Upload
duongque
View
241
Download
6
Embed Size (px)
Citation preview
Imagination at work
Materials Selection for Additive ManufacturingK. Rogers,
Technology Leader, Additive Manufacturing
GE Center for Additive Technology Advancement
August 10, 2016
Key additive manufacturing facilities
2
GE Healthcare AM COE, Milwaukee, WI
(PBFAM metals & polymers, direct write)
GE Global Research, Niskayuna, NY
(DMLM, laser cladding, polymers, ceramics, AM
design)
GE Corporate Center for Additive Technology
Advancement, Pittsburgh, PA(DMLM, EBM, polymers, sand binder jetting, laser cladding)
GE Power Advanced Manufacturing Works,
Greenville, SC(DMLM, polymers, AM design)
GE Aviation, Auburn, AL(LEAP fuel nozzle production
DMLM)
GE Aviation Additive Technology Center,
Cincinnati, OH(DMLM, EBM, polymers,
AM design)
GE Power AM COE, Baden, Switzerland(DMLM, polymers)
GE Oil & Gas, Talamona, Italy
(DMLM production)
GE Aviation, Avio Aero, Turin, Italy
(EBM)
GE Oil & Gas, Florence, Italy
(DMLM, polymers)
AM Technologies at GE
15 µm 200 µm 500 µm
Large-scale features
• Turbomachinery applications• Test hardware• Limited production since 2014
• Repair & feature addition; reduced buy-to-fly
• LRIP casting; NPI acceleration• In use
U/S probes Functional metal, ceramics & polymer partsCommercial polymer & metal machines
Large low volume functional metal partsCustom built machinesFoundry of the future enabler
Macro-scale featuresMicro-scale features
• Ultrasound probes• Integrated circuitry• Direct-written CBM sensors
• Direct ceramic deposition• Direct written sensors
• DMLM & Electron beam• Commercial polymer AM
• Spray technologies• Laser & EB cladding• Sand casting mold and core
CBM Sensors
Ceramics printing
Direct write
Mission Statement
This will be the flagship center for GE additive manufacturing where we will be on the forefront of implementing industrial applications for the benefit of all GE businesses. This site will be a hub of innovation and promote training and development in both design and applications for this breakthrough technology
Center for Additive Technology Advancement
Project Details
• First multi-modal US site
• ~50 employees
• 125,000 sq ft
• $39M Corporate investment
• April 2016 Opening
Pittsburgh, PA
Technology readiness level
• Part & process design tools
• Next generation equipment
• Material development
• Develop, prototype, scale & mature
• Should-be cost development
• Low rate initial production
• Large scale output
• Proven technology
• Standard routers & quality plans
Develop ImplementInvent
GRCCATA
Business
1 3 7 10
Applying additive technology
5
Repairs & ServicesCrankshaft repair
Design prototypesNPI applications
Low rate initial productionComplex geometries
Lighter weight parts/ efficiency
ProductionLEAP fuel nozzle
Flex tips
ToolingBoth metal & polymer tooling applications
IndustrializationMachine change-over reduction
In process monitoring
Identify
Develop
Industrialize
Globalize
Product offering
differentiationUnique concepts that leverage non-traditional solutions for customers
GE Supply Chain... Delivering REAL Production Parts
250K+
parts by
2020…
and growing!
T25 Housing Flex Tip
Materials Selection (traditional)*
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with a large 40000+ alloys to select a few materials that look
promising
3. Selection of Candidate Materials
– Analyze candidate materials in terms of tradeoffs of product performance, cost,
fabricability, and availability
» Best material for the application
4. Development of Design Data
– Determine the key materials properties for the selected material and process to obtain
statistically reliable measurements
– ASTM / AMS specifications
*George E. Dieter, Engineering Design A Materials and Processing Approach, McGraw-Hill, 1983 9
Relations between failure modes and mechanical properties, Smith & Boardman, “Metals Handbook 9th ed., vol 1, ASM international, Metals Park, OH 1980 10
UT
S
YS
Co
mp
. Y
S
Sh
ea
r S
tre
ng
th
Fa
tig
ue
Du
cti
lity
Imp
ac
t
Tra
nsi
tio
n T
Mo
du
lus
Cre
ep
ra
te
K1
C
K1
SC
C
Ele
ctr
oc
he
mic
al
Po
ten
tia
l
Ha
rdn
ess
CT
E
Yielding
Bucking
Creep
Brittle Fracture
LCF
HCF
Contact Fatigue
Fretting
Corrosion
SCC
Galvanic Corrosion
Hydrogen Embrittlement
Wear
Thermal Fatigue
Corrosion Fatigue
Materials Selection: Interrelationship of design, materials and processing
11
Design
service conditions function
Cost
Processing
Equipment Selection
influence on properties
cost
Materials
Properties
availability
cost
Product Reliability
Example: Paperclip
12
TRADITIONAL MATERIALS SELECTION EXAMPLE
1. Materials Requirements1. Elasticity
2. Strength
3. Wire diameter, clip design, etc.
Too much opening force
Too little clamping force
Permanent bend
MODULUS
YIELD STRESS
Materials Selection (Additive)
Can you print me a valve controller body out of a soft
magnetic material like 430 Ferritic Stainless or Nickel
Iron alloy?
14
We have several MIM & conventional machining
quotes and need some next month
Yes, But…...
Magnetic properties?
• Never heard of 403 stainless in DMLM additive…
weldable but prone to cracking – Possible?
• 50% Nickel–Iron alloys? Does anyone make
powder?
• Binderjet?
15
Yes, But…
Magnetic properties?
• Never heard of 403 stainless in DMLM additive…
weldable but prone to cracking – Possible?
• 50% Nickel–Iron alloys? Does anyone make
powder?
• Binderjet?
16M300 Maraging steel, magnetic
permeability in test
Yes, But…...
Lets do some math
• 30000 Lb casting
• @ 10 lbs per hour for WAAM (www.waammat.com)
= 3000 hours or 2.9 parts per year!
18
Title or Job Number | XX Month 201X 20
People can have the Model T in any color, as long as it’s black”-Henry Ford
You can have any alloy you want….
Andy Snow, GE Aviation October 2015 21
LASER POWDER BED PROCESS I.E.. SLM / DMLM
As long as it’s CoCrMo!
Materials Selection Compared (metals)
Traditional Data Sources• ASM Metals Handbooks
• SAE Handbooks
• Structural Alloys Handbook
• Grey and Ductile Iron Handbook
• Steel Castings Handbook
• Woldman’s Engineering Alloys
• Mil Standards
• Aerospace Materials Standards
Additive Data Sources
22
LASER POWDER BED PROCESS I.E.. SLM / DMLM
• Senvol Database – 400 alloys
• Senvol Indexes - 2?
• Manufacturer data sheets – 100?
Limited data available
COMING SOON:
ASTM standardsSME AMS standards
Process Selection (Additive)
24
Production Vs Prototype
Material Type (Polymer, Metal, Ceramic)
• Part Size (<400mm)• Production
rate/volume• Tolerances• Feature size• Surface Finish
High level materials requirements
Preliminary AM selection
• Part orientation• Build Time
• Cost
Final AM selection
LASER POWDER BED PROCESS I.E.. SLM / DMLM
• Topology optimization• Shorten NPI manufacturing time• Eliminate process steps• Reduce outsourcing• Design performance improvements• Product design freedoms• Reduce assembly costs• Design CNC machining fixtures on the additive part• Incorporate datum features into the part design• Reduce prototype lead times and costs• Reduce inventory• Build internal passages into almost any geometry• Change multiple part assemblies to be designed as one part
geometry• Eliminate welds in an assembly
Additive Advantage
IMAGE: GE Reports
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
26
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Material Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with the 359 metal results to select a few materials that look
promising
27
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Senvol database search 8 Aug 2016 5PM EDT http://senvol.com/5_material-search/
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with 359 metal results to select a few materials that look
promising
3. Selection of Candidate Materials
– Analyze candidate materials in terms of tradeoffs of product performance, cost, and
availability
» Best material for the application
28
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Use Casting Data as an approximation
29
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Additive materials property data (CTE, YS, HCF) is “typically” between cast and wrought data
• LCF, FCGR , toughness, creep, environmental effects unknown
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
2. Screening of Candidate Materials
3. Selection of Candidate Materials
» Best material for the application
4. Development of Design Data
– Determine the key materials properties for the selected material and process to obtain statistically reliable measurements
– Machine parameter optimization
– Support Structure & design optimization
ASTM / AMS specifications
30
LASER POWDER BED PROCESS I.E.. SLM / DMLM
CATA Additive Materials - DMLM
Current– CoCrMo
– Stainless steels - 316L, 15-5PH, 17-4PH
– Nickel Superalloys – IN718
– Haynes 188
– Maraging steel
Near Future – Aluminum – A205
– Nickel Superalloys - Haynes 282
31
GE Proprietary Information
Summary & the additive future
• Feasibility of production AM established @ GE
• Game changing, high performance product
• Industrialization of supply base & GE
businesses via CATA
Keys to success:
• Materials & process selection
• Design data development
…..Exciting times to be in AM
“We are standing in front of a potential revolution in manufacturing.”
Michael IdelchikVP of Advanced Technologies, GRC