Challenges for Metallic 3D-Printed Parts. Do we want to print a plane?

Transcription

1 Challenges for Metallic 3D-Printed Parts Do we want to print a plane? by Emiel Amsterdam, Gerrit Kool Aerospace Vehicles Division, Department Gas turbines & Structural Integrity Forum on Tracking Detector Mechanics June 2015, Amsterdam Science Park Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR

2 National Aerospace Laboratory - NLR The national knowledge centre in the Netherlands for aerospace research and technology Provision of ready-to-use technology for innovative products and services All stages in product life cycle 700 personnel, 2 locations in the Netherlands High-quality Research, Development, Test and Evaluation facilities Mission NLR s mission is to make air transport and space exploration safer, more sustainable and more efficient. The organisation s activities are relevant to society, marketoriented and undertaken on a non-profit basis. To support the national industry and SMEs in developing innovative and competitive products in the field of aerospace. Forum on Tracking Detector Mechanics

3 Additive manufacturing, 2008 Laser Additive Manufacturing (LAM) Forum on Tracking Detector Mechanics

4 Selective Laser Melting (SLM), 2012 Forum on Tracking Detector Mechanics

5 SLM NLR (2012) F100 forward engine mount lug Jet engine model parts source NLR: Ti6Al4V and 17-4 PH thrust reverser parts for jet engine models in wind tunnel testing Forum on Tracking Detector Mechanics

6 Where are we now with AM? President Barack Obama called 3D Printing a technology that has "the potential to revolutionize the way we make almost everything" Forum on Tracking Detector Mechanics

7 3D printed gas turbine engine Monash University Centre for Additive Manufacturing Forum on Tracking Detector Mechanics

8 Siemens in Sweden is using SLM to repair fuel burners Hybrid build up to recondition fuel burners SLM system that allows to place the burner in the machine bed to rebuild the damaged section of the part. Benefits 1. Reduces high skilled labour and the chance of human error 2. Components upgraded with new design features for performance improvements 3. Optimized cooling channels and reinforcement of critical sections - increase efficiency and life time Forum on Tracking Detector Mechanics

9 Highly innovative production applications of 3D printing by General Electric GE aviation fuel nozzle for Leap-X engine 19 fuel nozzles 3D printed in CoCr-alloy per jet engine Advantages: 20 components integrated in one part 5 times more wear resistant 33% lighter Reduced fuel consumption through optimized design Production: 2014: start of production 2015: 30,000 nozzles per year 2020: 100,000 nozzles per year Forum on Tracking Detector Mechanics

10 Other equipment manufacturers Aviadvigatel PD-14 engine Swirler Pratt & Whitney 1500G (geared turbofan) Synch ring bracket Compressor stators Airbus ± 30 ton Ti-6Al-4V in 2018 bij AM Forum on Tracking Detector Mechanics

11 NLR: SLM Solutions 280 HL Selective Laser Melting (SLM) powder bed small details low deposition speed Build Chamber in mm (x/y/z) Laser Power Build Speed Pract. Layer thickness Min. Wall Thickness Operational Beam Focus Scan Speed Inert Gas Consumption in Operation 280 x 280 x /1000 W, YLR-Faser-Laser 20 ccm/h / 35 ccm/h 20µm - 75µm / 100µm 150 / 1000 µm µm / 700µm 15 m/s Ar/N 2, 2,5 l/min Forum on Tracking Detector Mechanics

12 NLR Selective Laser Melting Forum on Tracking Detector Mechanics

13 NLR Selective Laser Melting Forum on Tracking Detector Mechanics

14 Aluminium engine inlet part designed by Aeronamic Selective laser melting (SLM) manufactured by NLR Forum on Tracking Detector Mechanics

15 Inconel 718 LPT seal with honeycomb (SLM) leak tight thin walls, cooling holes and limited residual stresses Forum on Tracking Detector Mechanics

16 Process challenges: influence of parameters Design Face orientation Thickness variations Supports Ratio cross section area-perimeter... Process parameters Layer thickness Laser power Wave length Laser spot size, intensity profile Focus offset Scan speed Hatch distance Scan strategy Temperature (gradients) Inert gas type, velocity,... Apparent density of powder layer Optical system dynamic properties Time between exposure... Material parameters Particle size distribution Particle Shape Chemical composition Moisture content Oxygen & Nitrogen pick-up Thermal conductivity Radiation absorptivity Specific heat capacity Thermal diffusivity Melting point Latent heat of fusion Surface tension Melt viscosity... Laser based Powder Bed Fusion Post processing Powder removal Heat treatment Removal supports Surface treatments... Criteria Build rate Porosity Surface roughness Accuracy Residual stresses Mechanical performance Reliability/repeatability... Forum on Tracking Detector Mechanics

17 SLM powder Al10SiMg Ti-6Al-4V Inconel 718 Forum on Tracking Detector Mechanics

18 Process parameters Process parameters Scan pattern parameters Hatch distance Scan strategy Time between exposure Forum on Tracking Detector Mechanics

19 SLM Ti-6Al-4V microstructure after post processing Improvement by Hot Isostatic Pressing (HIP) Stress relieve + b-anneal HIP + b-anneal Forum on Tracking Detector Mechanics

20 SLM Inconel 718 tensile properties Comparison: HIP, without densification and wrought Yield (MPa) UTS (MPa) Strain at UTS (%) Same solution + precipitation heat treatment Forum on Tracking Detector Mechanics

21 Fatigue properties AM Inconel 718 Condition: solution heat treat + precipitation Plate (wrought) Batch1 SLM pores/defects Batch2 SLM SLM + HIP Batch3 O LAM dense Δ LAM pores/holes Forum on Tracking Detector Mechanics

22 Variability Forum on Tracking Detector Mechanics

23 Why aren t we doing more AM? QUALIFICATION Forum on Tracking Detector Mechanics

24 Where should we use AM? Complex parts with a high added value Short lead time Change in design philosophy is necessary! Forum on Tracking Detector Mechanics

25 Examples Airbus Forum on Tracking Detector Mechanics

26 Shape optimization without AM Siemens develops world-record electric motor for aircraft Technical milestone: five times more powerful than comparable motors Thanks to its record-setting power-to-weight ratio, larger aircraft with takeoff weights of up to two tons will now be able to use electric drives for the first time. Forum on Tracking Detector Mechanics

27 Challenges for AM Change in design philosophy Quality and quality assurance Material quality Microstructure Repeatability Process control Power feedback Continuous quality check Forum on Tracking Detector Mechanics

28 Challenges for AM (2) Production rate Multiple lasers Precision At high production rate Costs Production rate Powder Multi-material Forum on Tracking Detector Mechanics

29 Tackling the challenges Four years programme on Metal-AM for high tech applications NLR & TNO programme (Q4 2014) Public-Private Partnership with international participants More participants welcome Forum on Tracking Detector Mechanics

30 Technical objectives Efficient method to determine AM processing parameters Database with design values Metal-AM Design guide lines, methods and tools, for AM manufacturing Topology optimization Post-processing ; Powder removal, heat treatments, surface finishing Material qualification and process certification methodologies for AM Technology demonstrators Forum on Tracking Detector Mechanics

31 Conclusion Are we going to print a plane? No, only parts Yes, but small ones Forum on Tracking Detector Mechanics

32 Forum on Tracking Detector Mechanics 2015