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Additive Manufacturing at GE Mohammad Ehteshami VP & GM, GE Additive
August 29, 2017
Capabilities of full production 35,000 – 40,000 per year
PARTS
DURABLE MORE
WEIGHT
LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines
It started with 1 part …
25%
20 1
5x
REDUCTION
2
Then a system … Advanced Turboprop
PARTS
WEIGHT REDUCTION
Combustor test schedule reduced from 12 months to 6 months
LOWER FUEL BURN
20 %
5 %
855 12
At an enterprise level Design Manufacturing Services
Additive
1 Digital Twin
6-8 Engineers
1 Mfg. sources
Inspection Sys. &
Component to Repair
1 1 data lake
…powering
300 parts
60 Engineers 5
Conventional
40 data systems
Mfg. sources 50+
Turbine frame
Same frame
Repair Sources
• HQ in Lichtenfels, Germany
• 400+ employees
• Products: • Metal additive machines (Laser technology)
• Industries served: Aerospace, Medical/Dental, Auto, Jewellery
• HQ in Mölndal, Sweden
• 340+employees
• Products: • Metal additive machines (Electron Beam technology) • Materials (from AP&C) • Additive Service Bureau for Medical Industry (DTI)
• Industries served: Aerospace, Medical, Auto, Tooling
GE Additive
Focused on three
main offerings:
• Materials
• Machines
• Engineering Consultancy Services
Today…
• 1100 employees
• 22 sites
• Stakes in Concept Laser & Arcam AB
1
Machine Qualification
Qualification … and then fixed process control
Material Qualification … must buy-into material allowable curves, must meet material specs
Part Qualification … process must be in control, dimensional, functional
Part Inspection … methods based on traditional castings (gage, white light, FPI, X-Ray, CT)
Every Machine is a “Micro” Foundry
2
Certification: Material Qualification
Process Structure Properties
As-Built Structure
Isotropic Structure After Thermal Processing
Physical properties
Strength properties (static, fatigue)
Damage Tolerance
Variation (Lots, machines, etc)
X, Y, & Z Build direction
Surface finish factor
Part feature factor (e.g. thin wall)
Cycles to Failure
Alt
Str
ess
Machined
As-built surface
Powder specification
Machine parameters
Build chamber environment
Machine calibration
Thermal processing
Post processing
Powder re-use
Expanding Materials Capability
Inco 718
Inco 625
SS 316L
17-4 PH
SS 15-5
MS-1
Bronze AlSi10Mg
6061 T6
CoCr Hast X
Ti 6242 Ti 64
W
TiAl
A205
F357
HS188
Rene 80
Material allowables identified (GE Redbook design data)
Process/Part/System Validation
Fuel Nozzle Example
9
TIME AT TEMP
RIG TESTING
NOZZLES TESTED
CERT TESTING
PREDICTED LIFE
COMPONENT TESTING DESIGN ALLOWABLE
low cycle fatigue test 1-cup coking rig LEAP-1A Icing test
DIMENSIONAL
FEATURE DEBIT
9x 100% 500+
Powder Specification DMLM Process Specification
Chemical composition
Melting and atomization method
Powder quality
Process control
Particle size distribution (PSD)
Component Specification
Additive Specification Control
Fixed Process Controls
Equipment qualification & Preventative Maintenance
Power level verification
Facility environmental controls
Powder handling and reuse
Software control
Operator training
Record keeping
Machine restarts
Chemistry & Composition
Structure/ Porosity
Properties
Surface finish
Thermal processing
Proprietary specs evolving to industry wide specs
Building Industry Capability
Specifications Industry Groups
Accelerating the Additive Revolution
We’re focused in three areas…
Materials
Engineering
Machines +
Customer Collaboration
• Application Engineering • Rapid Prototyping • Low Rate Manufacturing
Customer Support
• Field Support • Spare Parts • Materials • Logistics
Customer Training
• Additive Design • Additive Machines • Additive Materials
GE Additive Customer Experience Centers
Our Customer Experience Centers are designed to help customers
understand the additive process; from design to prototyping to production and support them along the way
Pittsburgh Munich More coming soon…
Investing in a limitless future
PRIMARY AND SECONDARY SCHOOLS (ages 8-16)
• $2 million for 3D-printing equipment and curriculum
• Focus on STEM/STEAM programs
• Over 400 recipients in 2017
COLLEGES AND UNIVERSITIES (2 and 4-Year)
• $8 million for metal additive manufacturing equipment
• Focus on additive learning efforts
• 8 recipients in 2017