www.cranfield.ac.uk

Cost effective large scale AM

Dr Filomeno Martina + WAAMMat team

30th May 2017

waammat.com

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The making of the world’s biggest part

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The making of the world’s biggest part

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WAAM // Business drivers

• Lead time reduction • Example: lead time for large forgings can be up to 14 months + 4 months for roughing and

finishing. WAAM can reduce this to weeks

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WAAM // Business drivers

Aluminium: • 14 months for forging • 4 months for machining • 90% waste

Titanium: • 10 times worse

problems

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WAAM // Business drivers

• Lead time reduction • Example: lead time for large forgings can be up to 14 months + 4 months for roughing and

finishing. WAAM can reduce this to weeks • Manufacturing cost reduction

• Better material utilisation. Example: reduction of BTF to <2 ! cost savings up to 70% compared to machine from solid

• Potential for additional material savings via topological optimisation

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WAAM // Example of cost savings

Manufacturing option Mass (kg)

BTF Cost (£k) Cost red.

Original machined 20 12 16.2 -WAAM + machining 20 2.3 5 69%

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WAAM // Business drivers

• Lead time reduction • Example: lead time for large forgings can be up to 14 months + 4 months for roughing and

finishing. WAAM can reduce this to weeks • Manufacturing cost reduction

• Better material utilisation. Example: reduction of BTF to <2 ! cost savings up to 70% compared to machine from solid

• Potential for additional material savings via topological optimisation • Improvement in parts’ properties

• Hybrid processes (f.i. WAAM + cold-work) • Multi-material structures

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WAAM // Multi material

W

Mo

Ta

Cu

Fe

Fe

WC

Cast Fe

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WAAM // How does it compare?

(our assessment)

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What we’ve deposited so far

• Titanium • Grade 2 • Grade 5 • Grade 23

• Aluminium • 2024 • 2319 • 4043 • 5087

• Refractories • Tungsten • Molybdenum • Tantalum

• Invar

• Steels • ER60 • ER80 • ER90 • ER120 • Maraging grade 250 • Maraging grade 350 • Stainless (17-4 PH, 316L, 420)

• Inconel • 625 • 718

• Bronze • Copper

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10 years of WAAM

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Recent nice parts

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Wire + Laser AM = WLAM

1 mm 1 mm

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So what’s the problem?

There are no commercial systems available.

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WAAM // The software workflow

WAAMSoftWAAM Data (API)

WAAMCtrl

WAAMDesign

Primary process parameters

Thermal mass calculation around path

Allocation of thermal, geometrical & system compensations

Import CAD model

Partition (manually/ automatically)

Allocate partition and interface build strategies and sequence

System controller

Tool path generation

Simulation, collision detection

Tooling geometry

Process monitoring and

control, geometry and temperature

Generate net shape and check WAAM compatibility and baseplate

positionCost analysis

Programme for CNC machines/ robots

Allocate baseline bead geometrical parameters

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WAAMSoft // OverviewWAAMCore

Robotic API Feature-based design Assisted design AutomatedPath Planning for WAAM

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Path Planning: Robotic API

• MoveL • MoveC • MoveArcL • MoveArcC • …

• ABB • Fanuc • KUKA • CNC • …

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Path Planning // Feature-based Design

Choosing Feature Define

Features Parameters

WAAMCore

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Path Planning // Feature-based Design

• Layer height • Cooling time • Independent layers parameters • Independent zones parameters

• Stepover

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Path Planning // Feature-based Design

• Layer height • Cooling time • Independent layers parameters • Start and stop position • Deposition orientation and reverse • Independent oscillation parameters

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Path Planning // Feature-based Design

• Layer height per revolution • Deposition orientation • Independent zones parameters

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Path Planning // Feature-based Design

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ADMIRE // EU project to set up MSc course on Metal AM

Finally – not forgetting we are supposed to educate as well!

Plans • Pilot course: Oct 2018 • Full launch: Oct 2019 • Steering council – open to all industry partners – what do you want in this course

Industry partnersAcademic partners

Powder-based AM processes

Modelling and software

NDT and inspection aspects

Wire-based AM processes

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Wrapping up

Much more information on WAAM on our website

waammat.com OR CONTACT: Dr Filomeno Martina f.martina@cranfield.ac.uk

THANK YOU FOR YOUR ATTENTION ☺? ?

• Many new developments through the WAAMMat programme including new process variants promising high fidelity high build rate process and in-process cold-work solutions

• WAAM is progressing to the qualification phase

• Commercial systems with intelligent software will be available in 2018