Addressing U.S. Advanced Manufacturing and Clean Energy Technology Challenges

Transcription

1 Addressing U.S. Advanced Manufacturing and Clean Energy Technology Challenges January 10, 2014 NSF Workshop: Faculty Development Needs for the U.S. Manufacturing Enterprise Robert Ivester, Ph.D. Deputy Director Advanced Manufacturing Office 1 Energy Efficiency and Renewable Energy eere.energy.gov

2 Outline U.S. Big Picture EERE and Advanced Manufacturing Office (AMO) Overview AMO Partnership Approach R&D Projects R&D Facilities Technical Assistance 2

3 What is Advanced Manufacturing? Advanced Manufacturing involves both: new ways to manufacture existing products, and especially the manufacture of new products emerging from new advanced technologies. Source: President s Council of Advisors on Science and Technology, Report to the President on Ensuring America s Leadership in Advanced Manufacturing, June 2011, p. ii 3

4 AMO is a member of the Advanced Manufacturing Partnership The Advanced Manufacturing Partnership Spark a renaissance in American manufacturing through public private partnerships that help our manufacturers compete with anyone in the world U.S. Dept. of Energy Office of Energy Efficiency and Renewable Energy Strengthen America's energy security, environmental quality, and economic vitality through enhanced energy efficiency and productivity Advanced Manufacturing Office Co-invest with private and public partners to improve U.S. competitiveness, save energy, create high-quality domestic manufacturing jobs and ensure global leadership in advanced manufacturing and clean energy technologies 4

5 AMO addresses the national need to: Make and export more high-value products using less energy. 5

6 Clean Energy: A Top Administration Priority Part of All-the-above Strategy Economy Competitiveness Competitiveness in clean energy Domestic jobs Security Clean Energy Solutions Energy selfreliance Stable, diverse energy supply Environment Clean air Climate change Health 6

7 AMO aims for economy-wide lifecycle impacts MAKE USE Products for efficient manufacturing Industrial 30.1 Quads Products for efficient use Transportation 27.5 Quads 18.2 Quads Residential 22.2 Quads AMO Projects: Commercial Lower energy steel production American Iron and Steel Institute Lower cost carbon fiber The Dow Chemical Company 7

8 AMO and the Office of Energy Efficiency and Renewable Energy Collaboration toward: Common goal to collectively increase U.S. manufacturing competitiveness 8

9 Advanced Manufacturing Office (AMO): Purpose AMO s Purpose is to Increase U.S. Manufacturing Competitiveness through: Industrial Efficiency - for Energy Intensive Industries examples: Aluminum, Chemicals, Metal Casting, Steel Carbon Fiber exiting Microwave Assisted Plasma (MAP) process POM laser processing Additive Manufacturing equipment Industrial Efficiency - Broadly Applicable Technologies and Practices examples: industrial motors, combined heat and power (CHP), efficient separations, microwave processing Cross-cutting Manufacturing Innovations - for Advanced Energy Technologies examples: carbon fiber composites, advanced structural metals/ joining, wide bandgap semiconductors/ power electronics 9

10 Advanced Manufacturing Office (AMO): Structure R&D Projects Industrial Efficiency Energy Intensive Industries Industrial Efficiency Broadly Applicable Cross-Cutting for Advanced Energy Technologies R&D Facilities Industrial Efficiency Broadly Applicable Cross-Cutting for Advanced Energy Technologies Industrial Technical Assistance Industrial Efficiency Broadly Applicable 10

11 Advanced Manufacturing Office (AMO): Goals R&D Develop technologies to reduce the life-cycle energy consumption of affected manufactured goods by 50% within 10 years of the start of each development effort Technical Assistance Reduce manufacturing energy intensity by 25% over ten years Support achievement of 40 GW of new combined heat and power (CHP) by 2020 Source: DOE FY 2014 Congressional Budget Request, page EE-187 and EE- 200, 11

12 EERE Core Questions for Investments 1. High Impact Is this a high-impact problem? 2. Additionality Will the Federal funding make a large difference relative to what the private sector is doing? 3. Openness Are we open to new ideas, approaches or parties in the broad problem to be solved? 4. Enduring Economic Benefit How will this Federal funding result in enduring economic benefit to U.S.? 5. Proper Role of Government Does the Federal funding represent a proper high-impact role of government versus something best left to the private sector? 12

13 R&D Investment level ($ log) AMO R&D: Bridging the Gap AMO Investments leverage strong Federal support of basic research by partnering with the private sector to accelerate commercialization Governments and Universities Private sector Technology Maturity (TRL; MRL; etc.) Concept Proof of Concept Lab scale development Demonstration and scale-up Product Commercialization 13

14 R&D Investment level ($ log) AMO R&D: Bridging the Gap AMO Investments leverage strong Federal support of basic research by partnering with the private sector to accelerate commercialization DOE Energy Innovation Hubs NSF Engineering Research Centers NIST Manufacturing Extension Partnership NSF IUCR Centers SBIR/STTR Governments and Universities Private sector Technology Maturity (TRL; MRL; etc.) Concept Proof of Concept Lab scale development Demonstration and scale-up Product Commercialization 14

15 R&D Investment level ($ log) AMO R&D: Bridging the Gap AMO Investments leverage strong Federal support of basic research by partnering with the private sector to accelerate commercialization Gap DOE Energy Innovation Hubs NSF Engineering Research Centers NIST Manufacturing Extension Partnership NSF IUCR Centers SBIR/STTR Governments and Universities Private sector Technology Maturity (TRL; MRL; etc.) Concept Proof of Concept Lab scale development Demonstration and scale-up Product Commercialization 15

16 R&D Investment level ($ log) AMO R&D: Bridging the Gap AMO Investments leverage strong Federal support of basic research by partnering with the private sector to accelerate commercialization Gap DOE Energy Innovation Hubs NSF Engineering Research Centers AMO R&D facilities projects NIST Manufacturing Extension Partnership NSF IUCR Centers SBIR/STTR Governments and Universities Private sector Technology Maturity (TRL; MRL; etc.) Concept Proof of Concept Lab scale development Demonstration and scale-up Product Commercialization 16

17 Partnership driven Three primary partnership-based vehicles to engage with industry, academia, national laboratories, and local and federal governments: 1. Research and Development Projects - to support innovative manufacturing processes and next-generation materials 2. Shared R&D Facilities 3. Technical Assistance 17

18 AMO Active R&D Projects Innovative Manufacturing Initiative (2012 FOA) Goal: Enable a doubling of energy productivity in U.S. industry Approach: Each project is a public-private partnership to accelerate commercialization of new product or process technologies at industrially relevant scales Focus: Cross-cutting, foundational manufacturing technologies Co-Investments: 13 selections in FY12 ($54M DOE) ($17M industry) 5 selections in FY13 ($23.5M DOE) ($8M industry) www1.eere.energy.gov/manufacturing/rd/innovative_manufacturing.html 18

19 R&D Projects - Materials 1) Low-cost production process for titanium alloy components. Photo courtesy Titanium and Titanium Alloys, Leyens & Peters 2) Pre-market-scale Carbon Fiber Technology Facility. Photo courtesy of Oak Ridge National Laboratory 3) Electrochemical solution growth of GaN substrates (conceptual diagram). Image courtesy of Sandia National Laboratory 19

20 R&D Projects - Chemicals Catalytic coating for furnace reactor coils will reduce production costs of olefins from natural gas liquids. Image courtesy of BASF Qtech. 20

21 R&D Projects - Fabrication Process Ultrafast, femtosecond pulse lasers (right) will eliminate machining defects in fuel injectors. Image courtesy of Raydiance. Protective coating materials for highperformance membranes, for pulp and paper industry. Image courtesy of Teledyne 21 Energy-efficient large thin-walled magnesium die casting, for 60% lighter car doors. Graphic image provided by General Motors. A water-stable protected lithium electrode. Courtesy of PolyPlus

22 R&D Projects - High Temperature Processing Direct conversion of iron ore in furnace without coke oven and blast furnace steps. Bench-scale process under construction (2013). Computer graphic courtesy of Berry Metal Company. 22

23 R&D Projects - Bioprocessing Advanced, energy-efficient hybrid membrane system for industrial water reuse. Combines forward osmosis and membrane distillation, and utilizes process waste heat. Image courtesy of RTI International. 23

24 R&D Projects - Waste Heat Continuous processing of high molecular weight, high thermal conductivity polyethylene sheets or fibers. Image courtesy of MIT Bio-electrochemical integration of waste heat recovery and waste-to-energy or chemical products. Image from Nam, Cusick, Kim & Logan (2012) Environ. Sci. & Technol. 24

25 R&D Projects - Automation Multi-scale modeling tools for enabling manufacturing-informed design. Image courtesy of Third Wave Systems. Technical Fact Sheets can be found at: www1.eere.energy.gov/manufacturing/rd/innovative_manufacturing.html 25

26 Partnership driven Three primary partnership-based vehicles to engage with industry, academia, national laboratories, and local and federal governments: 1. Research and Development Projects 2. Shared R&D Facilities - affordable access to physical and virtual tools, and expertise, to foster innovation and adoption of promising technologies 3. Technical Assistance 26

27 Shared R&D Facilities AMO supports an industrial commons including shared user R&D Facilities: Buy down the risk profile for innovators, SMEs Connect energy intensive sectors with SME innovations Focus a sector, or set of sectors around common technical challenges and build partnerships Address workforce challenges Fund critical space along the technology development lifecycle ( the missing middle ) 27

28 Shared R&D Facilities Address Barriers by providing: Proving ground to demonstrate the costs and efficiency gains of new technologies Affordable access to capital-intensive technologies and capabilities Focus a sector, or set of sectors, around common technical challenges Accelerated partnership development and supplier relationships Workforce training location for advanced manufacturing Effect on U.S. competitiveness: Increased domestic manufacturing capabilities and expertise Increased manufacturing collaboration between small, medium and large businesses, and university and government Positive feedback loop between production and research/design accelerates both Accelerated adoption of energy efficient technologies and manufacturing processes in existing U.S. manufacturing 28

29 Shared R&D Facilities Process control / metrology Advanced Manufacturing Technologies Design Capabilities Traditional Manufacturing Technologies Modeling and Simulation Tools Characterization and Testing Equipment Collaborative communities with shared R&D & Demonstration Facilities to provide access to physical and virtual tools to foster innovation and act as a proving ground to accelerate progress 29

30 Shared R&D Facilities Process control / metrology INPUT: Innovators with ideas for new/ improved materials or products Advanced Manufacturing Technologies Traditional Manufacturing Technologies Modeling and Simulation Tools Design Capabilities Characterization and Testing Equipment OUTPUT: Data to demonstrate business case for manufacturing new/ improved materials or products: - Processes established - Production rate data - Cost estimates based on production data - Risks understood / quantified - Partners Identified 30

31 Shared R&D Facilities Process control / metrology INPUT: Innovators with new production-enabling technologies Advanced Manufacturing Technologies Design Capabilities Traditional Manufacturing Technologies Modeling and Simulation Tools Characterization and Testing Equipment OUTPUT: Market adoption of innovative new productionenabling technologies 31

32 Shared R&D Facilities Process control / metrology INPUT: Innovators with new production-enabling technologies INPUT: Innovators with ideas for new/ improved materials or products Advanced Manufacturing Technologies Traditional Manufacturing Technologies Modeling and Simulation Tools Design Capabilities Characterization and Testing Equipment OUTPUT: Data to demonstrate business case for manufacturing new/ improved materials or products: - Processes established - Production rate data - Cost estimates based on production data - Risks understood / quantified - Partners Identified OUTPUT: Market adoption of innovative new productionenabling technologies Innovative materials or products to market 32

33 AMO-supported R&D Facilities 1. Oak Ridge National Lab - Manufacturing Demonstration Facility 2. America Makes, The National Additive Manufacturing Innovation Institute 3. Critical Materials Institute (CMI): A DOE Energy Innovation Hub 4. Next Generation Power Electronics Manufacturing Institute (future) DOE Assistant Secretary David Danielson during ribbon cutting ceremony of the Carbon Fiber Technology Facility at Oak Ridge National Laboratory. Carbon fiber has the potential to improve the fuel efficiency of vehicles. Photo courtesy of Jason Richards, Oak Ridge National Laboratory. 33

34 Shared R&D Facility: Oak Ridge National Lab Manufacturing Demonstration Facility Supercomputing Capabilities Spallation Neutron Source Exit end of Microwave Assisted Plasma (MAP) process, jointly developed by ORNL and Dow Arcam electron beam processing AM equipment POM laser processing AM equipment Program goal is to accelerate the manufacturing capability of a multitude of AM technologies utilizing various materials from metals to polymers to composites. Program goal is to reduce the cost of carbon fiber composites by improved manufacturing techniques such as MAP, which if scaled successfully could reduce carbonization cost by about half compared to conventional methodology. 34

35 Interagency supported Shared R&D Facility: America Makes: The National Additive Manufacturing Innovation Institute America Makes is a private-public partnership created through an interagency collaboration between the Departments of Defense, Energy, Commerce, NASA and NSF to accelerate the adoption of additive manufacturing technologies in the U.S. manufacturing sector and to increase domestic manufacturing competitiveness. The goal of the institute is to bridge the gap between basic research and technology adoption. America Makes will also serve as an example of best practices for the National Network for Manufacturing Innovation (NNMI) as proposed by the Administration in March The National Center for Defense Manufacturing and Machining (NCDMM) was selected through a competitive process led by Air Force Man Tech personnel. August 2012 award of $30M in government funding which the proposing team matched with $39M to establish America Makes. 35

36 Additive Manufacturing and Energy Reduced product life-cycle energy consumption through Additive Manufacturing: Materials - Use less material Manufacture - Replace energy-intensive processes Transport - Reduce inventory of parts Use - Reduced fuel/energy consumption Disposal / Re-use - Remanufacturing and repurposing

37 Case studies for Additive Manufacturing: Aircraft Brackets 1. Avoiding machining: Cost savings to manufacture same bracket by Additive Manufacturing uses 95% less starting material resulting in more than 50% cost savings. * Conventional Process Additive Process 12 g 12 g (identical) 2. Optimized design: Resulting bracket is 65% lighter, saving manufacturing materials and resulting in use phase energy savings kg 0.38 kg (optimized) Source: MFI and LIGHTEnUP Team * Dehoff, R, Advanced Materials & Processes, March 2013, vol. 171 No. 3, pgs

38 Shared R&D Facilities The Critical Materials Institute - A DOE Energy Innovation Hub Critical materials* elements that are key resources in manufacturing clean energy technologies wind turbines, solar panels, electric vehicles, and efficient lighting Mission Eliminate materials criticality as an impediment to the commercialization of clean energy technologies for today and tomorrow. Funding investing up to $120 million over five years ( ) Consortium of 7 companies, 6 universities, and 4 national laboratories Led by Ames National Laboratory 38 * As defined by U.S. Department of Energy Critical Materials Strategy. Washington, DC: DOE.

39 The Critical Materials Institute (CMI): A DOE Energy Innovation Hub What is a Critical Material? Any substance used in technology that is subject to supply risks, and for which there are no easy substitutes. The list of materials that are considered critical depends on who, where and when you ask. 39 Data Source: Metal-Pages.com Nd and Dy metal 99% min FOB China (CN) $/kg prices from 1/2002 to 7/2013.

40 DOE s list of Critical Materials for Clean Energy Technologies Lighting Vehicles Solar PV Wind Dy Eu Nd Tb Y Li Te 40 Source: DOE s 2011 Critical Materials Strategy report.

41 Importance to Clean Energy Medium-Term Criticality ( ) for Clean Energy Technologies 4 (high) Neodymium Dysprosium 3 Lithium Tellurium Europium Yttrium Terbium Critical 2 Nickel Cerium Cobalt Gallium Indium Lanthanum Manganese Praseodymium Near-Critical Not Critical 1 (low) Samarium 1 (low) (high) 41 Supply Risk Source: DOE s 2011 Critical Materials Strategy report.

42 The Mission of the Critical Materials Institute Eliminate materials criticality as an impediment to the commercialization of clean energy technologies for today and tomorrow. 42

43 Goals of the Critical Materials Institute Developing Substitutes A substitute permanent magnet that exhibits properties similar to current rare earth permanent magnets, but containing half or less Dy and Nd than current magnets New phosphors that eliminate Eu (red) and Tb (green) from fluorescent lamps Crosscutting Research Evaluate the supply chain and criticality of materials for forward looking assessments of raw materials may become critical to the deployment of clean energy technologies. Reuse & Recycling Reduce loss of critical rare earths due to domestic manufacturing by 50% Reduce critical rare earths elements going to domestic landfills by 35% Diversifying Supply Enable commercial extraction of at least one new source of critical materials Increase the efficiency of separations and metals production processes 43

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45 Advanced Manufacturing Office Investments in Innovative R&D Industrial Sectors Benefiting from R&D Chemical Forest Products Metal Casting Non-ferrous Metals Petroleum Steel Combined Heat and Power Crosscutting multiple sectors Advanced R&D Facilities (DOE $) Manufacturing Demonstration Facility ($50M) Additive Manufacturing and Carbon Fibers Critical Material Hub ($120M) National Additive Manufacturing Innovation Institute ($10M) Next Generation R&D Projects 18 R&D Projects Focused on foundational technologies crosscutting multiple industries DOE Investment: $75M 45

46 Future Shared R&D Facility: Wide Bandgap Semiconductor & Power Electronics Manufacturing Wide Bandgap (WBG) Semiconductors Higher temperatures, voltages, frequency, and power loads compared to Silicon. Smaller, lighter, faster, and more reliable power electronic Image source: istock components for more efficient conversion, distribution, and use of electric power. Clean Energy Manufacturing Innovation Institute 46 Semiconductor Material Bandgap Energy (ev) Silicon 1.1 Silicon Carbide 3.3 Gallium Nitride 3.4 Image source: DOE Oak Ridge National Laboratory 1 DOE Quadrennial Technology Review DOE Office of Electricity Delivery and Energy Reliability, Lux Research, Foundational technology. o WBG power electronics critical to and broadly applicable across EERE portfolio in both energy-intensive industries and clean energy products. 1 o 80% of electricity will flow through power electronics by Impacts. o Up to 75% reduction in electricity losses for AC-DC power conversion. o Up to 10% reduction of the ~69% electricity in industry consumed by motors via adoption of variable-speed drives enabled by WBG. o $3.3 B market opportunity by U.S. competitiveness. Opportunity to maintain U.S. technological lead in WBG and rebuild power electronics manufacturing lost overseas for Silicon. Need. Cutting-edge manufacturing for high-quality, affordable devices or chips to enable mass adoption in power conversion systems.

47 Partnership driven Three primary partnership-based vehicles to engage with industry, academia, national laboratories, and local and federal governments: 1. Research and Development Projects 2. Shared R&D Facilities 3. Technical Assistance driving a corporate culture of continuous improvement and wide scale adoption of technologies, such as combined heat and power, to reduce energy use in the industrial sector 47

48 Industrial Technical Assistance Efficient On-Site Energy Technical Assistance Partnerships (previously called Clean Energy Application Centers) Energy-Saving Partnership Better Buildings, Better Plants, Industrial Strategic Energy Management Student Training & Energy Assessments University-based Industrial Assessment Centers 48

49 Superior Energy Performance Certified Plants Facility Name % Energy Performance Improvement * Performance Level Volvo Trucks, NA Dublin, VA Dow Chemical Company Texas City, TX: Manufacturing facility 3M Canada Company Brockville, Ontario, Canada Cook Composites and Polymers Houston, TX Allsteel Muscatine, IA Owens Corning Waxahachie, TX Dow Chemical Company Texas City, TX: Energy systems facility Nissan, NA Smyrna, TN Freescale Semiconductor, Inc. West Austin, TX 3M Company Cordova, IL 25.8 Platinum 17.1 Platinum 15.2 Platinum 14.9 Gold 10.2 Gold 9.6 Silver 8.1 Silver 7.2 Silver 6.5 Silver 6.2 Silver SEP: Verified Energy Performance Improvements By facilities that conform to the ISO energy management system standard 49 * Energy performance improvement is over a 3-year period

50 Industrial Assessment Centers (IACs) IACs ( ) IAC Assessments (through 2012) 50

51 Industrial Technical Assistance: Workforce Development Industrial Assessment Centers: Creating the next generation of energy engineers: Conduct hands-on assessments of small and medium-sized manufacturing firms Foster a specialized energy engineering curriculum Over 3,100 students trained - nearly 60 percent of IAC graduates go on to careers in the energy industry Over 15,600 assessments and provided nearly 117,600 recommendations for small and medium-sized manufacturing plants Assessments have identified nearly $515M in energy savings and nearly 3.4 million metric tons in CO2 emissions reductions since 2006 Certified Practitioner in Energy Management System program developed 50 certified practitioners to date 51

52 Regional Technical Assistance Partnerships (CEACs) (previously called Clean Energy Application Centers) Market Assessments: Analyses of CHP market potential in diverse sectors, such as health care, industrial sites, hotels, & new commercial and institutional buildings. Eight Regional CEACs & International District Energy Association Education and Outreach: Providing information on the benefits and applications of CHP to state and local policy makers, regulators, energy endusers, trade associations and others. Technical Assistance: Providing technical information to energy endusers and others to help them consider if CHP makes sense for them. Includes performing site assessments, producing project feasibility studies, and providing technical and financial analyses. cturing/distributedenergy/ceacs.html 52

53 Opportunities to Work at Advance Manufacturing Office AAAS Fellowships ORISE Fellowships IPA Agreements Detail assignments from other agencies 53

54 Thank you! Robert Ivester, Ph.D. Deputy Director Advanced Manufacturing Office U.S. Department of Energy 54

55 55 Appendix Slides

56 Additive Manufacturing Additive manufacturing, also known as 3D Printing, is a suite of emerging technologies to fabricate parts using a layer-bylayer technique, where material is placed precisely as directed from a 3D digital file. Additive manufacturing can 1 : reduce energy intensity and waste enable remanufacturing support innovative designs create agile supply chains reduce time to market 1 AeroMet process Boeing, Northrup Grumman, NavAir 56

57 Promise of Additive Manufacturing Unprecedented capability to design and create products Topology optimization. Same strength, half the weight in our lifetime at least 50% of the engine will be made by additive manufacturing Robert McEwan GE 57

58 Case Study 1 - Lockheed Martin Aircraft Bracket Primary Processing (15.9 MJ/kg) Conventional Machining - Buy-to-Fly Ratio 33:1 Mill Product (slab, billet, etc.) Secondary Processing (400 grams) Machined Product Final Processing (12 grams) Finished Part Ingot (918 MJ/kg embodied energy) Atomization (14.8 MJ/kg) Additive Manufacturing - Buy-to-Fly Ratio 1.5:1 Powder (20 grams) Electron Beam Melting (EBM) Final Processing (12 grams) Finished Part Final weight 12 grams Key assumptions: Source: MFI and LIGHTEnUP Team Ingot embodied (source) energy 918 MJ/kg (255 kwh/kg) [5] Forging kwh/kg [5], Atomization kwh/kg [6,7,8], Machining 9.9 kwh/kg removed [9], SLM 29 kwh/kg [10, 11], EBM 17 kwh/kg [10] 11 MJ primary energy per kwh electricity Machining pathway buy-to-fly 33:1 [15], supply chain buy point = forged product (billet, slab, etc.) AM pathway buy-to-fly 1.5:1, supply chain buy point = atomized powder Argon used in atomization and SLM included in recipes but not factored into energy savings in this presentation 58 Process Final part (grams) Ingot consumed (grams) Raw mat l (MJ) Manuf (MJ) Transport (MJ) Use phase (MJ) Machining ,420 2,835 EBM ,420 2,441 Total energy per bracket (MJ)

59 Case Study 2 Optimized Aircraft Bracket* Primary Processing (15.9 MJ/kg) Ingot (918 MJ/kg embodied energy) Atomization (14.8 MJ/kg) Conventional Machining - Buy-to-Fly Ratio 8:1 Mill Product (slab, billet, etc.) Powder Secondary Processing (8.72 kg) Electron Beam Melting (EBM) Final Processing Finished Part Additive Manufacturing - Buy-to-Fly Ratio 1.5:1 (0.57 kg) Machined Product Final Processing (0.38 kg) Finished Part 1.09 kg 0.38 kg Process Final part (kg) Ingot consumed (kg) Raw mat l (MJ) Manuf (MJ) Transport (MJ) Use phase (MJ) Total energy per bracket (MJ) Machining , , ,945 EBM (Optimized) ,282 76,937 Key assumptions: Ingot embodied (source) energy 918 MJ/kg (255 kwh/kg) [5] Forging kwh/kg [5], Atomization kwh/kg [6,7,8], Machining 9.9 kwh/kg removed [9], SLM 29 kwh/kg [10, 11], EBM 17 kwh/kg [10] 11 MJ primary energy per kwh electricity Machining pathway buy-to-fly 33:1 [15], supply chain buy point = forged product (billet, slab, etc.) AM pathway buy-to-fly 1.5:1, supply chain buy point = atomized powder 59 Argon used in atomization and SLM included in recipes but not factored into energy savings in this presentation Source: MFI and LIGHTEnUP Team

60 Case Study References 1. Altfeld, H. H. (2010). Commercial Aircraft Projects: Managing the Development of Highly Complex Products, Ashgate Publishing Ltd, Farnham, UK Dehoff, R, Advanced Materials & Processes, March 2013, vol. 171 No. 3, pgs Senyana, L.N. (2011). Environmental Impact Comparison of Distributed and Centralized Manufacturing Scenarios. Masters Thesis, Rochester Institute of Technology, Nov Hopkins, W.G. (2013). PSI Ltd personal communication with Josh Warren of Oak Ridge National Lab. Feb 15, Simonelli, M, et al. (2012). Further Understanding of Ti6Al4V Selective Laser Melting Using Texture Analysis. Proceedings of 23rd Annual International Solid Freeform Fabrication Symposium, Austin, TX. 9. Kruzhanov, V., Arnhold, V. (2012). Energy Consumption in Powder Metallurgical Manufacturing. Powder Metallurgy, 55, 1, p Baumers, M., et al. (2012). Transparency Built-in: Energy Consumption and Cost Estimation for Additive Manufacturing. J Ind Ecol, 00,0,p Kellens, K.E., et al. (2010). Environmental Assessment of Selective Laser Melting and Selective Laser Sintering. Proceedings of Going Green - CARE INNOVATION 2010: From Legal Compliance to Energy-efficient Products and Services, p8-11, Nov, Vienna, Austria. 12. Dehoff, R. (2011). Additive Manufacturing: Realizing the Promise of Next Generation Manufacturing. Presentation to Additive Manufacturing Workshop, Oak Ridge National Lab, Oak Ridge, TN, Feb 16, Helms, H. and Lambrecht, U. (2006). The Potential Contribution of Light-Weighting to Reduce Transport Energy Consumption. Int J LCA VSMPO (2011). Commercial Aerospace Demand. Presented at Titanium 2011 Conference International Titanium Association, Oct 2-5, San Diego, CA. 15. Case Study: Additive Manufacturing of Aerospace Brackets, Ryan Dehoff, et.al., ORNL, 0ab72460a967f77d3fbd 60