Concept Laser Industry Specific Solutions

Transcription

1 Concept Laser Industry Specific Solutions Advantages of the LaserCUSING process Aerospace Front End Software/ - interfaces Machine solutions Materials QM system Post treatment Case studies Seite 1 Hofmann Innovation Group

2 Individual solutions for aerospace industry Pre-series development: Components of an engine casing Complex, thin-walled structures in gas turbines Series production: Small light-weight components for an aircraft interior Small and complex components made of titanium alloy Seite 2 Hofmann Innovation Group

3 LaserCUSING provides Tool less manufacturing of components within only a few days (Manufacturing 24 h/ day) Manufacturing of small prototypes over night Components made of original material with corresponding material characteristics Wind tunnel tests immediate after the manufacturing process possible Saving waiting times reduction of the development time Seite 3 Hofmann Innovation Group

4 LaserCUSING Manufacturing process Seite 4 Hofmann Innovation Group

5 Front End software/ - interfaces 3D/CAD-design software CATIA/ Pro-Engineer/ AutoCAD/ Unigraphics Magics software (Materialise) Preparation of the data (create support structures, afterwards slicing of the data) LaserCUSING system Seite 5 Hofmann Innovation Group

6 Machine solutions M1 cusing Target group: Small components Build envelope: 250 x 250 x 250 mm Laser system: 200 Watt fibre laser M2 cusing Target group: Processing aluminium and titanium alloys Build envelope: 250 x 250 x 280 mm Laser system: watt fibre laser Seite 6 Hofmann Innovation Group

7 LaserCUSING materials CL 20ES (1.4404) / stainless steel Stainless steel for technical prototypes and small series production Acid and corrosion resistant CL 31AL (AlSi10Mg) / aluminium alloy Low weight For technical prototypes and small series production Quelle: DAe Systems GmbH CL 40TI ELI (TiAl6V4 ELI) / titanium alloy Titanium alloy for high performance prototypes and small series CL 100NB (Inconel 718) / nickel based alloy Nickel based alloy for aerospace components Heat resistant Seite 7 Hofmann Innovation Group

8 Technology QM system Real-time inspection of the melt pool Online laser and performance monitoring Software module for analysis and report generating after the build process Redundant monitoring and control of the oxygen concentration in the process gas atmosphere Analysis of the powder quality and excellent preservation of the powder quality with our external automatic sieving station Seite 8 Hofmann Innovation Group

9 Post- treatment Quelle: Laser Zentrum Nord GmbH Technische Universität Hamburg- Harburg Heat-treatment Microblasting/ shoot peening Conventional machining, like CNC milling Electrolytic polishing Vibratory grinding Seite 9 Hofmann Innovation Group

10 Case study 1: Component for an auxiliary oxygen supply system Aircraft: Customer Units: Eurofighter Typhoon BAe Systems GmbH approx. 100 per year Quelle: Requirements on the component: Withhold 200 bar operating pressure without leakage Withhold a burst pressure of 400 bar Seite 10 Hofmann Innovation Group

11 Case study 1: Component for an auxiliary oxygen supply system Conventional production process: Quelle: inner tunnel which has a 90 corner delamination of gas flow Conventional produced out of single tubes which have been welded together in a semiautomatic orbital welding process Quality problems concerning leakage Quelle: DAe Systems GmbH Seite 11 Hofmann Innovation Group

12 Case study 1: Component for an auxiliary oxygen supply system Additive manufacturing: Quelle: Machine: M3 linear Laser: Fibre laser 200 W Material: CL 20ES (1.4404/ 316L) Application: Small series production Customer: BAe Systems GmbH Design of the modified part for LaserCUSING process: Integration of all functions in one component, no assembly and joining processes required Internal tunnel has been modified (radius) to allow a steady gas flow without any delamination Quelle: BAe Systems GmbH Seite 12 Hofmann Innovation Group

13 Case study 1: Component for an auxiliary oxygen supply system Post-treatment after LaserCUSING process Quelle: Elimination of powder out of the internal channel Removal from the build platform Elimination of support structure Machining of interface and sealing surfaces Thermal flash removal Surface chromatisation Seite 13 Hofmann Innovation Group

14 Case study 1: Component for an auxiliary oxygen supply system Advantages due to LaserCUSING - technology Quelle: Reduction of the reject rate due to the elimination of leakage Reduction of the production time Reduction of the production costs Seite 14 Hofmann Innovation Group

15 Case study 2: Bionic brackets for connecting the outer shell of the aircraft to the passenger cabin Manufacturing system: Laser system: Material: Customer: M2 cusing Fibre laser 200 W CL 40TI ELI (TiAl6V4 ELI) Laser Zentrum Nord GmbH Technische Universität Hamburg-Harburg Advantages of the laser-generated component: Lightweight natural construction solutions can be generated almost 1:1 using generative LaserCUSING. Quelle: Laser Zentrum Nord GmbH Technische Universität Hamburg- Harburg The laser-generated component with an optimised structure delivers a weight saving of up to 50% compared with the component produced by conventional means! Seite 15 Hofmann Innovation Group

16 Thank you for your attention! For further question, please feel free to contact us. Mr. Oliver Edelmann Head of Sales & Marketing Concept Laser GmbH An der Zeil 8 D Lichtenfels T +49 (0) 9571 / F +49 (0) 9571 / Seite 16 Hofmann Innovation Group