3D Metal Printing: Oxygen Analyzers Are Essential

 

Metal 3D printing, also known as additive manufacturing, provides for the creation of complex metal parts by layering metal powders and, depending on the application, selectively sintering, fusing, or melting the powders using a high-powered laser or electron beam. This process offers numerous advantages over traditional manufacturing methods, including reduced waste, increased design freedom to create complex components, and faster production times. The industry applications of metal 3D printing are vast and growing rapidly. Metal 3D printed components are used in aerospace (for lightweight components with complex designs), automotive (for customized parts and prototypes), medical (for implants and prosthetics), and even jewelry manufacturing. The ability to create intricate metal parts with high precision has opened up new possibilities across a variety of industries.

3D Metal Printing Requires Low to Ultra-Low Oxygen Environments

3D printing processes require inert, low to ultra-low oxygen (i.e., nearly oxygen-free) environments to protect the integrity of the finished printed parts. Undue exposure to oxygen, even in small amounts, can result in various defects, such as porosity, oxidation, corrosion, and reduced mechanical properties. Porosity refers to small voids or gaps within a printed part that can compromise its structural strength. Oxidation results in surface discoloration, weakened structural integrity, and compromised part performance. Reduced mechanical properties can result from brittleness or reduced tensile strength caused by excessive oxygen exposure. In addition, dust from the metal powders can be combustible when exposed to oxygen. Some metals, such as titanium and aluminum, can burn quickly, at extremely high temperatures and, in some cases, may cause violent explosions.

To create the desired low oxygen environments, 3D metal printing facilities utilize inert gases—typically argon or nitrogen—within their build chambers. These inert gases deplete oxygen from the build chambers, creating stable printing environments, preventing fire hazards by keeping combustible dust inert, and reducing irregularities and defective elements.

Oxygen Analyzers Help Prevent Product Impurities

Oxygen analyzers are critical to monitoring and regulating oxygen levels within the build chambers during 3D metal printing operations. By utilizing a top-quality oxygen analyzer, metal 3D printer operators are able to monitor and maintain optimal oxygen levels throughout the printing process. An O2 analyzer helps ensure that printed parts are free of imperfections and meet required design specifications. Analyzers continuously track oxygen levels to provide real-time data on oxygen concentration, allowing for immediate adjustments if necessary.

PureAire Trace Oxygen Analyzers

PureAire Monitoring Systems' industry-leading line of Trace Oxygen Analyzers includes products built with both low parts-per-million (ppm), or low percent level O2 sensors, which are designed to operate effectively under continuous inert environments. The Analyzers have remote sensors that are placed directly within the build chambers to continuously monitor oxygen levels.

Depending on user needs, our Trace Oxygen Analyzers can be programmed to detect ultra-low oxygen concentrations, from as low as .0.01 ppm up to 1,000 ppm, as well as higher (albeit still low) oxygen concentrations, from 0% up to 25%. They can operate in a vacuum of 20 Torr or less, and their zirconium oxide sensor cells do not need an oxygen reference gas for proper operation. In the event of undesired changes in oxygen levels, our Analyzers will sound alarms, alerting personnel to take corrective action.

PureAire's Trace Oxygen Analyzers measure oxygen 24/7, with no time-consuming maintenance required. Our long-lasting zirconium sensors provide accurate readings, without calibration, for up to 10 years.

PureAire Oxygen Analyzers & Oxygen Monitors for Nitrogen Generators

Nitrogen has many uses in industrial applications where oxidation would be undesirable. From carbonizing beer to preserving food, reducing fire danger, and cleaning equipment, nitrogen is a safe, inexpensive gas. For companies that need a steady supply of nitrogen gas, nitrogen generators work well. Learn about the uses of nitrogen generators and why you should use oxygen monitors in environments where nitrogen gas is created. 

How Nitrogen Generators Work

Nitrogen for packaging works well in the food and beverage industry for food packaging and bottling of wine. Nitrogen also helps with metal processing, improving the end quality of the product by reducing the chance for oxidation. In the pipeline industry, nitrogen creates a high pressure environment that improves safety. 

Nitrogen generators allow you to create nitrogen from compressed air. If you use nitrogen cylinders, then you know how inconvenient they can be. If your supplier is late, you risk running out of nitrogen you need to run your business.


These generators are easy to operate. All you need to do is connect a compressed air line to the inline for the nitrogen generator. Then connect the outlet to the nitrogen line. Now, the generator can run continuously, and can create nitrogen gas that has as little as 10 parts per million of O₂. An oxygen analyzer can help you measure the amount of oxygen in the nitrogen gas, to ensure consistency.

It is both easy and cost-effective to use the nitrogen generator in-house. Since you can create nitrogen 24/7, the generator will pay for itself quickly and free you from the dependency on suppliers. 

By adding an oxygen analyzer to the nitrogen generator, you can check the level of oxygen present in the nitrogen gas at any time. Purity of the nitrogen is key to successful application. The O₂ analyzer runs constantly, allowing you to take at-a-glance readings and make sure that everything is working properly. 

Air separation is an alternative to purchasing a nitrogen generator. In an air separation plant, you can separate the air into its elemental components. Natural air is compressed and sieved, to remove any impurities. The compressed air is heated and cooled until the different elements reach boiling points, and separate out. The elements are then returned to a gaseous state, at which point they are ready to be used. As with nitrogen generators, air separation plants benefit from the use of an O2 analyzer to keep an eye on the levels of oxygen. 

Safety Benefits of Oxygen Monitors and Analyzers

While oxygen analyzers are beneficial, they also have a practical purpose when used with an air separation plant or nitrogen generator. The oxygen analyzer helps ensure that the nitrogen gas has a very low level of oxygen. It can measure oxygen levels from 0-1000 ppm and keep the oxygen to the minimum needed for your specific usage. 

An oxygen monitor can check the environment for levels of oxygen in the air. As long as there is enough oxygen in the air, then the O2 monitor is silent. Should levels of oxygen drop, the O2 monitor will sound an alarm and flash a light, alerting workers to the situation. While nitrogen generators do have a leak detection system, it's a good idea to add an oxygen monitor as a failsafe. 

Nitrogen gas actually depletes the levels of oxygen in the air. If enough nitrogen gas were to leak out, it would reduce the oxygen below safe levels. As a result, workers could become unconscious, experience dizziness, or even die from asphyxiation. By having an oxygen monitor, you can ensure that there is no leak of nitrogen gas from the generator or supply lines. 

PureAire offers oxygen monitors with a zirconium oxide sensor. Capable of lasting for up to 10 years with no maintenance, these O2 monitors are a reliable way to ensure that nitrogen does not pose a health hazard in your plant. When coupled with the oxygen analyzer, they allow you to product nitrogen to run your business without creating a health risk for your employees. 


To learn more about the oxygen analyzers and monitors offered by PureAire, please visit www.pureairemonitoring.com. 

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/