Additive Manufacturing Lab

NCAME's additive manufacturing lab houses a suite of advanced additive manufacturing machines including the EOS M290, Renishaw RenAM 500Q, 3D Systems DMP 350 Flex, Formalloy L5, VRC Gen IV, Renishaw AM250, Open Additive, CREATOR, and OPTOMEC 3D. The EOS M290 is equipped with EOSTATE MeltPool, and EOSTATE Exposure OT for in-situ monitoring, allowing for real-time process control for enhanced part quality. Currently, there are four EOS M290 at NCAME. Additionally, procurement of EOS M400x4 and FormAlloy L5 machines are in-process. These state-of-the-art systems enable the fabrication of complex metal parts with exceptional precision and detail. These machines can process a wide range of materials, providing versatility for diverse applications.

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EOS M290

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Quantity: 4
  • Build Volume: 250 mm x 250 mm x 325 mm
  • Laser Type: Yb-fiber laser
  • Laser Power: 400 W
  • Additional features: EOSTATE MeltPool, EOSTATE Exposure OT, In-situ monitoring, Real-time process control

Renishaw RenAM 500Q

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Build Volume: 250 mm x 250 mm x 350 mm
  • Laser Type: 4x Yb-fiber laser
  • Laser Power: 500 W
  • Additional features: Quad-laser system for faster build times

3D Systems DMP 350 Flex

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Build Volume: 275 mm x 275 mm x 425 mm
  • Laser Type: Yb-fiber laser
  • Laser Power: 500 W
  • Additional features: 3DXpert

Renishaw AM250

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Build Volume: 250 mm x 250 mm x 300 mm
  • Laser Type: Yb-fiber laser
  • Laser Power: 250 W

Open Additive

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Build Volume: 152 mm x 152 mm x 241 mm
  • Laser Type: Yb-fiber laser
  • Laser Power: 500 W
  • Additional features: Pre-heated platform

Coherent Creator 3D

  • Type: Laser Powder Bed Fusion (L-PBF)
  • Build Volume: 100 mm x 100 mm x 110 mm
  • Laser Type: Yb-fiber laser
  • Laser Power: 250 W

Optomec Lens3D

  • Type: Direct Energy Deposition (DED)
  • Build Volume: 500 mm x 325 mm x 500 mm
  • Laser Power: 1 kW
  • Additional features: 2 powder feeders

Mechanical Testing Lab

Mechanical testing lab is equipped with a comprehensive range of testing machines designed for a wide range of mechanical behavior studies. The lab houses equipment for tensile, uniaxial fatigue, multiaxial fatigue, rotating bending fatigue, and fatigue crack growth testing. These machines include MTS Landmark (100 kN, 7 Nos.), MTS Bionics (25 kN, 3 Nos.), and MTS axial-torsion (25kN/100 Nm and 100 kN/1000 Nm). These machines are equipped with three-point bending apparatus, high-temperature furnaces capable of performing test up to 1500 °C, CTOD gauges, extensometers (both room and high-temperature), and a pair of clevises for crack propagation tests. Additionally, the center has a rotating bending machine which is capable of performing fatigue tests at a temperature up to 800 °C. This extensive range of equipment enables in-depth investigations into material behavior under various loading conditions and environments.

MTS Landmark 370 (Floor Model)

  • Capacity: 100 kN
  • Quantity: 7
  • Additional Features: Three point bending apparatus, High temperature attachments, CTOD gauges, Extensometers, MTS 653 high temperature (1500°C) furnace, High temperature extensometers, Clevis grips

MTS Landmark 370 (Tabletop Model)

  • Capacity: 25 kN
  • Quantity: 3

MTS 810 (Floor Model)

  • Capacity: 100 kN

MTS 809 Axial/Torsion

  • Capacity: 100 kN/1100 Nm

MTS Bionix Axial/Torsion (Tabletop Model)

  • Capacity: 25 kN/250 Nm

MTS 653 High Temperature Furnaces

  • Temperature (Max/Min): 1500°C/100°C
  • Hot Zone Height: 19 mm
  • Hot Zone Width and Depth: 50 mm x 50 mm
  • Additional Features: Designed to accommodate MTS high-temperature axial extensometers

Zwick Roell ARBM 120 Rotating Bending Machine

  • Bending Moment: 2.5 Nm to 120 Nm
  • Rotating Speed: 500 RPM to 5000 RPM
  • Max. Bending Angle: 7°
  • Additional Features: High temperature furnace (850°C)

Kammrath & Weiss In-situ Tensile-Compressive Module

  • Load Range: 10 µN up to 5000 N (10 kN option)
  • Specimen Dimensions (max. sizes): 60 x 10 x 5 mm
  • Deformation Speed Range: 0.3 to 50 µm/sec
  • Additional Features: Extensometer +/- 1 mm, Resolution of <100 nm

Leco LCR500 Hardness Tester

  • Type: Rockwell
  • Load Ranges: 3 to 200 kgf
  • Additional Features: Automatic measuring mode

Material Characterization Lab

Material characterization lab houses state-of-the-art equipment with a Zeiss Crossbeam 550 Scanning Electron Microscope (SEM) equipped with a focused ion beam (FIB) imaging, Energy Dispersive Spectroscopy (EDS) detector, and crystallographic Orientation Image Mapping (OIM). The center also houses Xradia 620 Versa X-ray microscope equipped with LabDCT for non-destructive 3D imaging of internal structures and grain mapping. For routine microscopy, the center has a Keyence VHX-6000 Digital Microscope for high-resolution 2D imaging. This advanced instrumentation suite supports a wide range of materials characterization studies.

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Zeiss Crossbeam 550 Scanning Electron Microscope

  • Resolution: 0.7 nm at 30 kV (STEM mode), 1.6 nm at 1 kV (SEM mode), 3 nm at 30 kV (FIB)
  • Magnification: 12x - 2,000,000x (SEM), 300x - 500,000x (FIB)
  • Acceleration Voltage: 0.02 - 30 kV (SEM), 0.5 - 30 kV (FIB)
  • Available Detectors: Conventional secondary electron detector, In-lens energy selective backscattered (ESD) electron detector, a four-quadrant backscattered electron (BSD) detector, and Scanning transmission electron microscopy (STEM) detector
  • Available Techniques: Scanning electron microscopy (SEM), Focussed ion beam (FIB), Electron backscattered diffraction (EBSD), Transmission electron microscopy (TEM), Energy dispersive spectroscopy (EDS)

Keyence VHX-6000 Digital Microscope

  • Image Sensor: 1/1.8 inch CMOS
  • Resolution: 1600 x 1200
  • Scanning System: Progressive
  • Frame Rate: 50 fps

Zeiss Xradia 620 Versa X-ray Microscope

  • X-ray Power: 25 W
  • X-ray Energy: 30 - 160 keV
  • Spatial Resolution: 500 nm
  • Maximum Sample Size: 50 mm x 100 mm x 50 mm
  • Additional Features: Dual-stage magnification based on synchrotron-caliber optics and revolutionary RaaDTM, In-situ monitoring, Dual scan contrast visualization, Dragonfly Pro for advanced analysis

FT4 Powder Rheometer

  • Force: +/- 50 N maximum
  • Torque: 900 mNm
  • Vertical Travel: 185 mm
  • Rotor Speed: 120 rpm
  • Axial Speed: 30 mm/sec

Thermal Characterization Lab

The thermal characterization lab houses a variety of equipment including Linseis LFA 500 Light Flash Analyzer, Linseis L75 Vertical Push Rod Dilatometer, and Linseis Transient Hot Bridge. These equipment’s can measure the thermal properties such as thermal diffusivity, thermal conductivity, thermal expansion coefficients, specific heat values, and phase transition points of solid material up to 1500 °C.

Linseis L75 Vertical Push Rod Dilatometer

  • Capabilities: Linear thermal expansion, Alpha physical, Sintering temperature, Phase transformations, Softening points, Decomposition temperatures, Glass transition temperatures
  • Delta L Resolution: 0.03 nm
  • Measuring Range: +/- 2500 µm
  • Contact Force: 10 mN up to 1 N

Linseis Transient Hot Bridge

  • Capabilities: Thermal diffusivity, Thermal conductivity and specific heat
  • Thermal Conductivity: 0.01 up to 5 W/(mK)
  • Thermal Diffusivity: 0.05 up to 50 mm²/s
  • Specific Heat Capacity: 100 up to 5000 kJ/(m³K)
  • Operating Temperature: -150 °C up to 700 °C

Linseis LFA 500 Light Flash Analyzer

  • Capabilities: Thermal Diffusivity, Thermal Conductivity and Specific Heat
  • Temperature range: RT up to 1500°C
  • Sample Type: Solids, Liquids, Powders, Pastes, Thin films and more
  • Sample Dimensions: ∅ 3, 6, 8, 10, 12.7 or 25.4 mm square samples 6×6, 10×10 or 20×20 mm, from thin films to 6 mm thickness

Corrosion Lab

Corrosion lab is equipped with advanced Gamry 1010E interface (Potentiostat/Galvanostat/Zero Resistance Ammeter) for electrochemical corrosion testing and analysis, including potentiodynamic polarization, cyclic potentiodynamic polarization, electrochemical impedance spectroscopy, etc.,. This Lab is also outfitted with standard ParaCell electrochemical Cell Kit for a wide range of flat specimens and MultiPortTM Corrosion Cell to run the electrochemical corrosion tests for oversized specimens (e.g. tensile and fatigue) as per the ASTM G5, G59, or G61 standards. The lab focuses on understanding the mechanisms of corrosion, developing corrosion-resistance materials and studying the effects of environmental factors on material’s degradation.

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Gamry Interface 1010E

  • Max. Applied Current: ±1 A
  • Max. Applied Potential: ±12 V
  • EIS: 10µHz - 2MHz
  • Additional Features: Paracell electrochemical cell kit for flat specimens, Multiport corrosion cell

Heat Treatment Facility

The heat treatment lab is equipped with different furnaces, ovens, and quenching facilities that are necessary for thermal post processing of fabricated parts. This includes programmable muffle and tube furnaces with a wide operating range between 50 °C to 1125 °C. These furnaces are capable of performing a wide range of heat treatment processes including stress-relieving and annealing to alter the properties of fabricated parts.

Fisher Scientific 650-126 Isotemp Programmable Muffle Furnace

  • Operating Range: 50 °C to 1125 °C
  • Power: 4600 W
  • Heating Chamber Dimensions: 12 in x 14 in x 13 in

SENTRO Tech STT-1600 °C Tube Furnace

  • Standard High Alumina Tube Sizes: 1.5", 2.0", 2.5", 3.0", and 3.5"
  • Standard SiC, stainless, or Quartz Tube Sizes: 1.5", 2.0", 2.5", 3.0", 3.5", 4.0", 6.0" and 8.0"
  • Standard Heating Zone Lengths: 6", 12", 24", and 36"

SENTRO Tech ST-1200 °C Tube Furnace

  • Standard High Alumina Tube Sizes: 1.5", 2.0", 2.5", 3.0", and 3.5"
  • Standard SiC, stainless, or Quartz Tube Sizes: 1.5", 2.0", 2.5", 3.0", 3.5", 4.0", 6.0" and 8.0"
  • Standard Heating Zone Lengths: 6", 12", 24", and 36"

Machine Shop

The machine shop is capable of handling a variety of tasks requiring turning, cutting, milling, and grinding. The state-of-the-art machinery includes Milltronics SL6-II Slant Bed CNC machine, Kent USA Wsi-430 Wire electric discharge machine, Grizzly G9744Z2 Industrial Bandsaw, Grizzly G5963 Industrial Surface Grinder, Pace technology MEGA-M250 Abrasive Saw, and Turret Vertical Mill. This enables precise fabrication and machining of specimens made of a wide range of metallic materials such as Titanium, Inconel, stainless steels, high-strength aluminum etc.

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Milltronics SL6-II Slant-Bed CNC Turning Center

  • Swing Over Bed: 15.9 in
  • Swing Over Cross: 9.45 in
  • Max. Turning Diameter: 12.4 in
  • Max. Turning Length: 13.4 in

Kent USA WSi-430 Wire EDM

  • Max. Work Piece Size: 27.6" x 21.3" x 11.6"
  • Drive & Servo: Drive & Servo
  • Simulation Axis: X/Y/U/V (4 axes)
  • X/Y-Axis Travel: 15.7" / 11.8"
  • Z-Axis Travel: 11.8"
  • Wire Diameter Range: ∅ 0.1~ ∅ 0.3 mm

Turret Vertical Mill

  • Motor Power: 2 HP
  • Spindle Speed: Variable 80-5440 rpm
  • Direction Axis: X, Y, Z

Grizzly G9744Z2 Industrial Bandsaw

  • Motor: 1.5 HP
  • Cutting Capacity (rectangular): 10 in x 10 in
  • Blade Speeds: 114, 196, 288, 377 FPM
  • Blade Length: 121 - 1/2 in

Pace Technology MEGA-M250 Abrasive Saw

  • Motor Power: 3 hp (2.2 kW)
  • Cut-off Wheels: 10-in (250 mm) diameter
  • Speed: 2895 rpm (50 Hz), 3400 rpm (60 Hz)
  • Maximum Sample Diameter: 3-in (75 mm)
  • Short Sample Size: 2.4 in x 5.3 in (60 mm x 135 mm)

Sample Preparation Lab

The sample preparation lab is equipped with MTC Automatic Longitudinal Polishing System GR04 for preparation of the tensile and fatigue specimens for mechanical testing. EcoMet™ 30 Semi-Automatic Grinder Polisher and GIGA-1200 Vibratory Polisher enables the preparation of samples for microstructural characterization and analysis.

MTC Automatic Longitudinal Polishing System GR04

  • Specimen Type: Cylindrical and Flat
  • Polishing Cycles: Four
  • Polishing Force: 1 - 50 N
  • Features: Electronic control of process, Longitudinal surface polishing, Low stress tooling, Possibility of polishing different element geometry

GIGA-1200 Vibratory Polisher

  • Working Wheel Diameter: 12"
  • Frequency Control: 1 - 240 Hz
  • Timer: 0 - 9999 minutes
  • Soft Start Control: 1 - 25 seconds

EcoMet 30 Semi-Automatic Grinder Polisher

  • Motor Power: 440 W
  • Platen Diameter: 8", 10", and 12"
  • Platen Wheel Speed: 50 - 500 rpm in 50 rpm increments
  • Head Motor Power: 300 W
  • Head Wheel Speed: 30 - 200 rpm in 10 rpm increments
  • Central Specimen Force: 5 -4 0 lbs