Embed Size (px)
Citation preview
ESA UNCLASSIFIED - For Official Use
Additive Manufacturing applications in Space: requirements, opportunities, and challenges
Dr. Johannes Gumpinger
14/03/2018
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 2
Purpose of ESA
“To provide for and promote, for exclusively peaceful
purposes, cooperation among European states in
space research and technology
and their space applications.”
Article 2 of ESA Convention
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 3
AM based bellows
• => Artes 5.1 activity to investigate a
potentially more reliable and cost
effective manufacturing process => AM
• Characterizing the performance and the
reliability of the bellows produced
through a test campaign
• Targeted TRL for this activity was 4
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 4
AM based bellows
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 5
AM based bellows
• Fatigue testing and He
tightness testing performed
in sequence
• No failure / leaks detected
• => remaining challenge:
development of cleaning
procedure to achieve
required cleanliness
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 6
ATHENA optical bench with Additive Manufacturing
o ATHENA mission: X-Ray telescope
used to assess key astrophysical
questions
o Optical bench structure (3m
diameter, 30 cm height) material
trade off:
o E/r => max, CTE => low
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 7
ATHENA optical bench with Additive Manufacturing
o 16 axis twin robot system
o Turn-tilt table
o 1 robot performs welding task
o 1 robot performs milling task
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 8
AM R&D recap
Antennas
RF equipment
Source: Van der Vorst et al: Applicability of 3D Printing
Techniques for Compact Ku-band Medium/High-Gain
Antennas. Eucap 2016.
Source: ESA – TESAT(D) – ILT (D)
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 9
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 10
No maintenance!
Fit for purpose
Reliable
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 11
Requirements of AM for Space applications
Materials, Processes, Mechanical Parts for Space
Processes in ECSS-Q-ST-70C:
Process selection and training
• Reliable, inspectable, reproducible
• Processes data to be stored in database, customer access to be
granted
• Control of limited shelf-life materials
• Operators and inspectors shall be trained and certified for special
processes
Criticality analysis
• => evaluation phase
• => verification phase
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 12
Influencing factors on end-
product
Development phases of an AM
product
Requirements of AM for Space applications
Design
Material supply
Processing
Post processing
Testing / qualification
AM definition phase
AM evaluation phase
AM verification phase
Production of hardware
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 13
ESA Additive Manufacturing (AM) Benchmarking Center – Coventry UK • AM of space hardware => small, medium and large parts
• Services for :
• ESA Projects/ESA Directorates: access to state-of-the-art
3D Printing capabilities (metallic/non-metallic)
• Industry to mature their AM products and process
understanding
• Benchmarking of:
• AM powders
• produced materials
• post processing techniques
• AM machines
• Failure investigation/re-manufacture of parts
• Publication of a European Newsletter with
all results generated by the Centre
• Consolidate European leadership on AM
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 14
Additively Manufactured copper materials for launcher engines
Objectives:
• Investigate material properties of copper alloys suitable
for launcher liquid propulsion and Additive
Manufacturing
• Produce and assess crucial features of a VEGA TCA
liner: cooling channels, overhangs etc.
• Investigate manufacturability of the TCA: distortion,
dimensional accuracy etc.
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 15
Hybrid Additive Manufacturing
Objectives:
• Investigate intersection from wrought IN718 to Additively Manufactured IN718
• Will be assessed through mechanical and microsectional investigation
• Targeted applications of AM hybrid components:
Liquid propulsion elements
• Expected benefits: cost reduction, as only complex
parts would be produced with AM, standard
geometries through machining
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 16
Advanced Manufacturing ESA Cross Cutting Initiative
● Advanced Manufacturing (AM) cross cutting initiative has the following objectives:
● To create new high performance Space products by actively reducing the limitations imposed by the traditional manufacturing processes/concepts
o Identify and implement new manufacturing technologies for space applications enabling:
Design freedom
Performance improvement
Costs reduction
Lead time reduction (from concept to manufacturing)
Space Products
End-to-end Advanced Manufacturing Process
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 17
GSTP-6 Element 1 Potential Activities Advanced Manufacturing
More information: www.emits.esa.int => news
ESA UNCLASSIFIED - For Official Use Dr. Johannes Gumpinger | ESTEC | 14/03/2018 | Slide 18
Thank you for your attention!
Prepared by: Johannes Gumpinger Ana Brandao Laurent Pambaguian Thomas Rohr Tommaso Ghidini [email protected] www.esa.int
