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Additive Manufacturing Ecosystem

Luana Iorio, Ph.DApril 1, 2017

Additive Manufacturing … a 4 step process

Digital design Digital slicing Layer-wise manufacturing Final part

1 2 3 4

3

Direct Metal Laser Melting (DMLM)

Powder

Collection

Chamber

Dispenser

1

2

3

4

Transformational Power of AdditiveThe Additive Advantage

Expands What is Possible … opens up new design capability to optimize part & system designs in a way we cannot with traditional manufacturing processes

Improves Quality … eliminates design trade offs; reduced cycle times, digital v. analog control, reduced braze/weld/rivet/bolted joints

Simplifies Systems… more robust designs, reduced part counts and assemblies; shortened supply chains

Capabilities of full production35,000 – 40,000 per year

PARTS

DURABLEMORE

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

6

Sumps, bearing housings, frames, exhaust case, combustor liner, heat exchangers C-Sump

55% of major structures additively manufactured ATP engine for new Cessna aircraft - Denali

Each major component eliminates many sub-parts

PART WEIGHT25%

REDUCTIONPARTS

50 1PARTS

ENGINE WEIGHT5%

REDUCTIONFUEL BURN1%

REDUCTION

855 12

and now we’re building an engine ...

the Advanced Turboprop engine (ATP)

Acetabular Cup

Trabecular Structure

Tailored and bespoke designs

Additive Adoption Barriers & Opportunities

8

Immature design-for-additive tools

Limited materials base

Uncertain material properties

Machine size and speed limitations

Post-processing complexity

Part qualification, evolving industry standards

Topology optimization & analysis tools

Materials development

Process modeling

In-process monitoring

Rapid qualification techniques

Scaling machine capability – machine design, laser technologies, control systems

Non-destructive evaluation techniques

Barrier Technical Opportunity

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

Rapidly Expanding Materials Capability

Co-28Cr-6Mo

40

60

80

100

120

140

160

180

200

DMLS - V DMLS - H WroughtLow

WroughtHigh

YS (ksi) "UTS (ksi)"

18

22

26

30

34

38

42

DMLS - V DMLS - H Wrought Low WroughtHigh

Elongation (%) "Hardness (HRC)"

ASTM

ASTM

ASTM

ASTM

DMLM - V DMLM - H

DMLM - V DMLM - H

Understanding Structure-Property Relationships

Additive Manufacturing Development Process100+ Material & Machine Parameters

Powder Specification• Powder Source• Powder Size• Powder Composition• Reuse Procedures

Laser Parameters• Spot Size• Laser Power• Laser Travel Speed• Laser Dwell Time

Thermal Processes• HIP Cycle Parameters

• Heat Treat Atmosphere

• Braze HT Parameters

• Solution Temperature

Recoat Parameters• Layer Thickness• Recoater Arm Design

Build Chamber• Build Atmosphere• Purge Gas• Airflow• Preheat Temp

Hatch Strategy• Contour Pass • Sky Writing• Line Spacing & Overlap

Calibration & Maintenance• Preventative Maintenance• Pre-build Calibration• Factory Environment Controls

Post Processing• Mechanical Finishing

• Thermal Exposures

Supply Chain Shift In Progress

© 2015 General Electric Company - All rights reserved

Building the next generation workforce

$2 million for 3D-printing equipment and curriculum

Focus on STEM/STEAM programs

$8 million for metal additive manufacturing equipment

Focus on additive learning efforts

Primary and secondary schools Two- and four-year colleges and universities

Supporting Industry InitiativesSome of the opportunities …

Specifications Industry Groups

EASA Additive Manufacturing Workshop | 29 September 2016 GE AVIATION 15

GE Aviation Additive Technology Center