Additive Manufacturing for DoD Applications Ship Design & Materials Technologies Panel Meeting

Transcription

1 Additive Manufacturing for DoD Applications Ship Design & Materials Technologies Panel Meeting Mr. Rob Akans Senior Director, Metalworking Technologies Navy Metalworking Center (NMC) Technical Director 1

2 Background on CTC Established in 1987 Originally Metalworking Technology Inc. (MTI), a subsidiary of the University of Pittsburgh Trust Adopted the name Concurrent Technologies Corporation (CTC) in 1992 Separated from the University of Pittsburgh Trust in 1994 An independent, nonprofit, applied scientific research and development professional services organization ~ $200M in yearly revenues Staff of approximately 850 dedicated professionals Approximately 40 locations 2

3 Our Areas of Expertise Our reach is broad; our areas of expertise, diverse. Advanced Engineering & Manufacturing Information Technology Solutions Education & Training Intelligence Solutions Energy & Environment Logistics Environment, Safety & Occupational Health Special Missions Our strengths are derived from a broad continuum of capabilities including materials science; engineering; systems engineering; design & development; test & evaluation; and information technology & management. 3

4 Navy Metalworking Center An ONR ManTech Center of Excellence since 1988 Supports the Navy s mission to reduce total ownership cost by developing and optimizing metalworking and manufacturing processes Primary Focus: Implementation of technology in the U.S. industrial base Extensively uses Integrated Project Teams, comprised of government and industry entities

5 Naval Problem PMs are facing: total ownership costs and platform availability due to an number of part challenges including: 1. Very long Mean Logistics Delay Time for limited production parts. 2. High cost for limited production runs to make problem parts; many of those are cast components. May include large investments to create special tooling and complex castings. 3. Lack of commercial interest in low volume complex fabrication work and significant delays in contracting and workflow. 4. Increasing pressure on organic manufacturing capability. 5. Higher failure rates; new failure modes; exigent parts demand for critical components 6. Systems down/deadlined for part obsolescence issues; decreasing vendor supply base 7. Ageing fleets with severe parts supply issues. Examples: Amphibious Assault Vehicle will be 51 years old at the end of service life, leading to increase in components that fail that were never expected to be repaired or replaced Depots and ship repair facilities are increasingly making parts to combat these challenges and need new technologies for reliable & cost effective production of low volume parts. 5

6 Bottom Line Up Front Additive Manufacturing has great potential to impact the DoD across many platforms and applications More research, careful implementation, and qualification & certification is needed to gain confidence in additive manufacturing DoD is working with academia, industry, and across government organizations to mature AM Material performance design and engineering of AM parts materials not being addressed by industry (i.e., steel alloys, chem-bio resistant polymers, etc) Machine performance Identifying, improving and documenting key process parameters to enable qualification and certification of AM Digital Product Data: establishing digital product data as the authoritative source for product data verification and validation of model quality and data prior to manufacturing process. Need to intelligently accelerate AM design loop & thoroughly understand process to build confidence in AM & increase quality. This enables wider use of AM for Naval applications. 6

7 CTC s Role in AM Our People ~ 25 years of designing, developing, evaluating, qualifying, and transitioning manufacturing solutions Testing and Analysis Infrastructure Equipment (SLM and FDM in house) Targeted and Ongoing Internal and External Efforts Part Identification Reverse Engineering/Solid Modeling Part Manufacturing Performance/Mechanical Testing and Qualification Part Authentication/Cyber Security Equipment Selection and Transition Non Destruction Inspection Techniques for AM Secondary Process of AM Components IRAD s and other activities in progress America Makes - National Additive Manufacturing Innovation Institute (formerly known as NAMII) Governing Board member 7

8 Testing and Analysis Infrastructure for AM Metallurgical Analysis and Mechanical Testing Supplemental Equipment Faro Scanner Tensile/ Compression Furnace MTS Tensile/ Compression Machine Hardness Drop Tower Stress Corrosion Testing Microhardness Impact Testing SEM Metallography- Digital Imagery Large FSW machine is ideal for process development, prototyping & fabrication of large structures 8

9 Additive Manufacturing Equipment SLM 280 HL 280 x 280 x 350 mm (11 x 11 x 14 inch) build chamber 400W IR Fiber Laser Automated layer control system Real-time laser power display & monitoring 500 C Heated Build Plate Versatile, upgradable Materials: Stainless Steel Tool Steel Cobalt-Chromium Aluminum Titanium Inconel Stratasys Fused Deposition Modeling (FDM) Vantage SE Envelope size: 16 W x 14 D x 16 H Materials: PC, PC/ABS, ABS, and ABSi Three tip sizes (.005,.007, and.010 ) range of detail or run time 9

10 AM Solutions for the DoD America Makes Special Project (AFRL/RXMS) ~ Laser Powder Directed Energy Deposition (LPDED) for Repair Team: Leaders: Optomec (prime); CTC; Advanced Research Laboratory at Pennsylvania State University (PSU); Connecticut Center for Advanced Technology (CCAT); Edison Welding Institute (EWI); TechSolve Primary Technical Support: General Electric Aviation (GE); Lockheed Martin (LM); United Technologies Research Center (UTRC) Contributors: M-7 Technologies (M-7); Missouri University of Science and Technology (MS&T); Rolls Royce Corporation (RR); Stratonics; University of Connecticut (Uconn); Wolf Robotics; various powder suppliers Alternates: Univ of Louisville; Texas A&M; South Dakota School of Mines Objectives: Develop guidelines on optimum powder feedstock characteristics for high part quality Conduct improvements in process monitoring and control Develop design allowables and guides (Lead: CTC) Recommend Air Force (AF) part repair and sustainment applications (Lead: CTC) Materials: Ti-6Al-4V POP: July 2014 September 2016 Turbine Support Bearing Housing, After LENS Repair 10

11 LPDED System Overview Standard LENS 850R Features 900mm x 1500mm x 900mm process area Class 1 laser enclosure, hermetically sealed 5 axis motion control X,Y,Z with tilt & rotate table Gas purification system maintains O2 < 10ppm 2 or more powder feeders 380 mm diameter ante chamber 1kW to 10kW IPG Fiber Laser Benefits Can add features or repair material to a pre-existing structure Microstructure and material property control (e.g., grain size) Multi-material gradient capabilities (layer-to-layer & in-layer) Builds relatively large, complex geometries Minimal effect on substrate microstructure (small HAZ) In Development: Modular System for Larger Components 11

12 LPDED Materials Alloy Class Alloy Alloy Class Alloy Titanium Nickel CP Ti Tool Steel H13, S7 Ti , 17-4 Stainless Ti , 316 Steel IN , 420 IN718 Aluminum 4047 Waspalloy Cobalt Stellite 6, 21 Rene 41 Carbide Ni-WC Co-WC Alloy Class Alloy Alloy Class Alloy Titanium Nickel Materials Used Commercially Materials Used in R&D Ti Tool Steel A-2 Ti PH Stainless Ti 22Al-23Nb AM355 Steel IN , 416 Hastelloy X MarM 247 Copper GRCop-84 Cu-Ni Rene 142 Refractories W, Mo, Nb Ceramics Alumina Composites TiC, CrC 12

13 AM Solutions for the DoD Navy Metalworking Center (NMC) Non-Destructive Inspection (NDI) for Electron-Beam Additive Manufacturing (EBAM) of Titanium Team: NMC (CTC); AFRL; Lockheed Martin Aeronautics; Sciaky, Inc. Objectives: Implement EBAM material in place of titanium (Ti) forgings to reduce lead time and cost reductions wrt Ti die forgings and machined structures Validate NDI methods Assess capability of NDI methods (detect expected EBAM defect types) Quantify effects on detection capability (surface finish and heat treatment) Materials: Ti-6Al-4V Inspection Methods Considered/Evaluated Bulk: conventional ultrasonic inspection (UT); phased-array ultrasound (PAUT); film X-ray radiographic testing (RT); X-ray computed tomography (CT) Surface: fluorescent penetrant inspection (FPI); eddy current POP: October April 2015 Photo Courtesy of Sciaky Approved for public release; distribution is unlimited 13

14 The EBDM Process Wire-fed (1/8 dia) feed stock Electron beam (EB) heat source Alloys processed Titanium Tantalum Inconel Others Present focus Ti-6Al-4V Photo courtesy of Sciaky Illustration courtesy of Sciaky

15 Highest Payoff Applications In-situ melt pool measurement Typical bead size: 0.12 deep x 0.5 wide High deposition rates 10+ lbs/hr Consistent material properties have been demonstrated Up to 60% reduction in production cost Aerospace structural components Bulk of details machined from substrate plate Use EBDM to build up remaining details Thin, long and/or wide parts with protruding features Lugs Bosses Webs Photos courtesy of Sciaky

16 Part Inspection No standards currently defined for NDI of EBDM parts Must inspect specific areas of fracture critical aerospace components Limits of inspection technologies uncertain for this product form Focus: understand inspection limits and begin to prepare standards for inspection of EBDM builds

17 Test Approach Build geometry Simple shapes (rectangular, step, F-shape) Chunky section Prototype flaperon spar Seed defects of different type, size, location and orientation Mechanically introduced Flat-bottom holes (FBHs) Side-drilled holes (SDHs) Wire EDM slots Sinker EDM notches Intentional non-standard process anomalies Inspect Excessive gaps between neighboring beads Starts and stops Contaminants (vacuum oil, copper shavings or aluminum oxide flakes) Inclusions Low vacuum (air or excess helium added) NDI Destructive (Metallography)

18 Simple-Shaped Test Coupons Test Coupon A: as-received Vacuum Oil Test Coupon B: defects Aluminum Copper Condensate Filings Oxidized Surface Test Coupon D: finish build Test Coupon A: machined Test Coupon C: contaminants CTC photos Coupons ready for NDI

19 Prototype Flaperon Spar Part intentionally cut into two pieces to facilitate NDI Rough machined and introduced FBHs and sinker EDM cuts Currently undergoing CT inspection Early indications are positive Challenge in penetrating thick build features Will also CT inspect machined version of part CTC photos

20 Preliminary Results Conventional UT Inspection Capability 3/64 FBH detectability limits Thickness < 3 as deposited Thickness < 1 Beta annealed Surface roughness impact on UT signal attenuation 125 µin RMS: acceptable 250 µin RMS: unacceptable FPI procedure used for wrought products acceptable Radiography affected by section thickness Ineffective beyond 3 section thickness; further assessment required Limits inspectability of thick sections of preforms CT shows promise as acceptable inspection method (more work needed)

21 Conclusions UT inspection of EBDM builds are limited by banded microstructure of deposit Most pronounced after Beta heat treatment Viable inspection methods include - UT in as-deposited condition Radiography (RT) for sections sizes under 3 * FPI CT is currently undergoing evaluation * Note: Analysis is still ongoing

22 National Additive Manufacturing Innovation Institute National Institute of Standards and Technology (NIST) Project: Measurement Science Innovation Program for Additive Manufacturing Develop and validate NDE techniques for postmanufacturing inspection of laser powder bed fusion (L-PBF) components. Evaluate and mature inprocess sensing techniques on a L-PBF Sensor Test Bed to: Enable quality monitoring Address technical gaps in post process NDI Create a 3D Quality Certificate (3DQC) for each manufactured part using run-time process monitoring data indexed to part geometry.

23 AM Solutions for the DoD and Industry NIST Measurement Science Innovation Program for AM (cont) Non-Destructive Evaluation (NDE) Techniques for Post-Manufacturing Inspection of Laser Powder Bed Fusion (L-PBF) Components Team: CTC; NCSU; G.E. Aviation Objective: develop and validate NDE techniques for post-manufacturing inspection of L-PBF components Determine reliable means to seed flaws in simple L-PBF parts Quantify capability of NDE methods to detect seeded flaws UT, RT, CT, others TBD Apply knowledge to inspect complex parts with seeded flaws Material: Ti-6Al-4V CTC efforts: Planning of experimental validations Determining types/location of seeded defects Identifying and supporting NDE testing Machining POP: October September 2015 (POP in progress to Spring 2016) 23

24 AM Solutions for the DoD and Industry America Makes Electron Beam Melted (EBM) Ti-6Al-4V AM Demonstration and Allowables Development Northrop Grumman Prime Team: CTC; CalRAM Inc.; Robert C. Byrd Institute Objectives: Build full-scale, post-process surface finished demonstration parts Develop set of B-Basis Design Allowables database at defined thicknesses and build parameters Recommend and evaluate NDI methods for inspection of full-scale, post-process surface finished demonstration parts Material: Ti-6Al-4V CTC efforts: Mechanical and environmental testing Assess potential NDI methodologies for the inspection of EBM components (leverage NIST Program - Measurement Science Innovation Program for Additive Manufacturing) POP: October 2014 to March

25 Summary Additive Manufacturing has great potential to impact the DoD across many platforms and applications DoD is working with academia, industry, and across government organizations to mature AM Material performance Machine performance Digital Product Data AM has applications for shipbuilding and ship repair to Reduce lead time and increase availability for small production runs Mass customization and enabling geometric complexity Weight reduction via part consolidation/material substitution Need to intelligently accelerate AM design loop & thoroughly understand process to build confidence in AM & increase quality. This enables wider use of AM for Naval applications. What are your applications and how can we help? 25

26 Contact Information Mr. Rob Akans Senior Director, Metalworking Technologies NMC Technical Director Office phone: (703) Mobile: (814) Ms. Georgette Nelson Senior Director, Advanced Engineering and Sustainable Manufacturing Additive Manufacturing Market Lead Office phone: (412) Mobile: (412) Mr. Kenneth Sabo Senior Director, Advanced Concepts Additive Manufacturing Platform Lead Office phone: (814) Mobile: (814) CTC Proprietary 26

27 Backup Slides 27

28 What is Additive Manufacturing? Any process that can make three dimensional (3D) solid objects from a digital model, or build-up controlled 3D features onto an existing object, typically layer by layer. Supplemental Areas: Rapid Prototyping (RP): the physical modeling of a design using a special class of machine technology Rapid Tooling (RT): the production of tooling directly from an RP process 28

29 AM Benefits & Challenges Benefits Low quantity requirements (no tooling, setup, etc.) Difficult to manufacture parts (internal passages, etc.) Fast delivery (when compared to ordering parts) Excellent for doing what if scenarios, prototypes, research, testing, etc. Challenges Qualifying systems and materials Consistency across parts Determine when to use AM (cost and logistics) New thought process in designing for AM Heat treating, material finish, hot isostatic pressing, etc. Excellent for one of solutions, like the medical/dental industry (crowns, hip joints, skull/bone attachments) Real-time feedback Machine reliability Prices of metal AM machines and materials 29

30 Metal Processes Powder bed sintering (Laser) EOS), Concept Laser, Renishaw, SLM, Realizer, 3D systems (formerly Phenix) Powder bed sintering (Electron Beam) ~ Arcam Powder bed w jetted binder ~ ExOne, Voxeljet, Digital Metal (formerly Fcubic) Laser powder injection (Directed Energy) Optomec, Irepa, DM3D (formerly POM), Accufusion, Trumpf Wire fed electron beam ~ Sciaky Ultrasonic welding of foils ~ Fabrisonic Plastic Processes Background on AM Equipment SLS (EOS and 3D Systems), Fused Deposition (Stratasys), Stereo Lithography (3D Systems), Material Jetting (Stratasys and 3D Systems) 30

31 Metal AM: Powder Bed, Laser and EB Sintering ARCAM envelope, ~8 x 8 x 7 cube EOS envelope, ~10 x 10 x 13 cube Laser systems are typically in an inert atmosphere (nitrogen/argon gas) Arcam (EB system) is operated at an elevated temperatures and in a vacuum (supposedly helps with residual stress) EOS Materials: AlSi10Mg, CobaltChrome MP1/SP2, MaragingSteel MS1, NickelAlloy IN625/IN718, StainlessGP1,/PH1, Titanium Ti64 The EOS M 280Q10 is the new generation Laser system machine equipped with either a 200W or 400W laser. The Arcam Q10 is the new generation EBM machine is designed for industrial production of orthopedic implants. A2 is for the Aerospace Industry. 31

32 Metal AM: Wirefed Electron Beam Electronbeam wirefed action forms a molten pool to build parts in a layerwise fashion. Sciaky Materials: Titanium, Tantalum, Inconel, and Stainless Sciaky, EB Welding Net Shape ~19 x 4 X 4 cube 32

33 Metal AM Powder Bed Inkjetting and Sintering (EXONE) EXONE system stages, print binder, cure, depowder, sinter, infiltration, annealing, and finishing. EXONE, Net Shape on the M-Flex ~16 x 10 X 10 cube EXONE Materials: 316 Stainless Steel/Bronze 420 Stainless Steel/Bronze (Annealed & Non-Annealed) Bronze 33

34 Metal AM Directed Energy Deposition Directed energy systems use high power laser to melt powder into a molten pool to build or repair parts in a layerwise fashion. LENS Materials: Various Titanium's, Nickel, and Cobalt OPTOMEC, Laser Engineered Net Shape (LENS) Net Shape ~35 x 59 X 35 cube 34

35 1-800-CTC