As metal powder additive manufacturing advances from rapid prototyping to mass production, the importance of powder characteristics and composition has become widely recognized. In this presentation, various techniques for powder production will be explored, with the emphasis on variants in atomization technology. Conventional and emerging techniques for measuring powder characteristics will be discussed. Analysis of finished components that meet or exceed expected properties, while at the same time taking advantage of revolutionary part design, will be addressed. It is the intent to assist component designers and manufacturing engineers in both alloy selection and specification determination for optimum property results.

1. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved

2. C O N F I D E N T I A L
OMTEC 2017
June 13-15, 2017
Presented by: Ray DeFrain, Regional Metallurgist - Midwest U.S. /Canada
Claudia Mumau, External Collaborations Manager
Considerations for Metal Powders used in Additive Manufacturing

3. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 3
Introductions
– Claudia Mumau
External Collaborations Manager
email: cmumau@cartech.com
phone: 610.208.4003
– Ray DeFrain
Regional Metallurgist for Midwest U.S. & CANADA
email: rdefrain@cartech.com
phone: 484.793.5130

4. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
 Introductions
 Carpenter Technology: Overview
 Our Core Values and History
 Medical Market Focus & Current Snapshot
 Introduction to Additive Manufacturing
 Interest & growth trends in Medical market
 Identify opportunities and advantages of AM
 Identify challenges with AM
 Powder: 5 Whys?
 Common Powder Production Methods
 Carpenter’s selected methodology
 Important attributes of Powder
 Carpenter’s Production Method & Process Flow Path
 Powder Properties: Meeting Expectation
through Innovation
 Carpenter’s Commitment to Powder
 Carpenter’s Testing Capabilities & Powder Inspection capability
 The importance of defining design criteria
 Partnering with a design house & manufacturer-in-one!
 Case studies
 Examples of Printed Parts in use today
 Questions
4
Agenda

5. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 5
Advanced Specialty Alloys

6. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
INSTRUMENTS AND TRAUMA IMPLANTS
• CarTech 316, CarTech 440A/C
• CarTech Custom 455® Stainless
• CarTech Custom 465® Stainless
• Ti 6AI-4V ELI, CP 4 (Dental Implant)
• Various other ASTM F899 Alloys
* MP35N is a registered trademark of SPS Technologies, Inc.
FRACTURE FIXATION
• CarTech BioDur® 316LS Alloy
• Ti 6Al-4V ELI
• CarTech BioDur® 108 Alloy
HIP AND KNEE REPLACEMENTS
• CarTech BioDur CCM® Alloy
• CarTech BioDur CCM Plus® Alloy
VASCULAR DEVICES (stents)
• CarTech MP35N Alloy
• CarTech L-605 Alloy
ARTIFICIAL DISCS & SPINAL FIXATION
• CarTech Micro-Melt BioDur CCM® Alloy
• CarTech Micro-Melt BioDur CCM® Plus® Alloy
• CarTech Micro-Melt BioDur® GADS Alloy
SURGICAL NEEDLES AND STAPLES
• CarTech Custom 475® Stainless
• CarTech 420 Stainless
• Ti 6AI-4V ELI
Medical Alloy Snapshot

7. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
 Introductions
 Carpenter Technology: Overview
 Our Core Values and History
 Medical Market Focus & Current Snapshot
 Introduction to Additive Manufacturing
 Interest & growth trends in Medical market
 Identify opportunities and advantages of AM
 Identify challenges with AM
 Powder: 5 Whys?
 Common Powder Production Methods
 Carpenter’s selected methodology
 Important attributes of Powder
 Carpenter’s Production Method & Process Flow Path
 Powder Properties: Meeting Expectation
through Innovation
 Carpenter’s Commitment to Powder
 Carpenter’s Testing Capabilities & Powder Inspection capability
 The importance of defining design criteria
 Partnering with a design house & manufacturer in-one!
 Case studies
 Examples of Printed Parts in use today
 Questions
7
Agenda

8. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 8
Interest and growth in AM for Medical Market
According to Market Research Reports, Medical
demand for additive manufacturing powder is
projected to grow by 23% annually through 2025.
2,681
2,252
1,864
1,518
1,222
950
708
296
213156113
0
1,000
2,000
3,000
201620142012
Additive manufacturing market size ($M)
+23%
20202018
Source: Wohlers Associates (baseline data), SmarTech Publishing (forecast growth rate)
EIGA atomizer: ALD
ForecastHistorical
Powder atomization
Vacuum furnace upgrades
Titanium alloys
Screening & handling
ultrasonic cascading screens,
inert handling
Product management
Technical sales
R&D resources
AM application engineers
Addition of new AM powder capabilities
Dedicating addition of resources to AM
Carpenter’s Response to this Need

9. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 9
Interest and growth in AM for Medical Market
Key AM Takeaways: Interest and Growth
• Titanium, Titanium Alloys, and Cobalt-Chrome powders will be the
largest beneficiaries of increasing medical Additive Manufacturing
demand.
• Ti, Ti-alloys, and Co-alloys combine superior mechanical properties with excellent
biocompatibility.
• Each have shown success in Additive manufacturing practices, with production-level
precedence established in new designs.
• Additive Manufacturing has unique advantages over conventionally machined parts,
exhibited in the following slides.

10. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 10
Opportunities and Advantages of AM
AM Changes the “Economies of Scale” –
AM has the potential to reduce the capital
required to reach minimum efficient scale
for production, thus lowering the barriers
to entry to manufacturing for a given
location.
Reference: Atzeni, Eleonora, Luca Iuliano, and Allessandro Salmi.
2011. “On the Competitiveness of Additive Manufacturing for the
Production of Metal Parts.” 9th International Conference on
Advanced Manufacturing Systems and Technology.

11. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 11
Opportunities and Advantages of AM
Manufacturing flexibility –
reducing the costs associated with
production changeovers and
customization.
• Numerous, and often differing, parts
can be printed concurrently
• Single machine and tooling for internal
and external features
• Single input material, rather than
numerous variants of inventory

12. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 12
Opportunities and Advantages of AM
Customization –
• Hybrid conventional machining + AM build up
• Internal design features (Physical Modulus Manipulation)
• Patient specific design

13. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 13
Opportunities and Advantages of AM
510(k) clearance –
The FDA has approved multiple
devices using additive
manufacturing. Most of them
via the 510(k) or emergency
use pathways.
The FDA has developed draft
guidance approximately 1 year ago
for AM. Showing signs of their
expectation of further
implementation of this
technology.

14. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 14
Opportunities and Advantages of AM
Complex shapes –
• Ability to create novel shapes
• Forms that could promote faster healing
• Lattice / Hollow structures (only possible through AM) can enable:
• custom stiffness
• custom strength
• reduced weight

15. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 15
Current Challenges with AM
Current Challenges with the Technology:
• Low throughput, compared to traditional subtractive manufacturing
—New equipment design can advance, but still will be small volumes.
• “AM recipes” don’t necessarily produce consistent results across different machines
— Equipment manufacturers have tackled AM through different designs.
• Metallurgical properties not fully honed
— Carpenter Technology can be an integral partner for this, developing customer AM-
specific powder blends, as we have for numerous customers already.
• Lack of universal industry standards
— Wrought requirements and the expectations of AM parts vs. wrought parts have not
aligned to the point of wide-spread standard development. Committees to support this
growth have been established.
• Post-processing operations still required
— Many processes still require HIP to drive 100% consolidation.

16. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
 Introductions
 Carpenter Technology: Overview
 Our Core Values and History
 Medical Market Focus & Current Snapshot
 Introduction to Additive Manufacturing
 Interest & growth trends in Medical market
 Identify opportunities and advantages of AM
 Identify challenges with AM
 Powder: 5 Whys?
 Common Powder Production Methods
 Carpenter’s selected methodology
 Important attributes of Powder
 Carpenter’s Production Method & Process Flow Path
 Powder Properties: Meeting Expectation
through Innovation
 Carpenter’s Commitment to Powder
 Carpenter’s Testing Capabilities & Powder Inspection capability
 The importance of defining design criteria
 Partnering with a design house & manufacturer in-one!
 Case studies
 Examples of Printed Parts in use today
 Questions
16
Agenda

17. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
17
Common Powder Production Methods: Gas vs Water Atomization
• Material – High Alloy
• Morphology – Spherical
• Density – ~100%
• Oxygen level – ~100ppm
• Toughness – High
• Cost – High
• No Need to Press & Sinter
Gas Atomized Powder Water Atomized Powder
• Material – Low Alloy
• Morphology – Irregular
• Density – ~90-95%
• Oxygen level – ~2000ppm
• Toughness – Low
• Cost – Low
• Must Press & Sinter

18. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Metal Powder Basic Requirements
• Chemistry
• Particle Size Distribution (PSD)
DMLS 10-44 micron
EBM 44-106 micron
FLM 44-150 micron
• Morphology and Flow
• Cleanliness
PSD -44u

19. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Powder Characterization
Characteristic Test Method(s) ASTM Std. Benefits Limitations
PSD
Sieve analysis B214
Large sample size,
No algorithms
Size range (low discrimination)
Difficult for fine powder
Light scattering B822
Fast, high
resolution
Relative to sieve analysis, Powder shape and
light scattering assumptions
Digital image processing
Comparable to
sieve analysis
Much of current industry/customer base relies
on light scattering methods
Flow
Hall flow B213 Simple
Some non-flowing (per B213) powder works
well in AM
Carney flow B964
Amenable to
more powder
Not as commonly used
Angle of Repose B243 (def.) Simple
Little correlation available between test values
and real world AM results
Rheological Testing
(Freeman, Mercury, etc.)
Test many
properties
Expensive, Little correlation available between
test values and real world AM results
Density
Tap Density B527 Simple
AM machines lack tapping/driving force for
optimum packing in this manner
Apparent Density B212 / B417 Simple Not analogous to spreading regime in AM
• Standard test methods lack ability to discriminate between “good” and “bad” AM powder
• Further correlation between new test methods necessary to aid in evaluation of virgin and used material

20. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
20
Powder Production Methods: Detail on Gas Atomization
Environments
• Air, Inert Gas, or Vacuum Melt
Melting type
• Plasma
• Induction
• Vacuum (Soluble Gas) Atomization
Melt Nozzle
• Straight bore, conical, etc.
• Free Fall
• Close coupled
Chamber / Collection Vessel Configuration
Atomization
• Ar vs. N2 vs. He
Example: Carpenter’s VIM - Gas Atomization

21. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Melt/
Atomize
Screen Classify
Blend
and/or
Pack
Process Flow Chart
1. Melt in Furnace
2. Control flow in tundish
3. Pour out of Atomization
nozzle
4. Obliterate via Gas system
5. Cool in Atomization tower
6. Sealed in via mechanism
7. Collect in container
• Insure uniformity
• Inert gas handling
• Avoid moisture
• Work to strict packaging
requirements
Air classified to
segregate particle size
into proper distributions
for end applications

22. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
 Introductions
 Carpenter Technology: Overview
 Our Core Values and History
 Medical Market Focus & Current Snapshot
 Introduction to Additive Manufacturing
 Interest & growth trends in Medical market
 Identify opportunities and advantages of AM
 Identify challenges with AM
 Powder: 5 Whys?
 Common Powder Production Methods
 Carpenter’s selected methodology
 Important attributes of Powder
 Carpenter’s Production Method & Process Flow Path
 Powder Properties: Meeting Expectation
through Innovation
 Carpenter’s Commitment to Powder
 Carpenter’s Testing Capabilities & Powder Inspection capability
 The importance of defining design criteria
 Partnering with a design house & manufacturer in-one!
 Case studies
 Examples of Printed Parts in use today
 Questions
22
Agenda

23. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 23
Production Locations
CENTRAL
& SOUTH
AMERICA
EUROPE
NORTH
AMERICA
Powder
manufacturing
Regional sales office
Torshalla, Sweden
Air / PHT
N2
Bridgeville, PA
2 VIM
1 Air
Ar / N2
Woonsocket, RI
Inert Melt
Ar / N2
Global HQ:
Reading, PA
300 lb vacuum
(R&D furnace)
Bruceton Mills,
WV
Titanium
ASIA / APAC
Athens, AL
VIM
Ar / N2

24. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 24
Powders & Applications
• Nickel alloys
• High temperature superalloys
• Duplex and super duplex
• Austenitic stainless
• Magnetic alloys
• Nitrogen strengthened SS
• Precipitation hardened SS
• Tool steels
• Maraging steels
• HSLA steels
• Cobalt alloys
• Copper alloys
• Titanium alloys (coming soon)
High purity, gas-atomized
powder products
Serving performance end
applications across our markets
Metal injection
molding (MIM)
Additive
manufacturing (AM)
HIP Near Net
Shapes
HIP Mill Forms
Thermal spray Cladding / metal
deposition

25. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Titanium Powder Production
• Newly refurbished 55,000 square foot state-of-the-art Titanium & Titanium Alloy facility
• Powder Production: Gas Atomizer and Plasma Arc Melter
• ISO 9001 & AS 9100 certified

26. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Titanium Powder Production
• All Titanium System – eliminates iron contamination
• Refractory-Free – eliminates refractory contamination
• Pure, Spherical, Homogeneous powder

27. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Research and Development

28. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Research and Development
R&D Mirror of AM major process Needs
• Vacuum Induction Melting (VIM)
− Fe-base, Ni-base, Co-base
− Ingot sizes = 15kg & 180kg
• VIM Powder Atomization Unit
• 300lb capacity
• AM equipment testing on-site and through
partnerships
• Heat treating
Enabler for Product Development and Process Optimization

29. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Materials’ Characterization
Examples:
• X-ray Diffraction
• Metallography
• Orientation Imaging
• Electron Microprobe
• SEM
• Image Analysis565248444036322824201612840
Area (µm²)
0
150
300
450
600
750
Count
0
20
40
60
80
100
Cumulative(%)

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• Customer Collaborations
• Classifier for R&D programs
• New power supply for R&D atomizer
• Yield Improvements
• Enhanced controls
• Water modelling of atomization process
• Nozzle design – collaboration with Mikro Systems, Inc.
• Industry Participation/Standards Creation
• Mercury Scientific “Revolution” analyzer
• Freeman FT 4 Rheometer
• Microtrac for PSD
• Image Analyzer for Particle Shape
• Technique for measuring “hollow spheres”
• AM Strategy Team
• Addition of Resources
• Development of AM Technology Center
Emerging Measurement Techniques

31. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved 31
Became preferred supplier
Highest quality CCM powder
Custom powder PSD and chemistry
Optimized for machine performance
Provided supply chain solutions
Cooperative re-use / recycling
program
Improved CCM alloy for AM
production of aerospace component
Tailored 17Cr-4Ni PH powder for
Medical AM Instrumentation
Proprietary Engine
Component
(discussion limited)
Identified mechanical property issue
with commercially available powder
Leveraged Carpenter technical
expertise to develop alternatives
Improved mechanical properties for
AM components (ASTM A564)
Became preferred supplier
AM Development Case Studies

32. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Examples of AM Parts In Use Today

33. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved
Questions?
Thank you for your attention!
Are there any questions?

34. C O N F I D E N T I A L© 2017 CRS Holdings, Inc. All rights reserved