Crossing the Divide Between Promising Opportunities and Mainstream Additive Production Implementation SmartManufacturingSeries.com
Crossing the Divide Between Promising Opportunities and Mainstream Additive Production Implementation GE Additive August 9, 2018 Eric A. Ott
Our ecosystem, built around our customers Machine modalities Concept Laser, Direct metal laser melting Arcam EBM, Electron beam melting Software Predix GeonX AP&C Materials Advanced materials Powder supply Tested and validated Customer Experience Centers Pittsburgh, PA Munich Germany AddWorks Engineering Consultancy GE partner companies Baker Hughes, a GE company, Non-Destructive Testing (NDT) GE Capital, Financing solutions GE Global Research GE Power, Uninterrupted Power Supply (UPS) General Electric Company All rights reserved
ADDITIVE MANUFACTURING Expands what is possible opens up new engineering capability to optimize part & system designs in a way we cannot with traditional manufacturing processes manufacturing cost DECREASES & Improves quality eliminates design trade offs; reduced defect opportunities, digital v. analog control, reduced anomaly size and frequency v. traditional castings design complexity INCREASES & Simplifies systems more robust designs, reduced part counts, reduced braze/weld/rivet/bolted joints and assemblies; optimized systems
Additive manufacturing perceived hurdles 1. New & unknown - not like anything we ve done before 2. Limited accessibility, specialized & not for serial production 3. No engineering, manufacturing & data infrastructure 4. Onerous qualification & regulatory certification path
A new era of design and manufacturing POWER AEROSPACE TRANSPORTATION OIL & GAS HEALTHCARE
Impact on our materials journey Capabilities of full production 35,000 40,000 per year 30 % COST EFFICIENCY IMPROVEMENT 25 % WEIGHT REDUCTION 20 1 PARTS 5x MORE DURABLE 95 % INVENTORY REDUCTION LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines 7
In-process Understanding similarities between processes Additive Deposit parameters/themes Rapid solidification Deposit quality Casting / Weld Weld parameters Solidification Joint quality Additive CoCrMo (Co) Conventional Materials
Finished Understanding similarities between processes Additive Post processing Isotropy Design Capability Wrought Material Heat treatment Uniformity Material Properties Additive CoCrMo (Co) Conventional Materials (Ni)
Materials consideration in a production environment LEAP jet engine fuel nozzle with a design made possible by additive manufacturing will be mass-produced in Auburn, Alabama growing from an initial rate of 1,000 units per year to 40,000 per year by 2020 ultimately more than 50 additive manufacturing machines Additive Manufacture 7/24/2014, Peter Zelinski, Editor-in-Chief, Modern Machine Shop Laboratory to production scaling Powder raw material Sources Size distribution Cleanliness Additive Deposition Material management Productivity Process controls Post Processing Support structure Distortion management
Advancements in materials data availability Yesterday Today
Simplification of the additive qualification and certification processes Qualification requirements depend on part & application field Regulators are learning too Complex, high criticality parts Fixed processes - level of control Multiple specifications - process/mtl. Traceability/tracking Site audits - specific controls Intensive NDE - additional methods Periodic destructive evaluation Commodity, wearout failure parts Lot acceptance testing Basic material specification Basic quality checks (chemistry, density, etc.)
Turbocharger housings High temperature parts Weight reduction without compromising design Reduced amount of heat loss Freedom of materials selection with redesign for improved weight and mechanical properties 30% HEAT LOSS REDUCTION* 14% WEIGHT REDUCTION* *Based on GE design analysis
Additive form offers different capabilities than castings/forgings Ultimate Strength Additive Alloy 718 (Ni) Low Cycle fatigue Capability Kelkar, et.al., Superalloy 718 and Derivatives, 2018
Looking forward to materials advancements 1. Integration of in-process monitoring 2. Improvements in the understanding of variation 3. Expanding to new materials 4. Broader acceptance and experience
2017 General Electric Company - All rights reserved
Crossing the Divide Between Promising Opportunities and Mainstream Additive Production Implementation GE Additive supports customers with additive processing equipment, materials, technical data and engineering services to help enable the translation of additive opportunities into production reality. Drawing on experience from Aviation and other development and implementation actives, this talk will investigate the perceived hurdles in additive implementation and the advancement of technical understanding and engineering experience to address and surmount barriers to gain engineering, quality, and regulatory acceptance with a focus on materials aspects such as powder, processing, sensing, post processing, and properties. Reference to a few case study examples will be made. The talk will also highlight key continuing activities aimed at bringing additive materials and processes into the mainstream manufacturing portfolio. Eric A. Ott Dr. Eric A. Ott is a Principal Engineer at GE Additive with over 20 years of experience in materials engineering. Over the last 17 years, Eric has been involved in materials development and application engineering for metallic materials for aviation gas turbine engines and most recently has been focused on additive-produced metallic materials for aviation and other applications. In his roles he worked in and published work on aluminum, titanium, steel, cobalt, superalloy, and intermetallic material systems. He led the introduction of 3 new structural alloys for engine applications along with other efforts on new process technology, and novel material structures. Eric received BS, MS, and PhD degrees from Carnegie Mellon University in Pittsburgh PA in Materials Science and Engineering. He has been involved in various materials society committees, cross-industry collaborative programs, has a professional engineer license, and has been involved in specification, qualification and certification activities in materials.
Crossing the Divide Between Promising Opportunities and Mainstream Additive Production Implementation SmartManufacturingSeries.com