Army Efforts in Metals Additive Manufacturing & Data Management SmartManufacturingSeries.com 1
Army Efforts in Metals Additive Manufacturing & Data Management Ryan Carpenter U.S. Army ARDEC Presented to: SME Smart Manufacturing Series Additive Manufacturing 07 June 2018 UNPARALLELED COMMITMENT & SOLUTIONS Act like someone s life depends on what we do. U.S. ARMY ARMAMENT RESEARCH, DEVELOPMENT & ENGINEERING CENTER
Section 0 Background and Introduction BRIEFING OUTLINE Section 1 AM Overview 1.1 AM ManTech Program 1.2 Strategy and Challenges 1.3 DoD AM Roadmap Linkage Section 2 Process Development 2.1 Parameter Identification 2.2 Verification Testing 2.3 Data Analysis 2.4 Round Robin Testing 2.5 Build Examples Section 3 Data Management 3.1 Digital Challenges 3.2 Data Management Solution and Schema 3.3 Windchill Integration 3.4 Benefits 3.5 Vision and Path Forward Section 4 Summary and Conclusion 3
METALS ADDITIVE MANUFACTURING AT ARDEC PICATINNY ARSENAL, NJ ARDEC s leading facility in Additive Manufacturing (AM) of Metals. Located within ARDEC s Armaments Engineering Analysis & Manufacturing Directorate. AM Systems L-PBF EOS M270 Materials: Steel (4340/4140/17-4), Titanium, Aluminum, Inconel, Cobalt Chrome. E-Beam ARCAM A2X Materials: Titanium, Inconel, Cobalt Chrome, Tungsten. Support and Testing Equipment Powder Synthesis Plasma Reactors, High Energy Mills Post Processing HIP, Heat Treatment, Surface Finishing Machining Full Machine Shop (EDM, CNC, etc.) Testing Tensile, Charpy Impact, Hardness Characterization Scanning Electron Microscopy, Particle Size Analysis, X-Ray Fluorescence & Diffraction, Oxygen/Nitrogen Analysis Current Programs Additive Manufacturing for New Build, Remanufacturing, and Life Extension of Critical Weapons System Components ManTech AM for PEO Ammo Individual Army Customer Rapid Parts Prototyping Applications Additive Manufacturing equipment is used to prototype, develop, and fabricate metal parts via a layer by layer powder bed laser sintering process. AM provides a wide range of design flexibility over traditional manufacturing, allowing for rapid prototyping, part weight reduction, novel part design, reduced time to product, and overall manufacturing flexibility. Benefit to the Warfighter Reduced logistics footprint and Time to Field for replacement parts. Enabling manufacturing options to reduce single point failures. Enabling novel and improved part designs for reduced weight while meeting or exceeding performance requirements. A qualified, certified, and sustainable process for providing parts on a reduced cost, rapid response, on demand basis. Future Focus New materials systems (functionally graded materials, novel alloys, hybrid materials). Fielding of AM parts and AM systems for on-demand Battlefield manufacturing. Wide range of qualification & certification of materials, processes and parts via additive manufacturing. Advanced fabrication integration with sensors and electronics. 4
ADDITIVE AREAS OF INTEREST Novel Materials: Novel powder synthesis for Non-COTS materials. Rapid Prototyping: Multiple build iterations on the same build plate for design optimization. Small runs for prototype testing. Replacement Parts: Investigating component replacements which match properties but can be delivered in an accelerated timeframe. Novel Designs: Investigating novel weapons systems components with designs difficult or impossible with traditional machining. Process Monitoring Rapid Fielding: Investigating Additive Technologies to overcome the challenges of bringing metals additive to the field. Process Monitoring: Working to develop custom In-Situ Monitoring Hardware which can be retrofit on existing equipment. 5
MANTECH QUAD CHART Purpose: Develop and qualify additive new build and repair processes so that Project Managers may accept resulting components for use in armament systems. Define design and manufacturing process data required to support repeatable additive manufacturing production. Provide Additive Manufacturing Solutions for components which are damaged, hard to source, or not otherwise available. Products: Depot Maintenance Work Requirements (DMWRs) defining Cold Spray and LENS repair procedures for potential items: Proven process for manufacturing with Laser Powder Bed Fusion (L-PBF) technology, approved for selected armament system components In Process Inspection and Qualification System for rapid and cost effective component verification. Payoff: PM-ready processes applicable to manufacture/repair high-value and hard-to-source components. Between 10%-50% cost savings, and up to 50% reduction in lead time for component repairs vs. purchasing new. Significantly increased in-theater readiness and reduction of logistical footprint through provision of new and repaired components. Additive Manufacturing capability for weapons systems component fabrication for developmental cycle acceleration. 6
L-PBF STRATEGY From Left to Right: Enhanced Tactical Multi Purpose Grenade Builds in 4340 Steel via LPBF for blast testing, schematic of the LPBF process, AM quality Pyramid showing effort focus areas. Strategy: 1. Manufacturing Process Development (Materials and Parameters) at Picatinny. 2. Development of QA provisions / requirements. 3. Develop manufacturing guidelines for robust and reliable new build LPBF components. 4. Down select applicable components for new build demonstration and component testing. 5. Qualification and Certification of AM Components 6. Transition process to internal government facilities / industry. Product(s): Documented manufacturing guide to additively build armament systems components. PM/Program accepted Additively Manufactured components. Publications regarding manufacturing process. Knowledge base products aligning to Roadmap 7
ADDITIVE MANUFACTURING CHALLENGES Part acceptance for DoD applications relies on process qualification and certification The relationships between materials properties, processing parameters, and component performance are extremely complex, and complicated further by unique part geometries. Extremely large pool of materials and AM equipment to choose from. Raw materials must be readily available and trusted to manufacturer or internal specifications. Processing condition windows must be defined to ensure part quality. In-Situ Monitoring technology must be utilized and improved upon. Technology advancement introduces previously unforeseen manufacturing variables. AM standards are still in development In specific cases, companies have established their own proprietary standards. Need continuing collaboration between academia, industry, government agencies, and others to push standards adoption. Design for AM Need to educate and inform part designers on new principles and constraints for AM. Widespread adoption of the AM process is limited Raw materials cost, post processing, and process time are important considerations Utilization of Digital Product Data A system for controlled electronic data management and sharing must be implemented. Software types and digital file control must be set prior to manufacturing initiation 8
MANTECH ROADMAP LINKAGE * M&P Materials & Process * NDE Non Destructive Evaluation or Testing (NDT) * AM Additive Manufacturing * * The ultimate goal of the new build portion of this ManTech effort is to mature the manufacturing technology to qualify powder bed fusion AM technologies as a viable alternative manufacturing process to fabricate armament systems components. Multiple areas in the total manufacturing process need developmental efforts addressed to them to be able to produce an accepted additively manufactured component. Past, current, and future tasks under this program are outlined in the following slides and linked to where they impact the DoD Additive Manufacturing Roadmap. 9
INITIAL DEVELOPMENT 4340 Steel Powder was evaluated based on chemistry, particle size, and flow characteristics. Processing Parameters were developed focusing on energy density ranges and DoE was established looking at: Laser Power Scan Speed Hatch Distance Energy Density Range 325 samples were fabricated Parts were evaluated based on microstructure, density, porosity, and hardness. Mechanical properties comparable to wrought after stress relief, quench and temper heat treatment. 10
VERIFICATION BUILDS Four identical consecutive Four identical builds consecutive of mechanical builds test of mechanical specimens test specimens Location and orientation, 180 hours per build Focus on variations in location and orientation within and across builds Five clusters: each corner and center Collecting tensile, hardness, density, and toughness data. Normalize (furnace cool Powder to 1200F), sieved austenitize, to screen oil out quench, at 63 microns double temper after 375F each -build Time/temp will be per AMS 2759 11
LESSONS LEARNED XY parts had 12% higher elongation values than parts built in the Z direction. UTS, Density, and Hardness match wrought properties well, matching minimum requirements. Location 2 (Top Left) had the lowest properties (~9% less) Build 2 and Build 4 Z oriented tensile data had the lowest values - gas flow is worsened when the filters are nearly full. Many process conditions need to be taken into account: powder coverage, build plate material/condition, recirculating gas filtration, gas flow, part orientation, location on build plate All these parameters must be controlled for consistent mechanical properties. A manufacturing plan with defined operating windows is needed to ensure parts are made to specification. 12
Round Robin Demonstration ROUND ROBIN DEMONSTRATION Six participants involved with equipment including EOSM270, ProX320, SLM, and the EOSM280 Powder was procured from one lot to minimize variance Manufacturing guide written and disseminated to participants, outlining all major aspects of the manufacturing process Aim to observe variance in material properties as a function of orientation and plate location, across equivalent and different equipment types, with the same or equivalent process parameters. Provides insight into manufacturing process repeatability and reliability Over 250 unique data points Data analysis ongoing 13
METALS AM BUILD EXAMPLES Suppressors Property Verification Injection Molding Parts Weight Saving Structures 9 mm Pistol Small Arms Components M203 Grenade Launcher 14
DIGITAL DATA CHALLENGES Organizing and distribution of data, sharing across services Data Security Data Protection: How do we adequately protect digital data? Data Sharing: Different network security protocols, cloud based solutions not widely adopted. Data Classification: Data aggregation could raise the classification, requiring the need for a controlled system. Different formats between various machines Wide variety of OEM Machines for metals AM, no standardized software or file format. Data Organization: Unified file structure does not exist. Large amounts of data generation Complex data sets can be generated from a single build. Data storage solutions needed. Process monitoring solutions require large file storage spaces and bandwidth. Processing pedigrees There is a need for historical records of builds for data tracking and analysis to relate to performance. Don t want to duplicate efforts Best way to learn from mistakes or successes? IT infrastructure issues No uniform software and network system across branches and centers - difficult for approvals and data sharing. 15
DATA MANAGEMENT SOLUTION To overcome certain challenges, a software solution is necessary for traceability, storage, and analysis. MaterialCenter Solution Develop an additive manufacturing schema to enable the storage of all machine parameters along with corresponding material properties Utilize excel integration in order to map and import custom templates Collected Data Machine Information Part Data (CAD/STL/MAGICS Files) Starting powder properties Machine Build Parameters Build Layout and Orientation Laser Parameters Post Processing Metallographic Analysis Mechanical Testing Data Data feed to MSC MaterialCenter Flexible schema for different applications Automated method for input of material process information Data analysis: compare and contrast properties, understand how to optimize Traceability of test data 16
DATA SCHEMA Right of Test - Material products track from test to export Left of Test Capture manufacturing inputs that are used to create a part or specimen Leverages MaterialCenter Work Request, Pedigree and Process features Project tracks test specimen from raw material through specimen build process Track: Materials & environment Batch/Specimen numbers Tracking of Inspection Capturing the Entire Material Lifecycle 17
FLOWCHART OF DATA 18
MSC/WINDCHILL INTEGRATION Data Schema Materials Properties, Process Parameters, etc. Library of Components, Product CM Product Structure Per Component Component Data Files & Requirements Materials Center Pre-Build Information WindChill Post-Build Information Final Product Produced in Field Additive Manufacturing Component Fabrication 19
BENEFITS - CENTRAL DATA SYSTEM Always up-to-date for version control tracking Less duplication of efforts reduced costs Common file system for traceability, file security, historical storage, etc. A better collaborative environment in order to coordinate efforts Quicker fabrication of hard to replace parts with standardized file systems and organization Common data models for standardization and validation Single source of data for linkage between systems True lifecycle configuration management In order to make Additive Manufacturing as available as traditional manufacturing techniques, materials and process data must be linked to part data using enterprise epdm approach 20
BIG VISION (ARMY DATA) Army Standardized Tool Lifecycle support when printing a component. Provide confidence through validation to the end user in part performance Everything in the chain from raw material, files, machines, and post treatment validated to perform as designed. Data Capture: Enable automated processes to feed into the data management system On Demand Manufacturing: Qualified and authorized personnel with access to data Predictive Modeling: be able to know how a part will perform before printing Cooperation & Data Sharing: Saving money and time by building on the most up-to-date work. Data analysis: Optimize process parameters via statistical modeling. Understand the relationship between key process parameters 21
PATH FORWARD Data Schema Currently on its 9 th iteration with industry and academia contributors enabling a standard practice of recording the parameters, files, conditions, and parts. Integration with other enterprise software Windchill (EDGE) Integration Collaboration with other services such as the Air Force, Navy, etc. Expanding to other manufacturing processes and capture of legacy manufacturing data. Creation and storage of new data libraries Work through IT & Security issues with large scale adoption Align future vision with new alignment of Army Futures Command. Areas where we can collaborate 22
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