Development and Implementation of Metals Additive Manufacturing Presentation Title

Transcription

1 Development and Implementation of Metals Additive Manufacturing Presentation Title Ian D. Harris, Ph.D. Director, Additive Manufacturing Consortium (AMC) EWI 1of 31

2 Outline Brief EWI summary Additive Manufacturing (AM) what is it? Additive Manufacturing Consortium (AMC) Summary 2of 31

3 About EWI A $30M applied engineering services R&D company that develops and commercializes advanced manufacturing technologies A global leader in materials joining technology to advance our customers' manufacturing competitiveness Serves 240 member companies with over 1,200 locations worldwide, Incl Exxon Mobil, Chevron, etc 3of 31

4 Advanced Manufacturing Technologies 4of 31 Additive manufacturing Advanced arc welding Automation, sensors, controls Brazing and soldering Dissimilar materials joining Friction welding and processing Hot forming Laser processing Nondestructive examination Numerical modeling and simulation Plastic and composite fabrication Resistance welding Ultrasonic joining Ultrasonic machining Weldability testing, mechanical testing, and metallurgical analysis

5 Additive Manufacturing Progressive Layers Definition of additive manufacturing; Building a part directly from a 3D CAD file to produce a part Additive manufacturing - build in layers, using powder bed or wire fed processes - stress relieve/pwht, machine, as/if necessary for material and application 5of 31

6 From Conventional Fabrication Each step requires handling, logistics, capital 6of 31 equipment, time, material waste

7 to AM Part Fabrication The Promise - from machine directly to part make things that cannot be made any other way, eliminating many steps in current manufacturing The Barriers - Limited data, fragmented development process, most equipment is from overseas (jobs, manufacturing base) and has a small work envelope One step: reduces handling, logistics and supply chain, capital equipment, time, 7of 31 material waste

8 AM Processes for Metals EBW freeform fabrication - EB(FFF) Laser powder, POM, LENS, wire for FFF SLM, DMLS, EBM powder bed laser and EB Arcam,, EOS, in confined envelope Arc processes GTAW-HW, GMAW-P, PTA (wire/powder) for FFF VHP UAM very high power ultrasonic AM from strip Wide range of deposition rates 8of 31

9 Powder Bed Size Limitations Ti6Al4V Ti6Al4V ELI Titanium Grade 2 CoCrMo ASTM F75 9of 31

10 Example Metals AM Processes Concept Laser DCM EOS DMLS Optomec LENS Arcam EBM MTT SLM MTS Aeromet LAM (No longer in business). Phenix Systems Sciaky EBFFF 10 of 31

11 Deposition Rate vs Resolution Courtesy Boeing Increased Deposition Rate Decreased Resolution 11 of 31

12 MS&T 2011 Columbus Additive Manufacturing of Metals Symposium Organized by EWI, UL, OSU, NCSU, and Arcam 50 papers in six sessions over 3 days All aspects of Metals AM Columbus, Oct of 31

13 Example Applications Land vehicles OEM Repair Power generation, nuclear, oil and gas 13 of 31

14 Arc-Based Additive Manufacturing Demonstration of low cost arc-based processes for Titanium AM GMAW-P RWF-GMAW PAW (Cold Wire) PTA (Powder) PTA (Powder) GTAW (Hot Wire) GMAW-P GTAW (Hot Wire) Proprietary to Lockheed Martin Copyright 2009 RWF-GMAW 14 of 31 PAW (Cold Wire)

15 Precision-GMAW Build- Up 1.5mm Stainless Stainless steel steel edge edge build-up build-up ipm ipm Travel Travel speed speed Heat-input Heat-input < 1 kj/in kj/in 15 of 31

16 GTAW-HW Typically up to 500 A Up to 20 lb/hr 16 of 31

17 Ti Control arm with GTAW-HW First layer and completed deposit 17 of 31

18 Distortion Control End and side views showing low level of distortion 18 of 31

19 Process Applications - EBFFF. Machining Application: Rapid prototyping Eliminate or reduce expensive tooling and fixturing Ideal for aerospace application Lateral Application: Precision Repair Engine vane repair 19 of 31

20 EWI s s Laser Equipment 15-kW IPG Fiber Laser 4-way beam switch 15-kW Laser 20 of 31

21 Samples Stainless to Steel Inconel (2 pass) Stellite to Steel 21 of 31

22 10-kW Fiber Laser Dilution typically less than 5% 316L on mm rectangular spot 8 kw ~1 mm build-up up (single pass) ~2.6% Dilution 22 of 31

23 Advancing Manufacturing Readiness Manufacturing Readiness Manufacturers & Suppliers MRL 8-10 Incremental improvements and implementation Short time horizon Additive Manufacturing Consortium MRL 3-7 Significant commercial impacts in 2-5 years University & Federal Labs MRL <3 High-risk basic research and education Long time horizon Time to deployment 23 of 31

24 Additive Manufacturing Consortium Goal Advance the manufacturing readiness of additive manufacturing for the defense industrial base and other industries Air Force (Steve Szaruga) Army (Stacey Kerwien) NASA (Craig Brice) NAVAIR (Bill Frazier) NIST (Kevin Jurrens) Industrial Members GE R-R Boeing Lockheed Martin Northrop Grumman General Dynamics Morris Technologies Applied Optimization B6Sigma Universities/National Labs and Other Partners The Ohio State University (partner) University of Louisville (partner) University of Texas (partner) North Carolina State University (partner) South Dakota School of Mines (partner) Lawrence Livermore National Lab (partner) TechSolve (partner) NCMS (partner) 24 of 31

25 AMC Goal: Advance manufacturing competitiveness of a key emerging technology, namely AM Mission: Advance the manufacturing readiness of metal AM technologies to benefit consortium How: A network of industry, government and unis for maturing metal AM technology AMC was founded to provide a U.S. AM forum EWIs AMC Role: Organize, operate, seek funding, program manage, contribute to technology development activities 25 of 31

26 AMC Rapidly growing network of industry, government, and university partners, First Members Meeting Dec. 7, 2010 with 20 members/partners Currently 22 members with 4 more joining Recognized AM Aerospace and Defense consortium Aviation Week Nov. 1/8 Poised to grow in other sectors, oil and gas, medical 26 of 31

27 AM Gaps Design: Designers must be taught the performance and economics of AM Quality control: standards are needed to assure that every part meets requirements Cost and Flexibility: AM processes must be much more productive Supply Chains: U.S. companies need help to commercialize new AM technologies 27 of 31

28 Qualification Challenge Evaluation Stages BMS [1] Initial Screening [2] Process/Source Approval [3] Deposition Parameter Approval [4] Approval on Non-Critical Flight Hardware [5] Approval of Critical Flight Hardware Reference: Slattery, K., AeroMat 2008 Deposit Test Samples Substrate Characterization including geometry effects must be performed Must push for a better combination of 28 resolution, of 31 build envelope, and deposition rate

29 AMC - Proposed 1 st Year Goals Achieved Obtain broad industry and government support achieved for A&D, reaching out to O&G, others Organize National Test Bed Center research partners network in place with 22 partners Identify technology priorities and create plan priorities identified $60M of proposals Conduct SOA review of metal AM - complete Establish a database for collecting metal AM property information will use MMPDS 29 of 31

30 Summary and Conclusions AM for metals is rapidly developing through a range of technologies Additive Manufacturing Consortium (AMC) is poised for growth into other sectors AMC offers collaboration for development of metals AM 22 members, more welcome Looking for potential applications for oil and gas market Nominally unmanufacturable components High added value, long lead time items Adding features to low yield castings and forgings Repair applications 30 of 31

31 Contact information Presenters Name Company Name Address Phone Number (contact info slide is optional) 31 of 31