1 of 31

Development and Development and Implementation of Metals Implementation of Metals Additive Manufacturing Additive Manufacturing

Presentation TitlePresentation Title

Ian D. Harris, Ph.D.Ian D. Harris, Ph.D.Director, Additive Manufacturing Director, Additive Manufacturing Consortium (AMC)Consortium (AMC)EWIEWI

2 of 31

OutlineOutlineBrief EWI summaryBrief EWI summaryAdditive Manufacturing (AM) Additive Manufacturing (AM) –– what is it?what is it?Additive Manufacturing Consortium (AMC)Additive Manufacturing Consortium (AMC)SummarySummary

3 of 31

About EWI About EWI

A $30M applied engineering services R&D A $30M applied engineering services R&D company that develops and commercializes company that develops and commercializes advanced manufacturing technologies advanced manufacturing technologies A global leader in materials joining technology A global leader in materials joining technology to advance our customers' manufacturing to advance our customers' manufacturing competitiveness competitiveness Serves 240 member companies with over Serves 240 member companies with over 1,200 locations worldwide, 1,200 locations worldwide, InclIncl Exxon Mobil, Exxon Mobil, Chevron, etcChevron, etc

4 of 31

Advanced Manufacturing Advanced Manufacturing TechnologiesTechnologies

Additive manufacturingAdditive manufacturingAdvanced arc weldingAdvanced arc weldingAutomation, sensors, controlsAutomation, sensors, controlsBrazing and solderingBrazing and solderingDissimilar materials joiningDissimilar materials joiningFriction welding and processingFriction welding and processingHot formingHot formingLaser processingLaser processingNondestructive examinationNondestructive examinationNumerical modeling and simulationNumerical modeling and simulationPlastic and composite fabricationPlastic and composite fabricationResistance weldingResistance weldingUltrasonic joiningUltrasonic joiningUltrasonic machiningUltrasonic machiningWeldabilityWeldability testing, mechanical testing, testing, mechanical testing, and metallurgical analysisand metallurgical analysis

5 of 31

Additive Manufacturing Additive Manufacturing ––Progressive LayersProgressive Layers

Definition of additive manufacturing; Building a Definition of additive manufacturing; Building a part directly from a 3D CAD file to produce a partpart directly from a 3D CAD file to produce a partAdditive manufacturing Additive manufacturing -- build in layers, using build in layers, using powder bed or wire fed processes powder bed or wire fed processes -- stress stress relieve/PWHT, machine, as/if necessary for relieve/PWHT, machine, as/if necessary for material and applicationmaterial and application

6 of 31Each step requires handling, logistics, capital

equipment, time, material wasteEach step requires handling, logistics, capital

equipment, time, material waste

From Conventional Fabrication…From Conventional Fabrication…

7 of 31

……to AM Part Fabricationto AM Part Fabrication

One step: reduces handling, logistics and supply chain, capital equipment, time,

material waste

One step: reduces handling, logistics and supply chain, capital equipment, time,

material waste

The Promise The Promise -- from machine directly to part from machine directly to part –– make make things that cannot be made any other way, eliminating things that cannot be made any other way, eliminating many steps in current manufacturingmany steps in current manufacturingThe Barriers The Barriers -- Limited data, fragmented development Limited data, fragmented development process, most equipment is from overseas (jobs, process, most equipment is from overseas (jobs, manufacturing base) and has a small work envelopemanufacturing base) and has a small work envelope

8 of 31

AM Processes for Metals AM Processes for Metals EBW freeform fabrication EBW freeform fabrication -- EB(FFF)EB(FFF)Laser powder, POM, LENS, wire for FFFLaser powder, POM, LENS, wire for FFFSLM, DMLS, EBM powder bed laser and EB SLM, DMLS, EBM powder bed laser and EB ArcamArcam, EOS, in confined envelope , EOS, in confined envelope Arc processes Arc processes –– GTAWGTAW--HW, GMAWHW, GMAW--P, PTA P, PTA (wire/powder) for FFF(wire/powder) for FFFVHP UAM VHP UAM –– very high powervery high powerultrasonic AM from strip ultrasonic AM from strip Wide range of deposition ratesWide range of deposition rates

9 of 31

Powder Bed Powder Bed –– Size Size LimitationsLimitations

Ti6Al4VTi6Al4V ELITitanium Grade 2CoCrMo ASTM F75

10 of 31

Example Metals AM Example Metals AM ProcessesProcesses

Concept Laser DCM®

EOS DMLS®

MTT SLM®

Phenix Systems

OptomecLENS®

MTS Aeromet LAM(No longer in

business).

Sciaky EBFFF

Arcam EBM®

11 of 31

Deposition Rate Deposition Rate vsvsResolutionResolutionCourtesy BoeingCourtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

e

12 of 31

MS&T 2011 ColumbusMS&T 2011 ColumbusAdditive Manufacturing of Metals Additive Manufacturing of Metals SymposiumSymposiumOrganized by EWI, UL, OSU, NCSU, and Organized by EWI, UL, OSU, NCSU, and ArcamArcam50 papers in six sessions over 3 days50 papers in six sessions over 3 daysAll aspects of Metals AMAll aspects of Metals AMColumbus, Oct 17Columbus, Oct 17--2020

13 of 31

Example ApplicationsExample ApplicationsLand vehiclesLand vehicles

OEMOEMRepairRepair

Power generation, nuclear, oil and gasPower generation, nuclear, oil and gas

14 of 31

ArcArc--Based Additive Based Additive ManufacturingManufacturing

GMAW-P

PAW (Cold Wire)GTAW (Hot Wire) RWF-GMAW

PTA (Powder)

Proprietary to Lockheed Martin Copyright 2009

Demonstration of low cost arcDemonstration of low cost arc--based processes for based processes for Titanium AMTitanium AM

GMAWGMAW--PPRWFRWF--GMAWGMAWPAW (Cold Wire)PAW (Cold Wire)PTA (Powder)PTA (Powder)GTAW (Hot Wire)GTAW (Hot Wire)

15 of 31

PrecisionPrecision--GMAW BuildGMAW Build--UpUp

1.5mm

Stainless steel edge build-up• 18 ipm Travel speed • Heat-input < 1 kJ/in

Stainless steel edge build-up• 18 ipm Travel speed • Heat-input < 1 kJ/in

16 of 31

GTAWGTAW--HWHWTypically up to 500 ATypically up to 500 AUp to 20 lb/hrUp to 20 lb/hr

17 of 31

TiTi--66--4 Control arm with 4 Control arm with GTAWGTAW--HWHW

First layer and First layer and completed depositcompleted deposit

18 of 31

Distortion ControlDistortion ControlEnd and side views End and side views showing low level of showing low level of distortiondistortion

19 of 31

Process Applications Process Applications --EBFFFEBFFF

.

Machining

Application: Rapid Application: Rapid prototypingprototyping

Eliminate or reduce Eliminate or reduce expensive tooling and expensive tooling and fixturingfixturingIdeal for aerospace Ideal for aerospace applicationapplication

Lateral Application: Lateral Application: Precision RepairPrecision Repair

Engine vane repairEngine vane repair

20 of 31

EWIEWI’’s Laser Equipments Laser Equipment1515--kW IPG Fiber LaserkW IPG Fiber Laser

4-way beam switch

15-kW Laser

21 of 31

SamplesSamplesStainless to Steel

Stellite to Steel

Inconel(2 pass)

22 of 31

1010--kW Fiber LaserkW Fiber Laser

~2.6% Dilution

Dilution typically less than 5%Dilution typically less than 5%316L on 4130316L on 413099-- ×× 1212--mm rectangular spotmm rectangular spot8 kW ~1 mm build8 kW ~1 mm build--up (single pass)up (single pass)

23 of 31

Time to deployment

Man

ufac

turin

g R

eadi

ness

University & Federal Labs

Manufacturers & Suppliers

Additive Manufacturing

Consortium

MRL 3-7Significant commercial impacts in 2-5 years

MRL 8-10Incremental improvements and implementationShort time horizon

MRL

24 of 31

Additive Manufacturing Additive Manufacturing Consortium Consortium

Universities/National Labs and Other Partners

•The Ohio State University (partner)•University of Louisville (partner)•University of Texas (partner)•North Carolina State University (partner)•South Dakota School of Mines (partner)•Lawrence Livermore National Lab (partner)•TechSolve (partner)•NCMS (partner)

Goal Goal –– Advance the manufacturing readiness of additive Advance the manufacturing readiness of additive manufacturing for the defense industrial base and other manufacturing for the defense industrial base and other industriesindustries

Air Force (Steve Szaruga)Air Force (Steve Szaruga)Army (Stacey Kerwien)Army (Stacey Kerwien)NASA (Craig Brice)NASA (Craig Brice)NAVAIR (Bill Frazier)NAVAIR (Bill Frazier)NIST (Kevin Jurrens)NIST (Kevin Jurrens)Industrial MembersIndustrial MembersGE GE RR--RRBoeingBoeingLockheed MartinLockheed MartinNorthrop GrummanNorthrop GrummanGeneral DynamicsGeneral DynamicsMorris TechnologiesMorris TechnologiesApplied OptimizationApplied OptimizationB6SigmaB6Sigma

25 of 31

AMCAMCGoal: Advance manufacturing competitiveness Goal: Advance manufacturing competitiveness of a key emerging technology, namely AMof a key emerging technology, namely AMMission: Advance the manufacturing readiness Mission: Advance the manufacturing readiness of metal AM technologies to benefit consortiumof metal AM technologies to benefit consortiumHow: A network of industry, government and How: A network of industry, government and unisunis for maturing metal AM technologyfor maturing metal AM technologyAMC was founded to provide a U.S. AM forumAMC was founded to provide a U.S. AM forumEWIsEWIs AMC Role: Organize, operate, seek AMC Role: Organize, operate, seek funding, program manage, contribute to funding, program manage, contribute to technology development activitiestechnology development activities

26 of 31

AMC AMC Rapidly growing network of industry, Rapidly growing network of industry, government, and university partners, government, and university partners, First Members Meeting Dec. 7, 2010 with 20 First Members Meeting Dec. 7, 2010 with 20 members/partnersmembers/partnersCurrently 22 members with 4 more joiningCurrently 22 members with 4 more joiningRecognized AM Aerospace and Defense Recognized AM Aerospace and Defense consortium consortium –– Aviation WeekAviation Week Nov. 1/8Nov. 1/8Poised to grow in other sectors, oil and gas, Poised to grow in other sectors, oil and gas, medicalmedical

27 of 31

AM GapsAM GapsDesign: Designers must be taught the Design: Designers must be taught the performance and economics of AMperformance and economics of AMQuality control: standards are needed to Quality control: standards are needed to assure that every part meets requirementsassure that every part meets requirementsCost and Flexibility: AM processes must Cost and Flexibility: AM processes must be much more productivebe much more productiveSupply Chains: U.S. companies need help Supply Chains: U.S. companies need help to commercialize new AM technologiesto commercialize new AM technologies

28 of 31

Qualification ChallengeEvaluation Stages – BMS 7-361 [1] Initial Screening[2] Process/Source Approval[3] Deposition Parameter Approval[4] Approval on Non-Critical Flight Hardware[5] Approval of Critical Flight Hardware

Reference: Slattery, K., AeroMat 2008

Deposit

Substrate

Test Samples

• Characterization – including geometry effects – must be performed • Must push for a better combination of resolution, build envelope, and deposition rate

29 of 31

AMC AMC -- Proposed 1Proposed 1stst Year Year Goals AchievedGoals Achieved

Obtain broad industry and government support Obtain broad industry and government support ––achieved for A&D, reaching out to O&G, others achieved for A&D, reaching out to O&G, others Organize Organize ““National Test Bed CenterNational Test Bed Center”” research research partners network partners network –– in place with 22 partnersin place with 22 partnersIdentify technology priorities and create plan Identify technology priorities and create plan ––priorities identified priorities identified $60M$60M of proposalsof proposalsConduct SOA review of metal AM Conduct SOA review of metal AM -- completecompleteEstablish a database for collecting metal AM Establish a database for collecting metal AM property information property information –– will use MMPDSwill use MMPDS

30 of 31

Summary and ConclusionsSummary and ConclusionsAM for metals is rapidly developing through a range of AM for metals is rapidly developing through a range of technologiestechnologiesAdditive Manufacturing Consortium (AMC) is poised for Additive Manufacturing Consortium (AMC) is poised for growth into other sectorsgrowth into other sectorsAMC offers collaboration for development of metals AM AMC offers collaboration for development of metals AM 22 members, more welcome22 members, more welcomeLooking for potential applications for oil and gas market Looking for potential applications for oil and gas market

Nominally Nominally ‘‘unmanufacturableunmanufacturable’’ componentscomponentsHigh added value, long lead time itemsHigh added value, long lead time itemsAdding features to low yield castings and forgingsAdding features to low yield castings and forgingsRepair applications Repair applications

31 of 31

Contact informationContact information

Presenters NamePresenters NameCompany NameCompany NameEE--mail Addressmail AddressPhone NumberPhone Number(contact info slide is optional)(contact info slide is optional)