displace the oxygen in an enclosed area, asphyxiating anyone inside.

When using the right safety precautions, like an oxygen deficiency monitor, argon can be very useful. It is used as a shielding gas in metal work and welding to prevent burning, and can even be used to extinguish fires. As a preservative, argon can be used to displace oxygen out of packaging to extend shelf life by preventing oxidation and spoilage. Even light bulbs are filled with argon to prevent oxidation of the filament.

One of the most modern uses of argon gas is in selective laser melting, which is a type of 3D printing. In this process of additive manufacturing, layers of a powder are bonded together using a powerful laser (as opposed to sinter bonding them). Argon is an inert gas, and relatively inexpensive, therefore it creates the perfect environment for this process to take place in. The use of argon here permits a tightly controlled atmosphere, allowing for an oxygen free environment. Using this amount of argon requires the use of an oxygen monitor for safety.

An oxygen deficiency monitor tests the percentage of oxygen in an enclosed area to ensure it is safe to breathe. If a gas like argon were to leak, it would push breathable oxygen out as it filled the room displacing any breathable air. Having no color or odor, a person in the room would be unaware of this exchange of gasses until it was too late. Having an oxygen monitor, like ones sold by PureAire Monitoring Systems, would alert anyone around of a gas leak in time for them to seek safety. If you are interested in using argon gas, contact PureAire Monitoring Systems to learn about how easy it can be to stay safe with an oxygen monitor. Argon has an important place in our modern world, so spread the word and share the knowledge of how to use argon while practicing safety.