By Evan Butler-Jones,
Vice-President, Product & Strategy
As an aluminum powder developer, we are often asked about the safety considerations of using aluminum and titanium for additive manufacturing.
The topic came up for discussion again when an equipment supplier announced modifications to some of their commercial binder jet systems to make the equipment safer for reactive materials. The hardware and software changes made certain models ATEX-compliant. ATEX refers to two European Union directives describing the minimum safety requirements for workplaces and equipment used in explosive atmospheres.
It’s great that a supplier offers this option, but having ATEX-compliant equipment is only one element of a safety protocol for reactive metal powders. This equipment-based approach might mitigate the effects of a dust explosion at the printer, but the stringent protocols for aluminum and titanium dust still apply everywhere else in the facility.
In the absence of a way to reduce or eliminate the hazard of combustible dust, machine OEMs have had little choice but to choose traditional ways to address reactive materials in the workplace, but there is another way to approach the risk of a dust explosion: materials engineering.
OEMs have had little choice in how to address reactive materials in the workplace, but there is another way to approach the risk of a dust explosion: materials engineering.
Materials engineering makes aluminum safer for AM
What if you could have all the benefits of aluminum without the dust explosion risk?
The industry could shift from harm reduction to eliminating the risk at the source.
At Equispheres, we approached the challenges of using aluminum for additive manufacturing from a different angle. Using our materials expertise and unique process capabilities, we created a non-explosible aluminum powder, NExP-1, that eliminates many of the safety precautions needed for traditional aluminum powders. This removes the source of the hazard, which is always the preferred tactic of workplace safety programs.
I covered the operational benefits of choosing our non-explosible NExP-1 AM powder in an earlier blog post, but let’s recap four ways NExP-1 makes it safer and easier to introduce aluminum powder for AM to an industrial workplace:
The bottom line is that extensive (and expensive) storage and handling precautions associated with traditional aluminum powders can usually be mitigated when using NExP-1.
- NExP-1 can use existing powder storage areas since it does not require the specialized handling equipment and safety systems needed for explosive dust.
- The non-explosible, non-combustible nature of NExP-1 means the need for dust hazard analysis related to raw powder handling may be eliminated.
- Depending on local regulations, costs associated with explosion-related facility certifications may also be eliminated.
- With the explosion risk mitigated, employees may feel more at ease.
Working with newer aluminum powders
This purpose-built, innovative material reduces the risk associated with the day-to-day handling of aluminum powders.
In addition to being less hazardous to store and handle, it makes equipment clean-up quicker and easier.
Innovation in materials design led us to a non-explosible powder that makes aluminum more appealing for industrial AM.
NExP-1 retains all the best properties of a high-performance AlSi10Mg aluminum powder: faster printing and consistent mechanical properties. It is a less hazardous option for production printing of high-quality AM parts.
While NExP-1 cannot eliminate all the hazards related to powder handling in an industrial environment, it removes one of the most significant. Please note that NExP-1 does not eliminate all risks related to powder and safe handling practices are still required. For example, the laser powder bed fusion (L-PBF) process by its nature produces fine particulates so filter handling must always follow manufacturer recommendations. Using NExP-1 does not eliminate the production of these fine particulates.
Also, good industrial hygiene practices are still needed, especially for organizations using multiple materials in their AM processes. Be wary of the reactivity potential resulting from mixing materials.
Innovation in materials design led us to a non-explosible powder that makes aluminum more appealing for industrial AM. We’re applying similar materials engineering solutions to enhance print speed and part consistency. What other AM process challenges can we address by modifying materials?
