DEFENCE APPLICATIONS. Introduction of ALM components into complex weapons

Transcription

1 DEFENCE APPLICATIONS Introduction of ALM components A Manufacturing Perspective David Duerden MBDA UK Technologist, Mechanical / Electromechanical Methods and Processes

2 Contents The use of ALM in MBDA Process options investigated to date Process Maturity and its challenges Challenges to Manufacturing MBDA research program Challenges to implementation Current and future work Exploitation?

3 The introduction of ALM into MBDA has been and still is a Journey First use of ALM techniques in approx D systems stereolithography - Used as a design aid / Rapid prototyping - Space models, Trial assembly, Fit and foul trials - Still in use with improved resins Quick cast process - The use of SLA parts to move to metal via casting - Early process not very robust and Required careful preparation - Process continues to be used Production of soft and semi soft tooling

4 Process options investigated to date ALM Metallic Non Metallic (Plastics) Powder Processes Wire Processes Thermo plastic Thermo setting plastic Powder bed Blown powder Laser processes Arc processes Powder bed Molten jet Laser processes Electron beam processes

5 Introduction of ALM components Metal Additive Manufacture Methods Process Maturity Example Applications Images courtesy of 3T RPD Ltd (

6 Challenges to Manufacturing Working with massively reduce development timescales To reduce Unit Production Cost (UPC, not just a manufacturing challenge) The cheapest method of production is not always the quickest - Development timescales drive the use of machining from solid - The best manufacturing methods are generally not a direct read across from machined parts Company inertia in adopting new manufacturing methods - We do what we know - Projects don t like developing new technology - This leaves Internal Research and Development (IRAD) to fund development

7 IRAD 2011 (MBDA UK): Wire + Arc Additive Layer Manufacture (WAALM) - Collaborative program with Cranfield University - The objective of investigating the suitability and benefits of using this technology to manufacture near-net-shape missile structures Powder bed + Electron Beam ALM process - Programme led by EADS Innovation Works, Filton, incorporating applications proposed by MBDA as defence industry demonstrators for power beam-based ALM.

8 WAALM - Progress during and 8 mm thick (nominal) demonstrators manufactured in Ti6Al4V. 8 mm thick demonstrator illustrated.

9 WAALM - Progress during (cont.): Advantages of WAALM process to MBDA: - In theory can deposit any material that is available as a welding filler material. - In theory, relatively simple to change the metal being deposited - multi-functional deposits - Relatively high deposition rates. - No real limitations on size. Disadvantages of WAALM process to MBDA: - Can only fabricate relatively simple shape ( blanks ) - Grain morphology tends to be relatively large, columnar - Residual stresses are an issue - Limited immediate use to MBDA (needs watching).

10 EADS led program into novel technologies MBDA UK invited by EADS IW to provide defence industry demonstrators. Simulated missile structure produced in Ti6Al4V at Filton using a powder bed, electron beam melting, ALM process (Arcam A2), in March Part used to illustrate the possibilities within missile design.

11 Progress during 2012 [cont.] Novel Technologies for Complex Weapons Missile structure in Ti6Al4V Introduction of ALM components

12 Progress during 2012 [cont.] Additional studies with EADS Innovation Works, Filton (mid-2012 onwards). Representative missile structures in Ti6Al4V

13 Electron Beam process (cont.): Advantages of EB process to MBDA: - Able to fabricate complex shapes - Good material properties possible - No residual stresses due to elevated process temp - Has possible immediate use to MBDA. Disadvantages of EB process to MBDA: - Can only deposit materials that are available in powder form. - Difficult to change materials due to contamination of powders in the machine - Relatively low deposition rates at present. - Currently there are limitations on size of parts

14 Progress during 2012 [cont.] Missile structure Manufactured in Ti6Al4V, using the ARCAM Electron Beam ALM process.

15 Progress during 2012 [cont.] Missile structure after final machining. Introduction of ALM components

16 Challenges to implementation Process - Process parameter stability and consistency - Cross platform repeatability - Build capacity and deposition rate Materials - Material specification availability and traceability Structural - Do we need to factor down mechanical properties? - Surface finish in fatigue applications? Design for process - Willingness and ability to design for process - Capability of our current design tools Geometric inspection / validation - If we can design it can we characterise it? - Does it matter? Introduction of ALM components

17 Current and future work How to counter the challenges - Design optimisation through structural analysis - Looking for benefits above and beyond material savings - Understanding Material properties - Quantifying the limitations of the process - Consider lower cost non-structural parts - Less stringent validation / acceptance criteria - Non-metallic parts - Looking for quick hits and a way into the design process - Investigating alternative functionality of the parts - waveguides

18 ALM s potential to MBDA - Commercially available equipment Introduction of ALM components - Supply chain exists and is growing rapidly (no pun intended) - Possibility for vertical integration (masters of our own destiny) - Seamless transition from development to production - Currently development timescales drive production processes - Difficult to change process for production - Machine from Solid to Castings for example - Allows simpler transfer of process from one manufacture/ country to another - Process can be supplier independent - Build parameters are the process - Scaling for production?

19 Thank you