Additive Layer Manufacturing Technologies for Space Applications - Quality Management System in Additive Manufacturing

Transcription

1 UK-CH Bilateral Workshop on Space Technology Additive Layer Manufacturing Technologies for Space Applications - Quality Management System in Additive Manufacturing 31. January 1 st February 2017, Harwell Campus UK A.B. Spierings Head R&D SLM Inspire AG innovation centre for additive manufacturing Switzerland

2 Who is inspire? ETH Zurich St.Gallen, icams Technopark Zurich, Headquaters Fields of activity / institutes - Iwf-processes: Grinding, Cutting, EDM, - Iwf-machines: Machine Tools, Simulation, Analysis, Improvements - Iwf-micromachining: Laser- & mikrofabrication - icams: Additive Manufacturing (SLS, SLM) - Ipdz: Construction & Design - Ics: Composite-Structures - Icmi: Material integrity - Ifa: Automation, Optimisation, Mechatronic - Ivp: Virtual production / Forming technology

3 Inspire R&D focus in SLS & SLM Quality management systems Processes Applications Industry requirements Materials Industrial applications Machines Standardisation ASTM-ISO

4 Additive Manufacturing in space and general industry applications 4

5 Introduction AM: Many opportunities esp. in space Brackets Waveguides & Filters Antennas Manifold systems Heat panels / pipes Monts etc. Baffles Emissivity designs Ref to ESA-Project: «System impact of additive manufacturing technologies design features (AO/1-8005/14/NL/MV) 5

6 Introduction High quality requirements in sectors such as Space Aerospace Turbine industry Medical Automotive Flight crew rest compartment bracket installed on A350 Topology optimized bike front (inspire) Aluminium space frame Audi A2 As-built and polished turbine blade (Morris Technologies) Aluminium cube-sat parts, source: inspire / SSC Topologically optimized antenna bracket for Sentinel satellites (RUAG) 6

7 Quality Management System in Additive Manufacturing 7

8 What is quality in AM? Quality parameter Sub-property values Ideal quality goal Typical technical values Material integrity - Material density - Number / amount of defects, e.g. total crack lengths e.g. per mm 2 cross-section 100% dense Crack free > 99.5% max. total crack length per mm 2 and/or max. crack length Mechanical properties - Ultimate strength R m - Yield strength R P0.2 - Elastic modulus E - Fracture toughness Comparable or outperforming conventionally processed materials Free of anisotropy Material- and machine dependent - Microstructural integrity - Grain size distribution - Grain orientation Homogeneous grain sizes, no texture Ideal grain misorientation distribution Columnar grains Grain texture in build (z-) direction Surface properties - Roughness R a, R Z / S a, S Z Roughness as low as possible Rough surface qualities with R z m, dependent on powder, processing window and part orientation AlSi10Mg (Buchbinder, 2014) Dimensional tolerances - Parallelism of planes - x-, y- and z-dimensions As engineered / according to CAD Typical deviations in the range of 0.1mm Many quality parameters! 8

9 Quality management system SLM-processing chain From powder raw material to the final part Influencing factors in all sub-processes Cross-influences between processing steps 9

10 Influencing factors in the AM-process chain Example: Alloy composition Example: Powder properties 10

11 Influencing factors in the AM-process chain Example: AM-processing conditions / window The processing conditions influence the material microstructure, and finally mechanical properties «Master forming process» 11

12 State of the art in AM-quality management No quantitative standards Flowability: Conv. methods do not fit Powder qualification Particle size distribuiton Flowability Ref. Spierings (2015) Melt pool monitoring Powder layer quality Process qualifica -tion No information about final part quality For (future) feedback control No quantitative standards Complex machines Maschine qualificati on Atomsphere Laser Cleanliness Photo diode signal of the QM-meltpool monitoring solution of ConceptLaser CT scanning Conv. Part finishing Part qualification Costly Time consuming CT-scan for an Al-space part (inspire) 12

13 Conclusion: An AM-quality management system across the whole AM-process chain with defined parameters in all sub-processes measured quantitatively monitored over each build job / during the build job with defined quality gates between sub-processes Quality control chart for a certain parameter In order to Get insight into dependencies / correlations Directly qualify an AM-part after production Guaranteeing a certain quality level / -level for a given application Reproducibility Repeatability Derive appropriate standards 13

14 AM-quality management system = our main Inspire 14

15 Conclusions A comprehensive AM-quality management system is (compleatly) missing Inspire is therefor focussing on QM-management systems by addressing the whole AM-processing chain Materials Processes Machines Applications We are pushing this topic on a national & international level 15

16 Thank you for your attention Insight into inspire-icams 3 x SLM-machines 4 x SLS-machines Adriaan B. Spierings Head R&D SLM Lerchenfeldstrasse St.Gallen spierings@inspire.ethz.ch Fully equiped analyse and R&D lab, with 1 own developed open R&D SLM machine 16