The Democratization of Additive Manufacturing

The Democratization of Additive Manufacturing

The Democratization of Additive Manufacturing 2

What is required of AM to be democratized? Cost Reduction (faster deposition) measured in Kg rather than gramms per hour Larger work measured in meters rather than cm Build on existing structures leverage castings, forgings, plate, or bar Integration of subtractive processes machine mid-build Precision AM no longer an oxymoron Bimetallic builds and graded materials Ease of use common CAM for AM and SM Robust machines for the factory floor built for 24-7 production 3

4

5

Faster Deposition Larger LASERs Deposition Stratagies of higher effeciency Multiple deposition tools ATC for deposition tools 6

Larger Work Lathe-like envelopes are available for cylindrical work or elongated work 7

Pinch Fixturing Long parts can be deposited without a trunnion fixture, however milling operations require support. This is provided by Pinch Fixturing (patent pending) 8

Pinch Fixturing 9

Segregation of the AM Market The AM market is now clearly segrated between solutions for rapid-prototyping, and production Rapid Prototyping cannot benifit from any of the AM capabilities which cannot subsequently be performed by conventional production However if AM will be used for production we can utilize bi-metalic depositon, mid-process machining, and other unique AM capabilities GE s famous example of AM (shown) consolidates an assembly into a single component, but can only be pursued if no critical features are traped in the core making them innecesable for machining after deposition, and if all components are of the same alloy 10

Existing Structures Powder-spray can deposit on existing strucutres Castings Forgings Billet Deposition mass can be reduced by an order of magnitude Cycle time is reduced by two orders of magnitude if the built rate is also 10X faster 11

Existing Structures Nozzles can interfere with existing features Single nozzles can address this when fitted with a 6th axis (patent pending) 12

Single Nozzle Tangent Control (patents pending)

Tangent Control Traditional Method DMG MORI Original Method Advantages Constant Energy Absor Rotating Beam -More even energy

Laser for Thermal Management The laser can be used to surface harden Carbon steels, or used to pre-heat and re-heat to reduce quenching 15

Precision AM Precision AM has been an oxymoron 16

Grinding in the LASERTEC 4300 3D A turret which can support many application-specific dressing rolls A turret which can support many application-specific coolant nozzles CNC control of nozzle position (all patent pending or granted) 17

Ultrasonic Machining in the LASERTEC 65 3D Ultrasonic assisted machining has been proven very effective in hard metals 18

Integrated Additive Manufacturing PLM Managed Environment Full Process in NX CAD CAE CAM (AM and SM) Data Management and Shop Floor Connectivity Siemens Production Software and MES Systems

Residual Stress Typically AM parts are over-constrained during deposition resulting in high levels of residual stress Hybrid machines can address this with 3 point supporting Cooling can also be controlled

Case Study Rocket Motor Nozzle Nozzles are typicaly a Cu billet with a milled laberenth of cooling channels sheathed in Inconel AM production requires a hybrid machine to mill the channels as the part is deposited from the two alloys 21

Case 3 Rocket Nozzle Manifold Inconel 718 Nozzles typically require multiple manifolds for fuel, oxidizer, and cooling gasses In this case all three are combined and internal machining is required 22

LASER Welding of the Manifold 23

Realization of Wrought Mechanical Properties for Inconel 718 We usually claim meterial better than cast, but inferior to wrought Inconel 718 has exceeded 180 ksi ultimate tensile using standard heat treatment Future testing will focust on fracture and fatigue Inconel 718 Ultimate Tensile (ksi) 200 180 160 140 120 100 80 60 40 20 0 as deposited deposition and HIP heat treated per AMS 5663 HIP and AMS 5663 AMS spec. 24

Realization of Wrought Mechanical Properties in 6Al4V Titanium depositions have exceeded the AMS specifications for cast, AM, and wrought material Future testing will focus on fracture and fatigue 160 140 120 100 80 60 40 20 Ti Properties 0 AMS 4992 (Cast) AMS 4999 (Powder Bed) AMS 4928 (Wrought) DMG MORI LT 4300 3D 25 Yield Tensile Elongation

24-7 Production LASERTEC 65 3D Specifications Based on DMC65 mb Laser Power - 2 kw to 3.0 kw Deposition Rate in Stainless Alloy 2 Kg per kw per hour Max. Envelope of Work - 500 mm dia. X 400 mm length Max. Mass of Work 1000 Kg

24-7 Production LASERTEC 4300 3D Specifications Based on NT4300 Laser Power - 3 kw to 10 kw Deposition Rate in Stainless Alloy 2 Kg per kw per hour Max. Envelope of Work - 600 mm dia. X 1500mm length Max. Mass of Work 1700 Kg Dual milling spindles Dual work tables

Are we there yet? Faster depositions measured in Kg rather than gramms per hour Larger work measured in meters rather than cm Build on existing structures leverage castings, forgings, plate, or bar Integration of subtractive processes machine mid-build Precision AM no longer an oxymoron Bimetallic builds and graded materials Ease of use common CAM for AM and SM Robust machines for the factory floor built for 24-7 production 28

Questions? 29