Additive Manufacturing and 3D Printing LENS Technology

Transcription

1 Additive Manufacturing and 3D Printing LENS Technology ADDITIVE MANUFACTURING OF METAL COMPONENTS CONFERENCE AT IK4-LORTEK NOV. 27 th, 2013 Presented by: Matej Balažic -Manager Engineering & Applications EFESTO LLC MI, USA W: E:

2 LASER ENGINEERED NET SHAPING Your Logo The LENS 3D printer can process a wide variety of metals including titanium, nickel-base super alloys, stainless steels and tool steels - all of which are commercially available in the required powder form. The results from LENS consistently demonstrate better metallurgical and mechanical properties than other processes due to an improved microstructure.

3 Who is Efesto? Hephaestus, the God of Metallurgy, Sculpture, Engineering, Technology and Fire. The name is derived from and inspired by EFESTO High energy enterprise focused on 3D Metal Printing Solutions Active in Europe, Asia Pacific, Russia, and Americas Very close business partnership with Optomec Inc. Global leader on industrializing Laser Metal Deposition (Blown Powder Laser Deposition) technology and applications Visionary team of industry thought leaders & business professionals Modular systems, diverse applications in repair, hybrid manufacturing, Prototyping, materials R&D Targeting all key industrial segments + academia Plan Aggressive organic and acquisitive growth Plan Dedicated repair/prototyping/service bureaus with joint venture partners Plan Deliver more than 200 LMD standard and custom engineered systems by 2018 Primary Mission Delight Its Customers! Your Logo 3 2

4 Efesto Primary Focus and Markets INDUSTRIES Truly Global Footprint Aviation Defense Army, Navy, Air Force, R&D Oil and Gas/Energy Tooling/Die and Mould Academia advanced R&D including Bio-Medical Mining and Construction Space (Launchers and Satellites) Automotive APPLICATIONS Value Addition to Conventional as well as to Additive Manufacturing MRO maintenance, repair and overhaul Hybrid manufacturing, remanufacturing, redesign Gradient metals, multi-alloy, alloy discovery Prototyping medium and large sizes Advanced materials R&D Education and training 4 3

5 POSSIBLY THE LARGEST 3D PRINTED PARTS MADE TODAY Keep in mind, building such parts can cost > $ 100,000, and what if: A mistake is made near the end of the process A small feature needs to be changed once part is made The part needs to be made of several dis-similar metals 5 4

6 POSSIBLY THE LARGEST 3D PRINTED PARTS MADE TODAY Keep in mind, building such parts can cost > $ 100,000, and what if: A mistake is made near the end of the process A small feature needs to be changed once part is made The part needs to be made of several dis-similar metals 6 5

7 THIS COULD BE A REALITY TOMORROW 7 6

8 Spain: Efesto represenatative Slovenia: 7

9 Slovenian LENS Instalation (Optomec 850R) LENS IN INDUSTRIAL ENVIRONMENT, DIFFERENT TOOL APPLICATIONS 9 8

10 The LENS Process Schematic Courtesy Optomec Inc. All Rights Reserved 1 0 9

11 LENS 450 System EDUCATION, R&D, SMALL FABRICATION/REPAIRS Standard LENS 450 Features 100mm x 100mm x 100mm process work area 400W IPG Fiber Laser Class 1 laser enclosure, hermetically sealed 3 axis motion control X,Y,Z Single powder feeder CE Certification available Courtesy Optomec Inc. All Rights Reserved

12 LENS MR-7 System R&D, MEDIUM SIZE FABRICATION/REPAIRS Standard LENS MR-7 Features 300mm x 300mm x 300mm process work area 500W IPG Fiber Laser Class 1 laser enclosure, hermetically sealed 3 axis motion control X,Y,Z Gas purification system maintains O2 < 10ppm Dual powder feeders with gradient capability 380 mm diameter ante chamber CE Certification available Courtesy Optomec Inc. All Rights Reserved

13 LENS 850R System LARGER FABRICATIONS/REPAIR,& HIGH POWER Standard LENS 850R Features 900mm x 1500mm x 900mm process work 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 powder feeders 380 mm ante chamber 1kW IPG Fiber Laser Courtesy Optomec Inc. All Rights Reserved

14 Product Description DESIGN LENS PROCESS PART 3D CAD Model Convert to STL file Tool path generation Multi Nozzle Powder Delivery Metal Powder melted by Laser Layer by layer part build/repair Up to 7 Axes range of motion Closed Loop Controls Controlled Atmosphere (<10ppm O2) Near Net Shape Fully Functional! Courtesy Optomec Inc. All Rights Reserved

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16 Examples 1. APU AND OTHER SYSTEM/ENGINE ACCESSORIES 2. JET ENGINE AND ITS SUBPARTS 3. FUSELAGE COMPONENTS 1 4. UNDERCARRIAGE

17 Examples Repair Process used by MTU including Electron Beam Welding Aerospace Tools for Hydroforming Produced in EMO/TIC-LENS; EADS A320 fuselage components

18 ADVANTAGES AND APLICATIONS Advantages: Near Net Shape Thin Layers/Less Weld Clean-up Low Heat Input/less part distortion Automated process / Precision control Small heat effected zone/low dilution Simple Low Cost Tooling/Fixture Shorter remanufacturing time Cost saving Applications: Blade tip repair and build-up Seal replacement and build-up Knife edge seals Unlimited alloys

19 LENS BENEFITS FOR REPAIR Small Heat Affected Zone (HAZ) Less heat input Less distortion Less propensity to crack Excellent density & adhesion Minimal effect on the component Powder Fusion has better integrity than welding LENS allows re-commission of parts deemed non-repairable via other processes. LENS Deposit Weld Deposit Courtesy of Optomec Inc. All Rights Reserved

20 LENS AS PART OF MANUFACTURING PROCESS Side/contact surfaces of the Jet Engine Turbine Assembly have to provide bigger wear resistance which is achieved by Stellite 6 and Stellite 12 material. Stellite material (4-5mm which wire) is manually welded to parts (T.I.G.) To achieve final dimension and geometry tolerances parts have to be finished (grinded). Due to removal of a large hard material quantity, grinding wheels wear extensively. LENS technology has been introduced to provide greater Near Net Shape of cladded Stellite layers, faster machining times, lower manufacturing costs and higher level of the process automation

21 LENS USE FOR REPAIR AIRFOILS Leading Edge Repair Scratch Repair Tip Repair and Coating Case Study: Ti Airfoil Repair Tip Repair Leading Edge Repair Surface defect (scratch) repair Time for Tip Repair Set-up and toolpath <1 minute Deposition 30 seconds for 2.5mm tall repair

22 Free form Application Critical Component Repair General Electrics CF34-3B Effective and time-saving repair process of jet engine compressor parts (dented blades) 5th compressor stage blade (Ti 6-4), 10th compressor stage (Inconel 718). Reduce repair times up to 50%* Reduced repair costs up to 30%* Total costs of repair regarding to new part price: 13% Ti 6-4 (300 EUR new part / 40 EUR LENS repair) 42% Inconel 718 (200 EUR new part / 80 EUR LENS repair) *(regarding to wire surface welding process) LENS system from Optomec Ti and Ni (Inconel) powder material of adequate quality Dented Blades 22

23 Material Structure CAD model 5th stage blade LENS cladding Ti6-4 powder Material structure-core Material structure LENS cladded layers CAD model 10th stage blade LENS cladding Inconel 718 powder Material structure-core Material structure LENS cladded layers

24 CERTIFICATION PROCESS In order to use specific Repair or Manufacture Process all needed approvals has to be given by Engine/Aircraft Manufacturer and appropriate State Authority. Engine/Aircraft Manufacturer has to evaluate proposed technology with its internal standards. This can lasts from few months in case of simple parts/components till few years in case of important components. Some Repair work of non-flying components can be done by authorized MRO (Maintenance and Repair Organization) without approval of the Manufacturer. Efesto/Balmar has established strong relations with Engine/Aircraft Manufacturers and regional MROs worldwide in order to support them at LENS technology implementation

25 REPAIR AND MAINTENANCE IN JET ENGINE SECTION-MRO Engine Casing/Surface Forms Repair Disk Surface Wear Repair Blades Repair and Surface Improvement

26 THE LENS PROCESS PROTOTYPING OF NOVEL DESIGN Bell Helicopter Mixer (Ti-6-4) 9 weeks classic manufacture ; LENS 3 weeks Rapid Prototype (Fully Functional) Unmanned Combat Armed Rotorcraft (UCAR) Courtesy of Optomec Inc. All Rights Reserved

27 LENS Application Examples Ti 6-4 Dual Wall Duct JSF Engine Proof-of-Concept LENS Article 10 cm Dia. Base, 25 cm Dia. Top x 10 cm Tall Courtesy of Optomec Inc. All Rights Reserved

28 Inconel Freeform Build Too large to build in most contemporary SLM/SLS machines Inconel Laser Freeform 24 tall x 24 long Courtesy of RPM Innovations Inc. All Rights Reserved

29 Inconel Freeform Build too large to build in most contemporary SLM/SLS machines Inconel 625 Freeform approximately 17 OD. Courtesy of RPM Innovations Inc. All Rights Reserved

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31 SOME FACTS ABOUT SPACE PRODUCTS To send 1kg of Space Vehicle or Satellite or any other product into Orbit it costs USD $ To send 1kg of Space Vehicle or Satellite or any other product to the Moon it costs USD $ (x 10) To send 1kg of Space Vehicle or Satellite or any other product to the Mars or any other near planet it would cost 1kg = 1kg of Diamonds. International Space Station (ISS) weights kg For all space applications it is known 1 EUR investment brings back 7 EUR benefit. Weight of Space Products is very important. Reduction of weight at same performance characteristics can be achieved by AM technologies like LENS technology

32 From Invention to Product Innovation

33 USAGE OF LENS FOR SPACE APPLICATIONS Direct from CAD to part no tooling required Superior material properties full functionality (Novel Microstructures) Near-net-shape build or repair minimal finishing Single-step process reduced time and cost (Time Compression) Low heat input low distortion and heat-affected-zone Closed loop for precision deposition control High efficiency lasers for reduced cost of ownership Novel 3D Shapes Functional Gradients Simplified Supply Chain Manufacturing Agility High level of Technology Readiness

34 SPACE APPLICATIONS - Satellite structures, solar panels, on-ground equipment Design, development, manufacturing and qualification of high performance satellite structures (good volume/weight ratio), Introduction of Function-gradient metal materials and shape effect into the structure, Light and high performance solar panels housing, Advanced method of metal elements joining

35 Prototyping and Manufacture of Specials Components for Satellites Support Elements for Antennas Joint Elements Support Elements for Solar Panels Thruster Nozzles Housing Panels Satellite Housing

36 SPACE APPLICATIONS - Satellite structures, solar panels, on-ground equipment Advanced Nozzles shapes for exhaust systems (rocket engine), Advanced cooling channels for rocket engine, Prototyping of advanced rotor (impeller) for cooling liquid in the rocket engine, Introduction of Function-gradient metal materials and shape effect into the launcher structure, Reducing weight of the launcher for 20% or more, Effective and advanced repair of existent space vehicles and launchers, Introduction of special additional protective coatings for the structure Prototyping of novel elements with laser manufacturing technology supports new concepts of space vehicles and engine propulsions

37 Development, Prototyping and Manufacture of Specials Components for Space Launchers Nozzle Elements Elements for Propulsion System Light weight Structures: Diffusion Bonded Titanium Honeycomb Turbine Blades

38 TOPICS THAT WE ARE INTERESTED IN Space technology Critical technology Space robotics Satellite technology Launcher In Space propulsion Small scale satellites Satellite Communication Satellite manufacturing Space Exploration Propulsion system Protection systems (thermal, radiation) Targeted field of cooperation Development, prototyping and manufacture of special components for satellites and space launchers, Production of component prototypes with LENS technology with parallel technology development and optimization, Laser welding of components for satellites and space launchers, Final machining of prototypes and components. Reference in Space projects: ESA/PECS Programme ( ): Project title: Development, Prototyping and Manufacture of special Metal Components for Space Applications with Advanced Laser Technology LENS (LENS FOR SPACE)

39 Your Logo

40 LENS APPLICATION M1ABRAMS TURBINE COMPONENT REPAIR Courtesy Anniston Army Depot

41 LENS APPLICATION M1ABRAMS TURBINE COMPONENT REPAIR Repair Facts: Material: IN718 Engine: AGT1500 LENS Process Advantages: Properties, Low Heat Input, Near Net Shape In Production at Anniston Army Depot, $5M saved in first year Courtesy Anniston Depot Army

42 Labyrinth Seal (Air Seal Restoration) Undersized Air Seals Courtesy Optomec Inc. All Rights Reserved

43 Labyrinth Seal (Air Seal Restoration) Pre- Machine Courtesy Optomec Inc. All Rights Reserved

44 Labyrinth Seal (Air Seal Restoration) LENS Build-Up Courtesy Optomec Inc. All Rights Reserved

45 Labyrinth Seal (Air Seal Restoration) Finished Machined LENS Procedure: Pre-machine undersized air seals. LENS Build-Up utilizing Inconel 718 material. Vacuum heat-treat (Aging). Final machine. Non-Destructive Testing LENS Cycle Time: 60 minutes per part Courtesy Optomec Inc. All Rights Reserved

46 LENS Application Examples MR7 in container) The Mobile Parts Hospital (MPH) is a compact communications and manufacturing unit. It is designed for deployment to remote locations for emergency repair of non-operational equipment. A combination of advanced technologies enables the MPH to quickly and efficiently produce new parts or repair parts on demand. ISO CONTAINER - DEPLOYED BY LAND, SEA OR AIR Courtesy Optomec Inc. All Rights Reserved

47 Ti-6Al-4V Feature Addition To A New Forging Ti-6Al-4V atomizer wheel. Ti-6Al-4V bosses are Laser Free Form Manufactured To reduce forging thickness and machining costs. Final Machined Atomizer Wheel Ti-6Al-4V Boss Added Ti-6Al-4V Boss Added Courtesy RPM Innovations Inc. All Rights Reserved

48 Industrial Applications: Feature Addition Hybrid Manufacturing gives Time Compression & 30% Cost Reduction Tough to cast, long lead time: 52 weeks to cast Hybrid route: machined disk with details added by LENS process Delivery Time: 3 Weeks. Superior Design: reduced weight Design changes implemented during development Electronics Housing in 310SS Courtesy Sandia National Laboratories. All Rights Reserved

49 Dual Thin Wall Cooling Channel Test Part IN625 Freeform Dual Wall Cooling Channel a = b = c = Approximately 0.06 Wall Thickness 10.5 a b c Channel Dimensions Final Deposition Final Deposition Courtesy Optomec Inc. All Rights Reserved

50 Ti-6Al-4V Freeform Geometry Capabilities (too large to build in SLM/SLS) Ti-6Al-4V Laser Freeform 28 inch tall The part shows internal piping various overhangs along with tying in walls to one another Courtesy of RPM Innovations Inc. All Rights Reserved

51 ECS Duct Example Ti-6Al-4V ECS Duct Prototype Utilizing Free Form Manufacturing Drastically Reduces Welds per Conventional Techniques Multi Axis Laser Free Form Manufacturing Finished Part Courtesy of RPM Innovations Inc. All Rights Reserved

52 "Today EFESTO will do what others won't, so that tomorrow our customers can do what others can't" Your Logo