Additive Manufacturing at Swagelok Changing a Culture

Transcription

1 Additive Manufacturing at Swagelok Changing a Culture Robert Bianco, PhD, FASM Senior Materials Scientist, Innovation & Technology

2 Outline Company Overview Manufacturing Culture Additive Manufacturing Program Application Examples Path Forward Challenges Future Opportunities

3 WHO WE ARE Fred Lennon establishes Crawford Fitting Company in The Swagelok Tube Fitting is introduced Swagelok Tube Fitting

4 WHO WE ARE Global distribution and service is established in 1954 Products are expanded to include Cajon, Nupro, Sno-Trik, and Whitey Unification of 5 company resources as one Swagelok in 1998 Today our products, services and global operations account $2 billion (USD) annual sales

5 OUR VISION Truly understand our customers needs and act on them. OUR MISSION Apply our collective talents with understanding and passion to improve each day.

6 EXPANDING TO MAKE THE WORLD SMALLER 1 6 Swagelok 70 Continents Countries 220 Sales and Service Centers 20 Manufacturing Facilities 5 Tech Centers Brazil China India Japan USA (Ohio)

7 EXPANDING TO MAKE THE WORLD SMALLER 5500 corporate associates 3900 sales and service associates Equaling 9400 associates worldwide

8 MARKETS SERVED Oil and Gas Semiconductor Chemical & Refinery Transportation Food Beverage & Dairy Shipbuilding Biopharmaceutical Pulp & Paper Power (Nuclear & Fossil Fuel)

9 AN EVER-EVOLVING PORTFOLIO Fittings Valves Regulators Quick-Connects Tubing & Tools Filters Hoses Sample Cylinders Welding Systems Measurement Devices Process Instrumentation Medium & High Pressure MPC Modular Systems Pre-Engineered Subsystems Leak Detectors, Lubricants & Sealants Swagelok Custom Solutions

10 MANUFACTURING CULTURE Extensive use of subtractive manufacturing for over 70 years CN CNC Machine Multi-Spindle Lathe Milling Machine ~85% of Swagelok products are made using subtractive manufacturing

11 Additive Manufacturing Overview Differs from conventional manufacturing processes Conventional Processes Formative Additive Manufacturing (7 categories of additive) Category Material 1 Vat Photo-Polymerization (SLA) Polymers Castings, Forgings Fabrication 2 Material Extrusion (FDM) Polymers 3 Material Jetting Hybrid 4 Binder Jetting Hybrid Welding, Assembly Subtractive 5 Powder Bed Fusion (PBF) Metals & Polymer 6 Directed Energy Deposition (DED) Metals 7 Sheet Lamination (UAM) Metals Milling, Drilling Focus on PBF and DED but exploring or utilizing all 7 types 11

12 Additive Manufacturing Program Vision: To create an additive manufacturing competency that designs and manufactures unique fluid systems that can t be manufactured using traditional methods Strategy Outcomes Additive Manufacturing Team High-Performance Materials Novel Methods Value Creation On-Demand/ Custom Solutions New Product Offerings Advanced, Unique Designs Manufacturing Support 12

13 Manufacturing Support Fixtures, Holders Test Fixture - Reduce lead time Inspection Tray - Reduce process time Test Alignment Fixture - Improve accuracy Custom Jaws - Reduce process time

14 Manufacturing Support Fixtures, Holders Inspection Fixtures - Improve efficiency Part Handling Trays - Reduce scrap Custom Tool Trays - Improve efficiency - Ergonomic

15 Manufacturing Support Chucker Loader Clip - Prototype Gantry claws - Prototype Double Drop Gripper Fingers - Prototype Wizmo Gripper Fingers - Prototype

16 Additive Manufacturing Program Vision: To create an additive manufacturing competency that designs and manufactures unique fluid systems that can t be manufactured using traditional methods Strategy Outcomes Additive Manufacturing Team High-Performance Materials Novel Methods Value Creation On-Demand/ Custom Solutions New Product Offerings Advanced, Unique Designs Manufacturing Support 16

17 New Product Offering Background of problem Thermal management of valves is often required to maintain process temperature/integrity Intimate contact of steam lines with valve body is difficult to achieve Cold spots in valve can result in freezing Current solutions void warranties 17

18 Steam Traced Ball Valve Alternate solution Integrated valve body design with internal steam or cooling fluid flow cavities to heat/cool valve Enabled by 3D printing other features easy to add Applicable to any number of Swagelok valves or regulators 18

19 Simulation Thermal Response Fluid Temperature Drops Through a Cold Valve Solution Validated Thermal Model Developed 19

20 Prototype Builds Prototypes/test articles printed in 316L stainless steel at two separate vendors Laser Powder Bed Fusion Process (L-PBF) Center Body Industrial Ball Valve 20

21 Material Performance 316L SS 316L Stainless Steel As-Built + Stress Relieved AM 316L CF-3M 21

22 Accomplishments - STBV Test articles built at two different vendors US patent application submitted - utility Completed in-house and started site beta testing Defined path to regulatory compliance and certification Instrumentation Panel 22

23 Challenges at Swagelok Quality Assurance Material Property Consistency Process Control Inspection Creating Value Unique Designs High-Performance Solutions Overcoming Embedded Manufacturing Culture Education Community of Practice Series Associate Engagement

24 Quality Management System Creating specification document hierarchy Working with standards committees to align with industry: ASME, ASTM, SAE AMS, AWS Swagelok AM Documentation SMS-AM-XXXXX 316L Material Specification Post Processing Cleaning Inspection Powder Procurement Specification Powder Bed Laser Fusion Thermal Processing Extrude Hone Part Quality Dimensional Inspection Process Control Document Stress Relief Electropolishing Digital X-ray Structured Blue Light Inspection Powder Removal Process Hot Isostatic Press (HIP) Bead/Grit Blast 3D Computed Tomography CMM Digital File Control / File Standardization Heat Treatment Peening Ultrasonic Inspection

25 Supply Chain Development Powder Quality Build Parameters Design Allowables Part Build HIP & Heat Treat Quality & Inspection Finishing Lab & Customer Tests 25

26 Rapid New Product Offerings To deliver qualified, new products and on-demand solutions with rapid development cycles Idea Initial Model Test Simulations Prototype Revised Model 26

27 Additive Manufacturing Future Metal powder bed systems examples EOS (powder bed) Build Speed (cm 3 /hr) SLM Solutions (powder bed) EOS M Build volume: 400 x 400 x 400 mm Build rate: 100 cm 3 /hr Laser system: 4 fiber lasers (400W) Materials: light metals, stainless / tool steel, superalloys Footprint: 4 x 1.6 x 2.4 m Price: ~$1.6M Machine Costs SLM 500HL Build volume: 500 x 280 x 365 mm Build rate: 105 cm 3 /hr Laser system: 2 4 fiber lasers (400W) Materials: stainless / tool steel, superalloys Footprint: 5.2 x 2.8 x 2.7 m Price: $0.85M $1.8M

28 Summary Company Overview Manufacturing Culture Additive Manufacturing Program Application Examples Path Forward Challenges Future Opportunities