Additive Manufacturing

Transcription

1 Additive Manufacturing

2 company profile HiETA Technologies Limited is a product design, development and production company exploiting the new technology of Additive Manufacturing (AM). Using Selective Laser Melting we can grow components from layers of very fine powders. The very high levels of 3D design freedom provided by the approach allow HiETA to deploy complex geometries, including lattices, and to integrate multiple components into single designs. This allows us to create more compact and efficient components than conventional manufacturing techniques. Based in Bristol and Bath Science Park, HiETA is pioneering the use of high performance metals, polymers and composite materials. There, in our new Technology Centre, our team of highly experienced and qualified engineers design, test, prototype and manufacture innovative high performance components. Our designs for thermal management and weight reduction aim to meet the increasing demand for the smaller, lighter, and more efficient engines and energy systems required for the aerospace, defence, automotive and clean energy sectors. Our team specialises in additive manufacturing. We can provide design, manufacture and support services across the whole value chain from conceptual design and materials science through to the application of the technology itself. The team provides modelling expertise using CFD, FEA, thermal and performance evaluation, testing and quality assurance, and then manage manufacture and production through the full supply chain.

3 Additive Manufacturing services AM services The HiETA service offer is based upon its validated value chain. It can: Assess the suitability of the conceptual design for your product for suitability for realisation by AM, not just in terms of physical design, but also for volume cost modelling and industrialisation Develop your existing or new material for use in AM by securing appropriate powder supply and defining AM process parameters Advise on the detailed design of your product to ensure manufacturability and performance Optimise your product for improved functional performance, light weighting or reduced cost Establish quality assurance principles for the realisation of your product with AM Translate your current AM prototype into a validated production environment

4 Additive Manufacturing value chain integration AM value chain integration Successful exploitation of additive manufacturing requires much more than just knowledge of AM machine operation. Successful applications require an understanding and control of the interaction of cost modelling, AM process selection, materials selection, detailed design and conceptual design drivers. HiETA s design and engineering approach captures these dependencies in a set of triedand-tested design principles. Developed initially for our own purposes and continually updated these design principles are coupled to a validated supply chain to ensure a high quality outcome. A key to HiETA design principles is design for additive manufacturing. Specifically accounted for are: Conceptual design drivers Detailed design Materials selection Powder material acceptance AM process selection Cost modelling Geometric influences on surface roughness Effects of micro-struture on creep Effects of surface and bulk defects on fatigue and damage tolerance Multi-objective optimisation, multi-disciplinary optimisation, topology optimisation Data handling and software interactions Build preparation including part-orientation and nesting Geometric limits on powder removal Powder removal strategies Form plate and support structure removal strategies External and internal surface control strategies, including sequential processes

5 Additive Manufacturing design engineering HiETA offers design engineering services. With extensive experience in understanding the principles of design for additive processes our engineering team also has expertise in thermo-fluids, structural analysis, 1D component and system modelling, 3D design, and perhaps most importantly, design for validation. Furthermore, with its comprehensive software toolbox, HIETA prepares data for AM production, including file slicing repair, and support design. sl Areas of specialism include: Thermal management with heat transfer and pressure drop requirements as the focus of product specifications, HiETA is capable of reviewing complex thermal management problems and, alongside customers, developing novel, more cost effective and efficient solutions. Light-weighting AM processes provide opportunities for optimising component topology. In particular, they allow the design and manufacture of conventional and innovative lattice structures that are integrated into AM components. Such lattices or honeycomb structures can combine both load-bearing and light-weighting functions. HiETA has gained considerable experience of their performance in a wide range of development projects. Component integration a further advantage of AM is that it allows the integration in single AM builds of two or more components that are normally manufactured separately. Advantages include reduced part-count and materials use; reductions in tooling and associated costs; reductions in final sub-system size, weight and costs; and higher efficiency. Novel functionality product functionality can be improved by designing multi-functions into previously single function components. For example, support structures, often in the form of the lattices noted above, can, in heat exchangers, be designed to have additional heat transfer or fluid flow control functions that again reduce size, weight and costs, and increase efficiency.

6 Additive Manufacturing case studies > defence Since our journey began back in 2012, we have demonstrated our expertise in a number of application areas with successful research and technology projects in defence, automotive, motorsport and aerospace innovations. Here we provide a number of case studies where we have lead a design to success. Our work carried out for the Centre for Defence Enterprise (CDE) provides an example of such a success. The project objective was to demonstrate the applicability of AM to helicopter exhaust systems where the process has the potential to increase cooling efficiency and minimise the weight penalty. HiETA developed an upswept exhaust concept with an integrated cooling passage and high stiffness lattice structure. The concept and detailed design was developed with structural analysis and CFD performed to optimise the architecture of the exhaust. Compression testing was used to inform the lattice unit cell design. Finally, a scaled suppressor was manufactured and tested on an engine platform with the surface temperatures measured along with distortion of suppressor under pressure and thermal loads. The concept was validated, with the surface temperature visible being over 200C lower than the pipework upstream.

7 Additive Manufacturing case studies > automotive This high efficiency, end-to-end, project shows another side to our current research and technology activities. This time the focus was on the industrialisation of the additive manufacturing powder-bed processes and supporting technologies for an automotive application. The project has taken a micro-turbine range extender recuperator as its baseline product and attempts to prove both physically and virtually that the challenging performance envelope can be achieved. The challenge has been the improvement of both productivity and quality output of the various processes to achieve the delivery of 10,000 recuperators in the next three to five years at the required price and performance. Two years into the HiEND project and, along with the other actors in the value chain, we have successfully decreased the production cost fourfold and have improved the quality of thin wall structures for this demanding high temperature application. HiETA are leading the design, testing of the recuperator itself and the cost modelling and integration of various pre and post processing activities.

8 Additive Manufacturing collaboration projects HiETA is an active member of the research and technology collaboration network, facilitated by Innovate UK and other organisations. We consider such projects a powerful tool to innovate using our technologies and allowing us to develop a strong network of supporting partners and institutions. Below are a selection of collaborative projects that we are currently working on. Innovate UK - HiEND The HiEND project is a three year multi-disciplinary project led by HiETA to prove the viability of Metal Additive Manufacturing (AM) in mid to high volume markets. The project tackles issues such as speed of production, pre & post processing and as importantly the elements that impact quality and reliability of production. Using an example of a high performance recuperator designed for a range extended electric vehicle it is concentrating on automotive market requirements and is due to finish in Innovate UK - SLaMMiT The SLaMMiT project is developing an ultra-lightweight, efficient micro-turbine built largely by Selective Laser Melting (SLM), a powder bed fusion version of Additive Manufacturing. It is exploring new component concepts, component architectures and integration of components enabled by and using SLM. The outcome is reduced system mass, volume and cost as well as increased system robustness. ro

9 Additive Manufacturing collaboration projects Innovate UK - SLaME The SLaME project is exploiting Selective Laser Melting (SLM), to design and build innovative components for ultra lightweight, efficient vehicle engines. It is developing micro turbine component concepts such as optimised and enhanced injectors and recuperators. SLaME also addresses internal combustion engines (valves, exhaust gas recirculation cooling, exhaust and exhaust manifold cooling, and light weight pistons) and concepts for exhaust energy recovery systems using an innovative scroll engine. Below are a selection of our collaborative projects. Innovate UK - LIGHT Metal Additive Manufacturing (AM) is considered as one of the most important emerging material processing technologies that will drive the future manufacturing industry. The geometric complexity offered by AM, coupled with freedom of tool-less manufacturing, is compelling. However, in practice complete geometrical freedom is constrained by the overhanging sections where supporting structures are required. The use of sacrificial structures is one of major limitations for AM. LIGHT project will implement and validate CAD/CAM solution for lightweight product application which utilises novel self-support low-density cellular lattice structures to efficiently support internal and external overhanging geometries of lightweight products, inspiring and enhancing new design freedoms.

10 Additive Manufacturing collaboration projects Innovate UK - AMAFS The AMAFS project is developing an innovative phase change heat exchanger for use in evaporatively cooled fuel cells for the automotive market. HiETA is leading the project in collaboration with Intelligent Energy, one of the market leaders in the full cell sector, Exeter University and the Logistics Business. Innovate UK - ibranch The ibranch project is developing an innovative heat recovery system for vehicle exhaust gases. Working with Bath University, Axes Design and supported by JLR the two year project aims to to develop a solution by exploiting the benefits of Additive Manufacturing which will present a quick and practical route to implementation.