Materials Selection for Additive Manufacturing

Transcription

1 Materials Selection for Additive Manufacturing K. Rogers, Technology Leader, Additive Manufacturing GE Center for Additive Technology Advancement August 10, 2016 Imagination at work

2 Key additive manufacturing facilities GE Healthcare AM COE, Milwaukee, WI (PBFAM metals & polymers, direct write) GE Corporate Center for Additive Technology Advancement, Pittsburgh, PA (DMLM, EBM, polymers, sand binder jetting, laser cladding) GE Global Research, Niskayuna, NY (DMLM, laser cladding, polymers, ceramics, AM design) GE Oil & Gas, Talamona, Italy (DMLM production) GE Power AM COE, Baden, Switzerland (DMLM, polymers) GE Aviation Additive Technology Center, Cincinnati, OH (DMLM, EBM, polymers, AM design) GE Aviation, Auburn, AL (LEAP fuel nozzle production DMLM) GE Power Advanced Manufacturing Works, Greenville, SC (DMLM, polymers, AM design) GE Aviation, Avio Aero, Turin, Italy (EBM) GE Oil & Gas, Florence, Italy (DMLM, polymers) 2

3 AM Technologies at GE Micro-scale features Direct ceramic deposition Direct written sensors Macro-scale features DMLM & Electron beam Commercial polymer AM Large-scale features Spray technologies Laser & EB cladding Sand casting mold and core Ceramics printing Direct write U/S probes CBM Sensors Functional metal, ceramics & polymer parts Commercial polymer & metal machines Large low volume functional metal parts Custom built machines Foundry of the future enabler Ultrasound probes Integrated circuitry Direct-written CBM sensors Turbomachinery applications Test hardware Limited production since µm 200 µm 500 µm Repair & feature addition; reduced buy-to-fly LRIP casting; NPI acceleration In use

4 Center for Additive Technology Advancement Mission Statement This will be the flagship center for GE additive manufacturing where we will be on the forefront of implementing industrial applications for the benefit of all GE businesses. This site will be a hub of innovation and promote training and development in both design and applications for this breakthrough technology Project Details First multi-modal US site ~50 employees 125,000 sq ft $39M Corporate investment April 2016 Opening GRC Pittsburgh, PA 1 3 Technology readiness level 7 10 Invent Part & process design tools Next generation equipment Material development CATA Develop Develop, prototype, scale & mature Should-be cost development Low rate initial production Business Implement Large scale output Proven technology Standard routers & quality plans

5 Applying additive technology Tooling Both metal & polymer tooling applications Identify Production LEAP fuel nozzle Flex tips Design prototypes NPI applications Low rate initial production Complex geometries Lighter weight parts/ efficiency Develop Industrialize Repairs & Services Crankshaft repair Globalize Product offering differentiation Unique concepts that leverage nontraditional solutions for customers Industrialization Machine change-over reduction In process monitoring 5

6 Additive supply chain

7 GE Supply Chain... Delivering REAL Production Parts 250K+ parts by 2020 and growing! T25 Housing Flex Tip

8 Materials Selection (Traditional)

9 Materials Selection (traditional)* Problem solving process 1. Analysis of the Materials Requirements Service/use conditions and use environment 2. Screening of Candidate Materials Compare needed properties with a large alloys to select a few materials that look promising 3. Selection of Candidate Materials Analyze candidate materials in terms of tradeoffs of product performance, cost, fabricability, and availability 4. Development of Design Data» Best material for the application Determine the key materials properties for the selected material and process to obtain statistically reliable measurements ASTM / AMS specifications *George E. Dieter, Engineering Design A Materials and Processing Approach, McGraw-Hill,

10 UTS YS Comp. YS Shear Strength Fatigue Ductility Impact Transition T Modulus Creep rate K1C K1SCC Electrochemical Potential Hardness CTE Yielding Bucking Creep Brittle Fracture LCF HCF Contact Fatigue Fretting Corrosion SCC Galvanic Corrosion Hydrogen Embrittlement Wear Thermal Fatigue Corrosion Fatigue Relations between failure modes and mechanical properties, Smith & Boardman, Metals Handbook 9 th ed., vol 1, ASM international, Metals Park, OH

11 Materials Selection: Interrelationship of design, materials and processing Design service conditions function Cost Product Reliability Materials Properties availability cost Processing Equipment Selection influence on properties cost 11

12 TRADITIONAL MATERIALS SELECTION EXAMPLE Example: Paperclip 1. Materials Requirements 1. Elasticity Too much opening force MODULUS Too little clamping force 2. Strength YIELD STRESS Permanent bend 3. Wire diameter, clip design, etc. 12

13 Materials Selection (Additive) LASER POWDER BED PROCESS I.E.. SLM / DMLM

14 Materials Selection (Additive) Can you print me a valve controller body out of a soft magnetic material like 430 Ferritic Stainless or Nickel Iron alloy? We have several MIM & conventional machining quotes and need some next month 14

15 Yes, But... Magnetic properties? Never heard of 403 stainless in DMLM additive weldable but prone to cracking Possible? 50% Nickel Iron alloys? Does anyone make powder? Binderjet? 15

16 Yes, But Magnetic properties? Never heard of 403 stainless in DMLM additive weldable but prone to cracking Possible? 50% Nickel Iron alloys? Does anyone make powder? Binderjet? M300 Maraging steel, magnetic permeability in test 16

17 Can you print me a bedplate out of grey iron? IMAGE: GE Reports 17

18 Yes, But... Lets do some math Lb 10 lbs per hour for WAAM ( = 3000 hours or 2.9 parts per year! 18

19 How many do you need this decade? IMAGE: GE Reports 19

20 People can have the Model T in any color, as long as it s black -Henry Ford Title or Job Number XX Month 201X 20

21 LASER POWDER BED PROCESS I.E.. SLM / DMLM You can have any alloy you want. As long as it s CoCrMo! Andy Snow, GE Aviation October

22 LASER POWDER BED PROCESS I.E.. SLM / DMLM Materials Selection Compared (metals) Traditional Data Sources ASM Metals Handbooks SAE Handbooks Structural Alloys Handbook Grey and Ductile Iron Handbook Additive Data Sources Senvol Database 400 alloys Senvol Indexes - 2? Manufacturer data sheets 100? Steel Castings Handbook Woldman s Engineering Alloys Mil Standards Aerospace Materials Standards COMING SOON: ASTM standards SME AMS standards Limited data available 22

23 How to really do materials & process selection (Additive) LASER POWDER BED PROCESS I.E.. SLM / DMLM

24 LASER POWDER BED PROCESS I.E.. SLM / DMLM Process Selection (Additive) Production Vs Prototype Material Type (Polymer, Metal, Ceramic) Part Size (<400mm) Production rate/volume Tolerances Feature size Surface Finish Preliminary AM selection Part orientation Build Time Cost High level materials requirements Final AM selection 24

25 Additive Advantage Topology optimization Shorten NPI manufacturing time Eliminate process steps Reduce outsourcing Design performance improvements Product design freedoms Reduce assembly costs Design CNC machining fixtures on the additive part Incorporate datum features into the part design Reduce prototype lead times and costs Reduce inventory Build internal passages into almost any geometry Change multiple part assemblies to be designed as one part geometry Eliminate welds in an assembly IMAGE: GE Reports

26 LASER POWDER BED PROCESS I.E.. SLM / DMLM Materials Selection (Additive) Problem solving process 1. Analysis of the Materials Requirements Service/use conditions and use environment 26

27 LASER POWDER BED PROCESS I.E.. SLM / DMLM Material Selection (Additive) Problem solving process 1. Analysis of the Materials Requirements Service/use conditions and use environment 2. Screening of Candidate Materials Compare needed properties with the 359 metal results to select a few materials that look promising Senvol database search 8 Aug PM EDT 27

28 LASER POWDER BED PROCESS I.E.. SLM / DMLM Materials Selection (Additive) Problem solving process 1. Analysis of the Materials Requirements Service/use conditions and use environment 2. Screening of Candidate Materials Compare needed properties with 359 metal results to select a few materials that look promising 3. Selection of Candidate Materials Analyze candidate materials in terms of tradeoffs of product performance, cost, and availability» Best material for the application 28

29 LASER POWDER BED PROCESS I.E.. SLM / DMLM Use Casting Data as an approximation Additive materials property data (CTE, YS, HCF) is typically between cast and wrought data LCF, FCGR, toughness, creep, environmental effects unknown 29

30 LASER POWDER BED PROCESS I.E.. SLM / DMLM Materials Selection (Additive) Problem solving process 1. Analysis of the Materials Requirements 2. Screening of Candidate Materials 3. Selection of Candidate Materials 4. Development of Design Data» Best material for the application Determine the key materials properties for the selected material and process to obtain statistically reliable measurements Machine parameter optimization Support Structure & design optimization ASTM / AMS specifications 30

31 CATA Additive Materials - DMLM Current CoCrMo Stainless steels - 316L, 15-5PH, 17-4PH Nickel Superalloys IN718 Haynes 188 Maraging steel Near Future Aluminum A205 Nickel Superalloys - Haynes 282 GE Proprietary Information 31

32 Summary & the additive future Feasibility of production AM GE Game changing, high performance product Industrialization of supply base & GE businesses via CATA..Exciting times to be in AM Keys to success: Materials & process selection Design data development We are standing in front of a potential revolution in manufacturing. Michael Idelchik VP of Advanced Technologies, GRC

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