Certificatie, safety en wat kan AM veranderen?

Additive Manufacturing

Frank van BockelMarch 14 - NvvK Jaarcongres, Papendal

Who are we?

About Lloyd’s Register

About LR – at a glance

Independent Wholly owned by the

Lloyd’s Register Foundation, a UK charity

dedicated to research and education in science

and engineering.

Who we areA global organisation with specific areas of focus around marine, energy, management

systems and inspection services.

HistoryFounded in 1760 as a marine classification

society.

• Mission to enhance safety of life & property, and advance public education

• Based in the UK but awards grants globally

• Impact and excellence are the major grant-giving criteria

LR Foundation

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LRF - Foresight reviewshttps://www.lr.org/en/innovation/safety-accelerator/

http://www.lrfoundation.org.uk/programmes

Inspection Innovation

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The changing world around us

Source: World Economic Forum

Steam engines for mechanical

production

Electricity for mass production

Information technology for

automated production

Digital and cyber: Fusing technologies and blurring of lines between physical,

digital and biological

Speed and impact of this 4th era has no

historical precedent

AGEING / INCREASE OF PROCESS COMPLEXITY

17841st Revolution

18702nd Revolution

19693rd Revolution

Today4th Revolution

Industry 4.0 technology

● Remote / Robotics

● Blockchain

● IoT – sensor technology

● VR/AR

● AI – Machine Learning

● Digitalization

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Smart solutions shaped with human intelligence

Additive Manufacturing

What is Additive Manufacturing?

About the Technology

About the technology

Additive manufacturing (AM) works by “adding” material layer by layer

● “Adding” can be melting, sintering, gluing, freezing…anything that can bind granules/layers of material

● Materials can be metal, plastics, ceramics, sand…anything that can be deposited in a granular/layer fashion

It’s been around in various processes for over 30 years

● It started in 1986 by hardening and combining layers of photo-sensitive liquid using UV light

● It’s been well established within Aerospace and Medical sectors, and is picking up speed in Energy, Marine, Automotive & Construction

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What is Additive Manufacturing

3D CAD model .stl file 3D printer 3D objectPost

processing

Copyright © TWI Ltd

About the technology

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Different Processes

Polymers

Metals

Composites

Thermoplastics

Metallic AM processes – Laser Metal Deposition

The MERLIN project has received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement No. 266271.

https://www.youtube.com/watch?v=yKnlmfuMSgo Copyright © TWI Ltd

Metallic AM processes – Powder Bed Fusion

https://www.youtube.com/watch?v=rEfdO4p4SFc

Used for educational purposes only to demonstrate Powder Bed Fusion process. Copyright © Solid Concepts

Applications & benefits

● Customisation

● Complexity

● Integration & consolidation

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Tailored to patient, application, client

Weight reduction, reduced waste,design freedom

Fewer component parts, integrated functions

Technology based

● Obsolescence

● Manufacturing location

● Reduced lead time & spares

Supply chain based

Applications & benefits

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Example: Grote Marktstraat, The Hague, The Netherlands

● Final iteration● Equivalent strength● 75% less steel used● Compact design

● First iteration● Equivalent size● Weight reduced but

not optimised

● Conventional node ● The structural nodes, which connect the cables to the struts, were all slightly different (a total of 1,600 nodes with 1,200 design variations)

Ref: Salomé Galjaard, Arup, Amsterdam

AM supply chain

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The current state of Additive Manufacturing Codes & Standards

Standardisation

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Standardisation strategy for AM

JG51(Terminology)

JG52(Standard test artefacts)

JG53(Requirements for

purchased AM parts)

JG54(Design Guidelines)

JG55(Specific’n for extrusion-

based AM of plastics)

JG57(PBF Design Guidelines)

JG58(Qualification & QA of

post-processing for PBF)

JG59(NDT for AM)

JG62(Guide for constructing

round robin studies)

JG64(AMF support for solid

modelling)

JG65(Specification for AM St.St.

alloys)

JG66(Technical specification on

metal powders)

Joint Working Groups

(ISO & ASTM)

JG68(EH&S for 3D printers)

JG69(EH&S for use of metallic

materials)

JG56(PBF Quality

Requirements)

JG60(Guide for intentionally

seeding flaws in AM parts)

JG61(Anisotropy effects in

mechanical properties)

JG70(Optimized medical image

data)

JG71(Powder)

JG72(Machine)

JG73(Digital product definition

& data management)

JG74(Personnel training)

JG63(Powder flow properties)

JG67(Design of functionally

graded AM parts)

ISO/TC 261 JWG1(ISO 17296-1)

JWG2(ISO 17296-2)

JWG3(ISO 17296-3)

JWG4(ISO 17296-4)

JWG6

ASTM F42 F42-91(ASTM 52900)

F42-05 F42-01 F42-04 F42-06

Work area Terminology Processes, systems & materialsTest methods and

quality specifications Data & design

Environmental, health & safety

Standardisation strategy for AMTerminology Methods, process & materials Testing Data & design

Environmental,health & safety

ISO/ASTM NP 23047 (52932)

: Determination of particle emission rates

from desktop 3D printers using material

extrusion

Available As Draft

ISO/ASTM DIS 52903-1:

Material extrusion based AM of plastic materials – Part 1:

Feedstock materials

ISO/ASTM 52900: General principles

Part 1: Terminology

Published ISO

ISO/ASTM 52901: General principles -

Requirements for purchased AM parts

ISO/ASTM 52910: Standard Guidelines for Design for

AM

ISO/ASTM DIS 52903-2:

Material extrusion based AM of plastic materials – Part 2:

Process/ Equipment

ISO/ASTM AWI 52907: Technical specification on metal powders

ISO/ASTM DIS 52911-1:

Technical Design Guideline for PBF – Part 1:

LPBF of metals

ISO/ASTM DIS 52911-2:

Technical Design Guideline for PBF – Part 2:

LPBF of polymers

AM in aerospace applications

ISO/ASTM PWI 52904: Standard Practice for Metal Powder Bed Fusion Process to Meet

Critical Applications

ISO/ASTM PWI 52908: Post-Processing Methods – Standard specification for quality assurance and post processing of powder bed fusion metallic

parts

ISO/ASTM PWI 52909: Guideline orientation/location

dependence of mechanical properties for metal PBF

ISO/ASTMPWI 52931:

Standard guideline for use of metallic materials

ISO/ASTM PWI 52902: Standard Test Artifacts

Working Document

ISO/ASTM NP 52903-3:

Material extrusion based AM of plastic materials – Part 3:

Parts

ISO/ASTM NP 52905: General principles - Non-destructive testing of AM

products

WK56649: Standard practice for

intentionally seeding replica into AM structures

WK55610: Characterization of powder

flow properties for AM applications

ISO/ASTM NP 52912: Technical report for the design of

functionally graded AM parts

ISO/ASTM 52913: AM – Cloud platform & model

specification

ISO/ASTM NP 52941: System performance & reliability – Standard test method for

acceptance of PBF machines for metallic materials for aerospace applications

ISO/ASTM NP 52942: Qualification principles – Standard guideline for qualifying

machine operators of LPBF machines in aerospace applications

ISO/ASTM NP 52943-1:

Specification for Directed Energy Deposition using

wire and arc in aerospace

applications

ISO/ASTM NP 52943-2:

Specification for Directed Energy Deposition using wire and beam in

aerospace applications

ISO/ASTM NP 52943-3:

Specification for Directed Energy Deposition using

laser blown powder in aerospace

applications

ISO/ASTM PWI 52906: Standard specification for qualification, quality assurance and

post-processing of powder bed fusion metallic parts(based on VDI3504-2)

ISO/ASTM 23046 (52916): Optimized medical image data for AM

ISO/ASTM 52915: Standard specification for AM file

format (AMF)

Standardisation strategy for AM – HSE

Environmental,health & safety

ISO/ASTM NP 23047 (52932): Determination of particle

emission rates from desktop 3D printers using material

extrusion

ISO/ASTMPWI 52931:

Standard guideline for use of metallic materials

The path to approval

Achieving Certification

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Achieving Certification

● Industry and market acceptance– Regulatory requirement (Marine, Offshore, Aerospace etc..)– Provides assurance to you and your clients.

● Safety– Operators, public, consumers– Assets and environment

● Assurance– Assures quality, especially given the sensitivity of AM processes– Protection against low quality machines and poor facility processes

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Why Certify?

LR-TWI Guidance Notes for AM

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LR & TWI JIP

• The Joint industry project between LR and The Welding Institute (TWI) brings together research and development efforts alongside real-world additive manufacturing practices to develop new industry product certification guidelines - paving the way for more widespread adoption of the additive manufacturing technology.

• ENGIE Lab-Laborelec and Rolls-Royce Nuclear have formally joined the project as sponsors in 2016, supporting the development of both organisations’ understanding and certification of additive manufacturing for non-aerospace applications.

LR AM certification process

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AM Component certification SOW

• Design• Powder Feed stock• Facility• AM Material• Part

Certification ProcessAccurate model, translation, offsets

Design for manufacture, for post-processing and for inspection.….

Configuration control, synchronicity between models (e.g. for analysis, manufacture, inspection)

Powder production, labelling transportation, storage & handling

Recycling & sampling methods; cleanliness of equipment

Powder characterisation (i.e. control parameters, test methods, suitability & maintenance of equipment

Test specimens for formed material testing

Build control (i.e. parameters, firmware, version control)

Pre-build checks, cleanliness, maintenance of equipment, calibration…

PPE, operator competence, auxiliary systems, work instructions…

Physical records, control specimens, consistency throughout build

Removal from AM system, cleanliness (i.e. loose powder)

Thermal treatments, separation from support structures & build platform

Surface finishing procedures (consistent with test specimens)

Destructive/non-destructive testing

Mechanical & metallurgical testing

Geometric inspection (method depends on complexity of geometry)

Operator qualifications & competency

Design Materials Manufacture Post-process Inspect

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• The technical review:

− Health & safety control

o Procedures shall show that appropriate Personal Protective Equipment (PPE) is to be used for different

aspects of the process (e.g. refer to the MSDS for required PPE when handling powder)

o Fine metal powder feedstocks used for AM present a dust fire and explosion hazard, therefore, adequate

extraction facilities shall be provided to ensure that the working environment meets national regulatory

requirements (e.g. IEC 60079-10-2 or equivalent)

o Hazardous gases (used for shielding) shall be stored in vented gas cabinets and provided with adequate

extraction facilities

o Gas alarms are required for any confined space that has gas storage or systems

o In the case of Laser Metal Deposition systems:

• programmes shall be run from outside the working area of the robot and laser system

• procedures/interlocks shall be in place to prevent unauthorised/unplanned operation

• evidence shall be provided to show that hazards, such as robot collision or entrapment, have been

mitigated.

Quality system

Additive manufacturing

● Change / shortening supply chains

● Design freedom

● Design IP challenges

● Change marco- economics

● What’s next: 4D printing / food printing / ?

● New Safety challenges?Lloyd's Register 27

How could it change what we do

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Get in touch

Head of Innovation & commercialisationFrank van Bockelfrank.vanbockel@lr.org

Find out more at: www.lr.org/additive-manufacturing