Cost effective large scale AM Dr Filomeno Martina + WAAMMat team 30 th May 2017 waammat.com www.cranfield.ac.uk
The making of the world s biggest part 2
The making of the world s biggest part 3
WAAM // Business drivers Lead time reduction Example: lead time for large forgings can be up to 14 months + 4 months for roughing and finishing. WAAM can reduce this to weeks 4
WAAM // Business drivers Aluminium: 14 months for forging 4 months for machining 90% waste Titanium: 10 times worse problems 5
WAAM // Business drivers Lead time reduction Example: lead time for large forgings can be up to 14 months + 4 months for roughing and finishing. WAAM can reduce this to weeks Manufacturing cost reduction Better material utilisation. Example: reduction of BTF to <2! cost savings up to 70% compared to machine from solid Potential for additional material savings via topological optimisation 6
WAAM // Example of cost savings Manufacturing option Mass (kg) BTF Cost ( k) Cost red. Original machined 20 12 16.2 - WAAM + machining 20 2.3 5 69% 7
WAAM // Business drivers Lead time reduction Example: lead time for large forgings can be up to 14 months + 4 months for roughing and finishing. WAAM can reduce this to weeks Manufacturing cost reduction Better material utilisation. Example: reduction of BTF to <2! cost savings up to 70% compared to machine from solid Potential for additional material savings via topological optimisation Improvement in parts properties Hybrid processes (f.i. WAAM + cold-work) Multi-material structures 8
WAAM // Multi material Cu Fe W WC Fe Cast Fe 9 Mo Ta
WAAM // How does it compare? 10 (our assessment)
What we ve deposited so far Titanium Grade 2 Grade 5 Grade 23 Aluminium 2024 2319 4043 5087 Refractories Tungsten Molybdenum Tantalum Invar Steels ER60 ER80 ER90 ER120 Maraging grade 250 Maraging grade 350 Stainless (17-4 PH, 316L, 420) Inconel 625 718 Bronze Copper 11
10 years of WAAM 12
Recent nice parts 13
Wire + Laser AM = WLAM 1 mm 14 1 mm
So what s the problem? There are no commercial systems available. 15
WAAM // The software workflow Import CAD model Generate net shape and check WAAM compatibility and baseplate position WAAM Data (API) Primary process parameters Thermal mass calculation around path Allocation of thermal, geometrical & system compensations Cost analysis Partition (manually/ automatically) Allocate partition and interface build strategies and sequence Allocate baseline bead geometrical parameters Tool path generation WAAMDesign WAAMSoft Tooling geometry Process monitoring and control, geometry and temperature System controller WAAMCtrl 16 Simulation, collision detection Programme for CNC machines/ robots
WAAMSoft // Overview WAAMCore Path Planning for WAAM Robotic API Feature-based design Assisted design Automated 17
Path Planning: Robotic API MoveL MoveC MoveArcL MoveArcC ABB Fanuc KUKA CNC 18
Path Planning // Feature-based Design Choosing Feature Define Features Parameters 19 WAAMCore
Path Planning // Feature-based Design Layer height Cooling time Independent layers parameters Independent zones parameters Stepover 20
Path Planning // Feature-based Design Layer height Cooling time Independent layers parameters Start and stop position Deposition orientation and reverse Independent oscillation parameters 21
Path Planning // Feature-based Design Layer height per revolution Deposition orientation Independent zones parameters 22
Path Planning // Feature-based Design 23
ADMIRE // EU project to set up MSc course on Metal AM Finally not forgetting we are supposed to educate as well! Academic partners Industry partners Wire-based AM processes Powder-based AM processes Modelling and software NDT and inspection aspects Plans Pilot course: Oct 2018 Full launch: Oct 2019 Steering council open to all industry partners what do you want in this course 24
Wrapping up Many new developments through the WAAMMat programme including new process variants promising high fidelity high build rate process and in-process cold-work solutions WAAM is progressing to the qualification phase Commercial systems with intelligent software will be available in 2018 Much more information on WAAM on our website waammat.com OR CONTACT: Dr Filomeno Martina f.martina@cranfield.ac.uk? ATTENTION THANK YOU FOR YOUR? 25