Fluid Power Applications

Fluid Power Applications for Emerging Trends in Additive Manufacturing

Lonnie Love Manufacturing Systems Research Manufacturing Demonstration Facility Oak Ridge National Laboratory

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Outline

• Background – ORNL’s push in manufacturing

• Bringing $B of scientific tools to manufacturing – Focus on Additive Manufacturing and Carbon Fiber

• Impact on Efficiency – Weight reduction – Mesoscale valves

• Zero tare flow, digital and thermal poppets – Creative designs blending additive/carbon fiber and fluid power

• Role in workforce development – Using AM to drive kids to STEM – Partnering with America Makes (NAMII) and FIRST

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DOE’s first Manufacturing Demonstration Facility at Oak Ridge National Laboratory

A DOE-funded facility promoting broad and rapid dissemination of advanced manufacturing technologies

ORNL’s Carbon Fiber Technology Facility A DOE-funded facility for demonstrating advanced technology scalability and producing market-development volumes of prototypical carbon fiber Production capacity:

25 tons/yr fiber from multiple precursors in various forms

Additive Manufacturing enabling product customization, improved

performance, multifunctionality and lower overall manufacturing costs

Carbon Fiber and Composites enabling widespread deployment in high-volume,

cost-sensitive energy applications

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Additive Manufacturing (AM)

“Additive Manufacturing will become the most important,

most strategic, and most used manufacturing technology ever.”

Wohlers 2012

• Increased Complexity • Less Material Scrap • Shorter Design Cycle • Reduced Part Count • Faster • Cheaper • Better!

CAD Model to Physical Part

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Additive Manufacturing (AM) MDF Thrust Area

Leveraging key resources at ORNL to accelerate technology implementation • Developing advanced materials

– Titanium alloys, Ni superalloys, stainless and ultra high-steels

– High-strength, carbon-reinforced polymers

• Implementing advanced controls – In-situ feedback and control for rapid certification and

quality control

• Understanding material properties and geometric accuracy

• Exploring next-generation systems to overcome technology barriers for manufacturing – Bigger, Faster, Cheaper

– Integrating materials, equipment and component suppliers with end users to develop and evolve the supply chain

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• Developing in-situ characterization, feedback and control

• Precision melting of powder materials

• Processing of complex geometries not possible through machining

Electron Beam Melting (4)

• Simultaneous additive and subtractive process for manufacturing complex geometries

• Solid-state process allows embedding of optical fibers and sensors

Ultrasonic Additive Manufacturing (1)

• Site-specific material addition

• Application of advanced coating materials for corrosion and wear resistance

• Repair of dies, punches, turbines, etc.

Laser Metal Deposition (1)

• High Resolution • Unsintered support powder (easy removal)

• Wide variety of materials

Laser Powder Bed (1)

• High deposition rate • Large volume • Metal, polymer and ceramic feedstock

Laser Sintering (2)

9 Metal

Working with AM equipment providers to develop high-performance materials, low-cost feedstocks, processing techniques and in-situ characterization and controls to enable broad dissemination of technologies

Current Equipment


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• Developing in-situ characterization, feedback and control

• New high strength materials

• Increased z-strength

Fused Deposition Modeling (4)

• Multi-materials • Very high resolution

Stereolithography(1)

• Enormous growth • Low-cost (<$2K) • Open source so easy

for new material and control development

Desktops (15)

20 Polymer Current Equipment


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Leveraging Billions of Dollars of R&D Science to Application

Critical to widespread adoption of technology

Profilometry map illustrating distortion

• Advanced materials and processing to expand available materials

• Sensing and controls to provide reliability • Neutron science and advanced microscopy to

understand material properties • High performance computing to build models

to enable future design and processing tools

Laser AM creates large residual

stress leading to distortion

laser AM of turbine blade

Understanding link between residual stress and additive manufacturing

Utilizing neutron science to impact industry

turbine blade

Reconstructed image using neutron tomography

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E-beam approach: Hydraulic hand • Additive processes enable integrated pump, fluid passages and pistons into a

structure with mesh for weight reduction • Titanium hand made using E-beam fusion (operating pressure 3000 psi)

Curved fluid passages

Pistons integrated into structure

Integrated motor and pump

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Mechanical considerations • Mechanical Strength

– Hold to well over 6000 psi at 0.020” wall thickness on 0.125” tube

– Wrought Mechanical properties, even for 0.015” AM mesh

– Polish internal cavities

No finishing Aggressive finishing


Mesh structures for weight reduction

• Blending hydraulics and AM

• Less mass means – Less material – Less energy – Faster build – Lower cost

Solid palm weighing 857 grams. Meshed palm weighing 178 grams


Office of Naval Research: Underwater robotics • Completely printed arm

– Target is neutrally buoyant without any floatation devices • Shell structures for weight reduction (0.030” wall thicknesses)

• Total weight of 60” long arm is 25 lbs.

– Integrated hydraulics and electronics (nothing penetrates the skin) – No hoses, fluid passages integrated into structure – Anthropomorphic design

• 7 Degrees of freedom • Antagonistic actuation at each joint • Each joint has 180 degrees of rotation

– Custom thermal valves for energy efficiency


ONR underwater robotics

Involute cam joint

Barrel cam joint

Design rule: Provide 0.030” to 0.050” excess material on bearing surfaces and piston bores.


Mesoscale valves • High pressure (>3000 psi), low flow (<10 mL/min) control valves • Three designs all based on poppet valves

– Direct flow control via liquid cooled SMA • Zero tare flow • Independent chamber control (regeneration) • Low bandwidth (< 10 Hz), but low-cost fabrication/assembly • Very mature (have manufactured hundreds, implemented on underwater robot)

– Digital flow control • Zero tare flow • High bandwidth (> 200 Hz) • Still needs maturation

– Two stage digital valve • High flow rate via two stage poppet • Digital valve modulates pressure in large poppet


Carbon Fiber FDM Composites

CF-ABS

2x strength

4x stiffness

ABS

CF-ABS

• Compounded filament printed on Solidoodle 3 • 10-15% CF by weight

Dramatically reduced curl

Lindahl ACCE (2013)


• Collaboration between ORNL, Lockheed Martin and Equipment Manufacturer – Materials – low CTE, high strength materials – Deposition – new methods of deposition and

control – Multiple-robot coordination (8’ x 8’ x 8’ gantry,

Kuka Robot) • Pellet-to-Part: Enables manufacturing of large

components using pelletized feed.

Big Area Additive Manufacturing (BAAM)


Big Area Additive Manufacturing (BAAM)

Large scale deposition system • Unbounded build envelope

• High deposition rates (~20 lbs/h)

• Direct build components

• Tools, dies, molds

Carbon fiber material reduces warping out of oven


Out-of-oven • Manufacturing carbon fiber reinforced

materials – Shows increased strength and significant

reduction in distortion – Preliminary testing on in-situ post-processing

was successful

• Making sample parts for NavAir Cherry Point.

• Exploring new materials – CF ABS, CF Ultem, PEKK…

• For surface finish, have integrated fly cutter


FIRST Robotics Competition 2011–2012 teams now at work • Founded by Dean Kamen

(Segway inventor): For Inspiration and Recognition of Science and Technology

• Goal: Inspiring youth to be science and technology leaders

• Opened ORNL MDF to work with 8 area high schools

• Over 50 mentors and teachers • Over 200 students • Over $200K in industrial

support (Stratasys, DOE AMO, NFPA, Bimba )

• All schools learn to use AM • 2012 Smoky Mountains Regional

Competition • Hardin Valley Academy

Engineering Excellence Award (first completely AM Robot!)

• Oak Ridge High School Top Rookie All Star Award & Nationals Contender

• Webb High School Woodie Flowers Finalist Award

• Knoxville Catholic High School and Seymour High School Ranked in the Top 5

The future of manufacturing? STEM - High School Robotics Teams


ORNL, FIRST and HVA • Using FIRST as a platform to teach next generation of engineers about

manufacturing – Shown to over 200 companies, 1000 visitors – Students took to NAMII kickoff and DMC

Five students designed system

Shooter signed by policy makers

This is the highlight


Hybrid Assemblies

• First Robotics Team #3824 – Hardin Valley Academy – RoHawktics – Sponsored by ORNL Manufacturing Demonstration Facility

(MDF) • Hybrid Assembly

– FDM Fittings – Pultruded Rods – Filament winding

• Benefits – Additive is great at relatively smaller more complex – Carbon fiber is great at long, simple, light weight, high

strength structures – Combining provides strengths of both technologies


First Robotic Team #3824 • Application

– Robot Chassis – Stiff/light weight

• Solution – FDM light weight end pieces with critical

interfaces – Pultruded carbon rods for spanners – Filament wound for bonding and

strength/stiffness • Results

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Part Length AM Only Hybrid

Fab Time Weight Fab Time Weight

Long Beam 54” 90 hrs 14.64 lbs 15.5 hrs 3.86 lbs

Short Beam 21” 24 hrs 7.44 lbs 8.25 hrs 1.77 lbs


Team #3824, supported by DOE’s MDF, wins award for most 3D printed parts on robot, ranks #10 in division

Science, Technology, Engineering & Mathematics (STEM) DOE’s MDF Partners with NAMII to Showcase Additive Manufacturing at 2013 FIRST Championship in St. Louis


Conclusion • Many opportunities for fluid power industry in advanced

manufacturing • Additive for:

– Weight reduction – Integration of hydraulics with structure

• Existing program with Aerovalve (Ellen Mell) – New carbon fiber reinforced polymers for wider spectrum of

applications

• Low cost carbon fiber – Target $5/lb – Integration with feedstock or development of hybrid systems

• Importance of STEM – ORNL and NAMII partnering with FIRST


Discussion

Lonnie Love [email protected] (865) 576-4630

Documents

Fluid Power Applications