Metal Additive Manufacturing for

Aerospace Markets

Shawn Kelly PhD

Senior Engineer Additive Manufacturing and Lasers

Director Additive Manufacturing Consortium

skellyewiorg 6146885145

1

Ian D Harris PhD

Technology Leader Arc Welding

Founding Director Additive Manufacturing Consortium

iharrisewiorg 6146885131

7th International EWITWI Aerospace Seminar Seattle WA Sept 17-18 2014

Outline

Existing and emerging metal AM processes and capabilities

Associated priorities for manufacturing transition Property data

In-process monitoring

NDE

EWI capability role and interactions

Summary

2

Advanced Manufacturing

Technologies at EWI

Innovate mature commercialize Materials Joining and Manufacturing technology for industry

Laser processing

Nondestructive evaluation

Numerical modeling and simulation

Plastic and composite fabrication

Resistance welding

Ultrasonic joining

Weldability and mechanical testing metallurgical analysis

AcousTechtrade Machining

Additive Manufacturing

Advanced arc welding

Automation sensors controls

Brazing and soldering

Dissimilar materials joining

Friction processing

Hot forming

AM is Materials Joining

Manufacturing of complex 3D parts by joining successive layers

1-inch L-PBF Cube

5 miles of weld

675 feet of weld

(Audi R8)

3400 feet of weld

4

AM Processes for Metals

Laser and EB powder bed from eg EOS and Arcam in confined envelope (ghr) ndash Primary AMC focus is PBF-L

EBW freeform fabrication - EB(FFF) (kghr)

Laser powder and wire FFF from companies such as POM Optomec (LENS) EFESTO (kghr)

VHP UAM ndash very high power ultrasonic AM of strip ndash Fabrisonic (kghr)

Emerging - Arc processes ndash SMD MER GTAW-HW (EWI IRD) GMAW-P PTA (wire and powder) based on commercially available equipment for FFF (kghr)

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incre

ase

d D

epositio

n R

ate

Large FFF parts

lsquoBig metalrsquo

eg aero structure

Small intricate parts- eg complex fuel nozzle ndash PBF-L and PBF-EB

GTAW-HW

and other

arc processes

EBFFF VHP UAM

LAM

Advanced Manufacturing

Technologies at EWI

Innovate mature commercialize Materials Joining and Manufacturing technology for industry

Laser processing

Nondestructive evaluation

Numerical modeling and simulation

Plastic and composite fabrication

Resistance welding

Ultrasonic joining

Weldability and mechanical testing metallurgical analysis

AcousTechtrade Machining

Additive Manufacturing

Advanced arc welding

Automation sensors controls

Brazing and soldering

Dissimilar materials joining

Friction processing

Hot forming

AM is Materials Joining

Manufacturing of complex 3D parts by joining successive layers

1-inch L-PBF Cube

5 miles of weld

675 feet of weld

(Audi R8)

3400 feet of weld

4

AM Processes for Metals

Laser and EB powder bed from eg EOS and Arcam in confined envelope (ghr) ndash Primary AMC focus is PBF-L

EBW freeform fabrication - EB(FFF) (kghr)

Laser powder and wire FFF from companies such as POM Optomec (LENS) EFESTO (kghr)

VHP UAM ndash very high power ultrasonic AM of strip ndash Fabrisonic (kghr)

Emerging - Arc processes ndash SMD MER GTAW-HW (EWI IRD) GMAW-P PTA (wire and powder) based on commercially available equipment for FFF (kghr)

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incre

ase

d D

epositio

n R

ate

Large FFF parts

lsquoBig metalrsquo

eg aero structure

Small intricate parts- eg complex fuel nozzle ndash PBF-L and PBF-EB

GTAW-HW

and other

arc processes

EBFFF VHP UAM

LAM

AM is Materials Joining

Manufacturing of complex 3D parts by joining successive layers

1-inch L-PBF Cube

5 miles of weld

675 feet of weld

(Audi R8)

3400 feet of weld

4

AM Processes for Metals

Laser and EB powder bed from eg EOS and Arcam in confined envelope (ghr) ndash Primary AMC focus is PBF-L

EBW freeform fabrication - EB(FFF) (kghr)

Laser powder and wire FFF from companies such as POM Optomec (LENS) EFESTO (kghr)

VHP UAM ndash very high power ultrasonic AM of strip ndash Fabrisonic (kghr)

Emerging - Arc processes ndash SMD MER GTAW-HW (EWI IRD) GMAW-P PTA (wire and powder) based on commercially available equipment for FFF (kghr)

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incre

ase

d D

epositio

n R

ate

Large FFF parts

lsquoBig metalrsquo

eg aero structure

Small intricate parts- eg complex fuel nozzle ndash PBF-L and PBF-EB

GTAW-HW

and other

arc processes

EBFFF VHP UAM

LAM

AM Processes for Metals

Laser and EB powder bed from eg EOS and Arcam in confined envelope (ghr) ndash Primary AMC focus is PBF-L

EBW freeform fabrication - EB(FFF) (kghr)

Laser powder and wire FFF from companies such as POM Optomec (LENS) EFESTO (kghr)

VHP UAM ndash very high power ultrasonic AM of strip ndash Fabrisonic (kghr)

Emerging - Arc processes ndash SMD MER GTAW-HW (EWI IRD) GMAW-P PTA (wire and powder) based on commercially available equipment for FFF (kghr)

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incre

ase

d D

epositio

n R

ate

Large FFF parts

lsquoBig metalrsquo

eg aero structure

Small intricate parts- eg complex fuel nozzle ndash PBF-L and PBF-EB

GTAW-HW

and other

arc processes

EBFFF VHP UAM

LAM

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incre

ase

d D

epositio

n R

ate

Large FFF parts

lsquoBig metalrsquo

eg aero structure

Small intricate parts- eg complex fuel nozzle ndash PBF-L and PBF-EB

GTAW-HW

and other

arc processes

EBFFF VHP UAM

LAM

Example Aerospace Applications

EB FFF and laser powder (DMLS) parts

LM Aero calculate 50 cost reduction for Ti6-4 EBFFF versus forging for lsquoflaperonrsquo spar

A new paradigm in LMD from

RPMEFESTO

8 87-in 922 m) high part in Ni-based alloy

Mori- Seiki CNC build and

machine

httpwwwyoutubecomwatchv=aUX_Hm01KMc

9

$165M CNC system with LAM build and integrated machining

to produce a finished part

I steels and austenitic stainless steels such as 304L maybe

but for Ni-based alloys Ti-based alloys will still need PWHT

and finishingmachining

A new paradigm in LMD from

RPMEFESTO

8 87-in 922 m) high part in Ni-based alloy

Mori- Seiki CNC build and

machine

httpwwwyoutubecomwatchv=aUX_Hm01KMc

9

$165M CNC system with LAM build and integrated machining

to produce a finished part

I steels and austenitic stainless steels such as 304L maybe

but for Ni-based alloys Ti-based alloys will still need PWHT

and finishingmachining

Mori- Seiki CNC build and

machine

httpwwwyoutubecomwatchv=aUX_Hm01KMc

9

$165M CNC system with LAM build and integrated machining

to produce a finished part

I steels and austenitic stainless steels such as 304L maybe

but for Ni-based alloys Ti-based alloys will still need PWHT

and finishingmachining

EWI Activities in AM

AM is a technology area at EWI Expertise in lasers materials NDI sensing and controls

design fusion welding (arc laser EB) modeling and ultrasonics

Focus Areas Metals Laser Powder Bed Fusion (EOS M280 DMLS) MaterialProcessProperty Development Complete Supply chain (materials heat treatment inspection) In process sensing

Other AM Process Areas Arc-Based AM Ultrasonic AM Laser Directed Energy Deposition Repair AM

Operate the Additive Manufacturing Consortium Innovative Ceramics and Polymer AM at EWI-NY

10

Ultrasonic Additive

Manufacturing

Solid state full metallurgical bond

Enables multi-material-system multi-functional AM with embedded function

Excels in materials that are difficult to fusion weld (Al+Ti etc)

Up to 6rsquox6rsquox3rsquo (2mx2mx1m)envelope with 5 axis CNC + machining (3 sizes)

Developed by EWI and spun off as a for-profit machine manufacturer

httpwwwfabrisoniccom

Capabilities Robotic Arc Based

AM

AM is not limited to laser or electron beam equipment for FFF

Robotic arc based deposition methods

Readily available equipment ndash transitioning to full robotic AM CAD to part

Still requires much of the process control infrastructure needed for laser and EB AM processes

Deposition rates from 1 in3hr to ~100rsquos in3hr up to 40 lbshr

Serves aerospace and additional defensecommercial markets

Five beads on a

16 mm edge

GMAW-RWF

Defense ground

vehicle 80 lb build in

Ti-6-4 using GTAW-

HW

Nuclear component

Using GMAW-P

GTAW (Hot Wire)

Wing stiffenerrib

GTAW-HW for AM at EWI

Recent work GTAW-HW for Ti-6-4 ELI (AWS WJ March 2014)

Full AM (CAD to part) robotic deployment

13

GTAW-HW for FFF

Element

Actual

Composition

(wt)

Nominal

Composition for Ti 6-4 ELI

Castings(1)

(wt)

Maximum Permissible

Composition for Ti 6-4

ELI Forgings(2)

(wt)

Hydrogen 00013 0006 00125

Nitrogen 00078 0010 003

Oxygen 0077 011 013

14

ID Specimen

Orientation Condition

Tensile

Strength

(ksi)

Yield

Strength

(ksi)

Elongation

()

Reduction in

Area

()

Baselin

e NA

Typical values for a

Ti 6-4 ELI castings(1) 120 110 13 22

1 Weld Direction

As-welded

1370 1245 109 319

2 1334 1161 93 256

3 Weld Direction

Solution heat

treatment + anneal

1152 1058 145 265

4 1168 1061 137 286

5 Weld Direction Anneal

1356 1230 129 189

6 1353 1220 94 200

7 Build Direction As-welded

1363 1192 97 288

8 1346 1174 109 380

9 Build Direction

Solution heat

treatment + anneal

1136 1018 133 265

10 1132 1033 122 318

11 Build Direction Anneal

1326 1169 81 200

12 1356 1247 110 211

Table 1 Composition of Hydrogen Nitrogen and Oxygen in the Weld Deposit Along with

the Nominal Composition in Ti 6-4 ELI Castings and the Maximum Permissible

Composition in Ti 6-4 ELI Forgings (Met all requirements)

Table 2 Tensile Test Data for the Sub-Sized Specimens Along with Typical

Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings (Initial work

close to requirements)

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

Ultrasonic Additive

Manufacturing

Solid state full metallurgical bond

Enables multi-material-system multi-functional AM with embedded function

Excels in materials that are difficult to fusion weld (Al+Ti etc)

Up to 6rsquox6rsquox3rsquo (2mx2mx1m)envelope with 5 axis CNC + machining (3 sizes)

Developed by EWI and spun off as a for-profit machine manufacturer

httpwwwfabrisoniccom

Capabilities Robotic Arc Based

AM

AM is not limited to laser or electron beam equipment for FFF

Robotic arc based deposition methods

Readily available equipment ndash transitioning to full robotic AM CAD to part

Still requires much of the process control infrastructure needed for laser and EB AM processes

Deposition rates from 1 in3hr to ~100rsquos in3hr up to 40 lbshr

Serves aerospace and additional defensecommercial markets

Five beads on a

16 mm edge

GMAW-RWF

Defense ground

vehicle 80 lb build in

Ti-6-4 using GTAW-

HW

Nuclear component

Using GMAW-P

GTAW (Hot Wire)

Wing stiffenerrib

GTAW-HW for AM at EWI

Recent work GTAW-HW for Ti-6-4 ELI (AWS WJ March 2014)

Full AM (CAD to part) robotic deployment

13

GTAW-HW for FFF

Element

Actual

Composition

(wt)

Nominal

Composition for Ti 6-4 ELI

Castings(1)

(wt)

Maximum Permissible

Composition for Ti 6-4

ELI Forgings(2)

(wt)

Hydrogen 00013 0006 00125

Nitrogen 00078 0010 003

Oxygen 0077 011 013

14

ID Specimen

Orientation Condition

Tensile

Strength

(ksi)

Yield

Strength

(ksi)

Elongation

()

Reduction in

Area

()

Baselin

e NA

Typical values for a

Ti 6-4 ELI castings(1) 120 110 13 22

1 Weld Direction

As-welded

1370 1245 109 319

2 1334 1161 93 256

3 Weld Direction

Solution heat

treatment + anneal

1152 1058 145 265

4 1168 1061 137 286

5 Weld Direction Anneal

1356 1230 129 189

6 1353 1220 94 200

7 Build Direction As-welded

1363 1192 97 288

8 1346 1174 109 380

9 Build Direction

Solution heat

treatment + anneal

1136 1018 133 265

10 1132 1033 122 318

11 Build Direction Anneal

1326 1169 81 200

12 1356 1247 110 211

Table 1 Composition of Hydrogen Nitrogen and Oxygen in the Weld Deposit Along with

the Nominal Composition in Ti 6-4 ELI Castings and the Maximum Permissible

Composition in Ti 6-4 ELI Forgings (Met all requirements)

Table 2 Tensile Test Data for the Sub-Sized Specimens Along with Typical

Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings (Initial work

close to requirements)

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

Capabilities Robotic Arc Based

AM

AM is not limited to laser or electron beam equipment for FFF

Robotic arc based deposition methods

Readily available equipment ndash transitioning to full robotic AM CAD to part

Still requires much of the process control infrastructure needed for laser and EB AM processes

Deposition rates from 1 in3hr to ~100rsquos in3hr up to 40 lbshr

Serves aerospace and additional defensecommercial markets

Five beads on a

16 mm edge

GMAW-RWF

Defense ground

vehicle 80 lb build in

Ti-6-4 using GTAW-

HW

Nuclear component

Using GMAW-P

GTAW (Hot Wire)

Wing stiffenerrib

GTAW-HW for AM at EWI

Recent work GTAW-HW for Ti-6-4 ELI (AWS WJ March 2014)

Full AM (CAD to part) robotic deployment

13

GTAW-HW for FFF

Element

Actual

Composition

(wt)

Nominal

Composition for Ti 6-4 ELI

Castings(1)

(wt)

Maximum Permissible

Composition for Ti 6-4

ELI Forgings(2)

(wt)

Hydrogen 00013 0006 00125

Nitrogen 00078 0010 003

Oxygen 0077 011 013

14

ID Specimen

Orientation Condition

Tensile

Strength

(ksi)

Yield

Strength

(ksi)

Elongation

()

Reduction in

Area

()

Baselin

e NA

Typical values for a

Ti 6-4 ELI castings(1) 120 110 13 22

1 Weld Direction

As-welded

1370 1245 109 319

2 1334 1161 93 256

3 Weld Direction

Solution heat

treatment + anneal

1152 1058 145 265

4 1168 1061 137 286

5 Weld Direction Anneal

1356 1230 129 189

6 1353 1220 94 200

7 Build Direction As-welded

1363 1192 97 288

8 1346 1174 109 380

9 Build Direction

Solution heat

treatment + anneal

1136 1018 133 265

10 1132 1033 122 318

11 Build Direction Anneal

1326 1169 81 200

12 1356 1247 110 211

Table 1 Composition of Hydrogen Nitrogen and Oxygen in the Weld Deposit Along with

the Nominal Composition in Ti 6-4 ELI Castings and the Maximum Permissible

Composition in Ti 6-4 ELI Forgings (Met all requirements)

Table 2 Tensile Test Data for the Sub-Sized Specimens Along with Typical

Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings (Initial work

close to requirements)

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

GTAW-HW for AM at EWI

Recent work GTAW-HW for Ti-6-4 ELI (AWS WJ March 2014)

Full AM (CAD to part) robotic deployment

13

GTAW-HW for FFF

Element

Actual

Composition

(wt)

Nominal

Composition for Ti 6-4 ELI

Castings(1)

(wt)

Maximum Permissible

Composition for Ti 6-4

ELI Forgings(2)

(wt)

Hydrogen 00013 0006 00125

Nitrogen 00078 0010 003

Oxygen 0077 011 013

14

ID Specimen

Orientation Condition

Tensile

Strength

(ksi)

Yield

Strength

(ksi)

Elongation

()

Reduction in

Area

()

Baselin

e NA

Typical values for a

Ti 6-4 ELI castings(1) 120 110 13 22

1 Weld Direction

As-welded

1370 1245 109 319

2 1334 1161 93 256

3 Weld Direction

Solution heat

treatment + anneal

1152 1058 145 265

4 1168 1061 137 286

5 Weld Direction Anneal

1356 1230 129 189

6 1353 1220 94 200

7 Build Direction As-welded

1363 1192 97 288

8 1346 1174 109 380

9 Build Direction

Solution heat

treatment + anneal

1136 1018 133 265

10 1132 1033 122 318

11 Build Direction Anneal

1326 1169 81 200

12 1356 1247 110 211

Table 1 Composition of Hydrogen Nitrogen and Oxygen in the Weld Deposit Along with

the Nominal Composition in Ti 6-4 ELI Castings and the Maximum Permissible

Composition in Ti 6-4 ELI Forgings (Met all requirements)

Table 2 Tensile Test Data for the Sub-Sized Specimens Along with Typical

Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings (Initial work

close to requirements)

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

GTAW-HW for FFF

Element

Actual

Composition

(wt)

Nominal

Composition for Ti 6-4 ELI

Castings(1)

(wt)

Maximum Permissible

Composition for Ti 6-4

ELI Forgings(2)

(wt)

Hydrogen 00013 0006 00125

Nitrogen 00078 0010 003

Oxygen 0077 011 013

14

ID Specimen

Orientation Condition

Tensile

Strength

(ksi)

Yield

Strength

(ksi)

Elongation

()

Reduction in

Area

()

Baselin

e NA

Typical values for a

Ti 6-4 ELI castings(1) 120 110 13 22

1 Weld Direction

As-welded

1370 1245 109 319

2 1334 1161 93 256

3 Weld Direction

Solution heat

treatment + anneal

1152 1058 145 265

4 1168 1061 137 286

5 Weld Direction Anneal

1356 1230 129 189

6 1353 1220 94 200

7 Build Direction As-welded

1363 1192 97 288

8 1346 1174 109 380

9 Build Direction

Solution heat

treatment + anneal

1136 1018 133 265

10 1132 1033 122 318

11 Build Direction Anneal

1326 1169 81 200

12 1356 1247 110 211

Table 1 Composition of Hydrogen Nitrogen and Oxygen in the Weld Deposit Along with

the Nominal Composition in Ti 6-4 ELI Castings and the Maximum Permissible

Composition in Ti 6-4 ELI Forgings (Met all requirements)

Table 2 Tensile Test Data for the Sub-Sized Specimens Along with Typical

Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings (Initial work

close to requirements)

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

6-9 axis robotic AM with arc

and laser welding and EBFFF

Hawk Gantry for large aerospace parts using arc and 20 kW laser capability (Arnon-vacuum)

Sciaky EBFFF for F-35 JSF (vacuum)

15

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

EWI Capabilities Laser Powder

Bed Fusion

Enables complex 3D shapes Internal passages for cooling light-weighting

Properties comparable to conventional (depending on alloy and heat treatment and surface condition)

As built surface finish 100-200 microin

Argon or Nitrogen Environment

Challenges Building on non planar surfaces

Composition grading

Heat

Exchanger

Titanium Spinal Implant

EOS M280 at EWI

Addressing Technical Gaps in

L-PBF and AM Technology

Development of custom process parameter sets for existing or new alloys (EWI is a materials development partner with EOS)

Holistic Approach to AM Understanding of the complete manufacturing chain including heat treatment

material understanding feedstocks distortion material properties etc

Development of material property data of a known pedigree

Next generation process equipment in-process sensing

productivity enhancements

Downstream manufacturing operations non-destructive inspection assemblyweldability of AM components

Prototype production when one of the above areas is involved EWI maintains relationships with several market specific service providers to

transition results to practice

17

Additive Manufacturing Supply

Chain

Final Part Material

Properties

Path Planning

Finishing

Thermal

History

Inspection

Qualification amp

Certification

AM Process Dimensional

Control

Heat

Treatment

CAD File

Material Process

Control

Residual

Stress

Process

Sensing

Process

Selection

Blue boxes are being addressed at

EWI presently

EWI is an EOS Materials

Development Partner

EWI offers understanding of process and material interaction from a welding and AM perspective

Currently 11 materials for EOS Represent low-hanging fruit for EOS business model

EOS lsquocontrolsrsquo parameter setmaterial combinations

Over 70 parameters that define a process

Limited EOS development capability in the US

EWI has developed parameters for tungsten 420SS 4140 steel 316L stainless Orders for other refractory metals and alloys in queue

420 Stainless 4140 Steel

Downhole Drill Bit in

420 SS

MampP Understanding Thermal History

Impacts Microstructure and Properties

Geometrically equivalent parts (Ti-6Al-4V) produced by scanning in two orientations

Microstructurally different -gt different properties

Long Axis

Short Axis Reduced Strength

Greater Toughness

High Strength

Reduced Toughness

Fraction Colony Alpha Impact on Property Scan Direction

Property Database

Generation

Problem Statement Methods for generating pedigreed property data for AM do not exist

Objective Develop data generation methods and documentation and begin to form a

foundational dataset

Nickel Alloy 625

NIST and Additive Manufacturing Consortium funding

Cannot overlook heat treatment Conventional heat treatment needed to be modified

Round robin testing (machine to machine vendor to vendor)

gt400

MPa

Range

Additive Manufacturing Supply

Chain

Final Part Material

Properties

Path Planning

Finishing

Thermal

History

Inspection

Qualification amp

Certification

AM Process Dimensional

Control

Heat

Treatment

CAD File

Material Process

Control

Residual

Stress

Process

Sensing

Process

Selection

Blue boxes are being addressed at

EWI presently

EWI is an EOS Materials

Development Partner

EWI offers understanding of process and material interaction from a welding and AM perspective

Currently 11 materials for EOS Represent low-hanging fruit for EOS business model

EOS lsquocontrolsrsquo parameter setmaterial combinations

Over 70 parameters that define a process

Limited EOS development capability in the US

EWI has developed parameters for tungsten 420SS 4140 steel 316L stainless Orders for other refractory metals and alloys in queue

420 Stainless 4140 Steel

Downhole Drill Bit in

420 SS

MampP Understanding Thermal History

Impacts Microstructure and Properties

Geometrically equivalent parts (Ti-6Al-4V) produced by scanning in two orientations

Microstructurally different -gt different properties

Long Axis

Short Axis Reduced Strength

Greater Toughness

High Strength

Reduced Toughness

Fraction Colony Alpha Impact on Property Scan Direction

Property Database

Generation

Problem Statement Methods for generating pedigreed property data for AM do not exist

Objective Develop data generation methods and documentation and begin to form a

foundational dataset

Nickel Alloy 625

NIST and Additive Manufacturing Consortium funding

Cannot overlook heat treatment Conventional heat treatment needed to be modified

Round robin testing (machine to machine vendor to vendor)

gt400

MPa

Range

EWI is an EOS Materials

Development Partner

EWI offers understanding of process and material interaction from a welding and AM perspective

Currently 11 materials for EOS Represent low-hanging fruit for EOS business model

EOS lsquocontrolsrsquo parameter setmaterial combinations

Over 70 parameters that define a process

Limited EOS development capability in the US

EWI has developed parameters for tungsten 420SS 4140 steel 316L stainless Orders for other refractory metals and alloys in queue

420 Stainless 4140 Steel

Downhole Drill Bit in

420 SS

MampP Understanding Thermal History

Impacts Microstructure and Properties

Geometrically equivalent parts (Ti-6Al-4V) produced by scanning in two orientations

Microstructurally different -gt different properties

Long Axis

Short Axis Reduced Strength

Greater Toughness

High Strength

Reduced Toughness

Fraction Colony Alpha Impact on Property Scan Direction

Property Database

Generation

Problem Statement Methods for generating pedigreed property data for AM do not exist

Objective Develop data generation methods and documentation and begin to form a

foundational dataset

Nickel Alloy 625

NIST and Additive Manufacturing Consortium funding

Cannot overlook heat treatment Conventional heat treatment needed to be modified

Round robin testing (machine to machine vendor to vendor)

gt400

MPa

Range

MampP Understanding Thermal History

Impacts Microstructure and Properties

Geometrically equivalent parts (Ti-6Al-4V) produced by scanning in two orientations

Microstructurally different -gt different properties

Long Axis

Short Axis Reduced Strength

Greater Toughness

High Strength

Reduced Toughness

Fraction Colony Alpha Impact on Property Scan Direction

Property Database

Generation

Problem Statement Methods for generating pedigreed property data for AM do not exist

Objective Develop data generation methods and documentation and begin to form a

foundational dataset

Nickel Alloy 625

NIST and Additive Manufacturing Consortium funding

Cannot overlook heat treatment Conventional heat treatment needed to be modified

Round robin testing (machine to machine vendor to vendor)

gt400

MPa

Range

Property Database

Generation

Problem Statement Methods for generating pedigreed property data for AM do not exist

Objective Develop data generation methods and documentation and begin to form a

foundational dataset

Nickel Alloy 625

NIST and Additive Manufacturing Consortium funding

Cannot overlook heat treatment Conventional heat treatment needed to be modified

Round robin testing (machine to machine vendor to vendor)

gt400

MPa

Range

Outcomes

33 Page Manufacturing Plan Four 200 Hour Builds

Heat Treatment Study RT and Elevated Temp Testing

Nickel Alloy 718 Heat

Treatment Development

Problem Statement Application of conventional nickel alloy

718 heat treatments to L-PBF material are not fully understood

or optimized

Objective Evaluate the heat treatment response of nickel alloy

718 produced using EOS M280 to define future heat treatment

optimization

Apply approach from 625 project

Evaluate the conventional heat treatment response of 718

Tensile and creep properties at 650degC (1200degF)

Material characterization information that will allow

improved understanding of the impact of the process on

material performance

Phase 1 = 1 year

As-built

SR+ST+Age

In Process Sensing

NIST MSAM Program National Additive Manufacturing Innovation Institute

Part 1 Part 21

Part 1 = Part 21

hellipat Layer 1 through 2000

Problem Statement L-PBF equipment lacks robust manufacturing quality controls

that conventional manufacturing employs

Objective Develop a robust informative in-situ process monitoring capability

standard for AM

Provide QAQC

lsquoInspect the un-inspectablersquo

Facilitates sensor screening and future machine design

Overall Objective of the NIST MSAM program is

to Measure and Certify Build Quality

National Additive Manufacturing Innovation Institute

Sensor Test Bed

Donrsquot limit process sensing because of constraints

Replicate important characteristics of the commercial process

Provide adequate space

Avoids problem of physical and software constraints

Sensor Test Bed Development

and Build (EWI)

Sensor Matrix

Pro

ce

ss

Ob

se

rva

tio

n

Sensor

Defect Type

Pro

ce

ss

Devia

tion

Dis

tort

ion

Ge

om

etr

y

Be

d F

latn

ess

Me

tallu

rgic

al

Vo

lum

etr

ic

De

fects

Lo

ca

l

Photodetector X X

Spectrometer X X

High Speed Video Defect Generation Understanding

Thermal Imaging X X

Glo

ba

l

High Resolution Imaging X X X

Laser Line Scanner X X X

Thermal Imaging X X

Photogrammetry (UNCC) X X

Projection Moireacute (UNCC) X X X

Pa

ss

ive

Acoustic X X X

Ultrasonic X

Interferometer X

Challenges and Path Forward

BIG Challenge = BIG Data throughput processingdistillation gono-go

storage

Global Imaging with 10MP camera 96 GB

Local sensing measurement every beam width gt80M data points

Path Forward Complete assembly and verify build conditions

(MayJune)

Install and test sensors (Summer)

Data processing (Fall)

Downselect viable sensors (Winter)

EWI is leading two other programs for in process sensing for L-PBF and L-DED

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Sensor Test Bed

Donrsquot limit process sensing because of constraints

Replicate important characteristics of the commercial process

Provide adequate space

Avoids problem of physical and software constraints

Sensor Test Bed Development

and Build (EWI)

Sensor Matrix

Pro

ce

ss

Ob

se

rva

tio

n

Sensor

Defect Type

Pro

ce

ss

Devia

tion

Dis

tort

ion

Ge

om

etr

y

Be

d F

latn

ess

Me

tallu

rgic

al

Vo

lum

etr

ic

De

fects

Lo

ca

l

Photodetector X X

Spectrometer X X

High Speed Video Defect Generation Understanding

Thermal Imaging X X

Glo

ba

l

High Resolution Imaging X X X

Laser Line Scanner X X X

Thermal Imaging X X

Photogrammetry (UNCC) X X

Projection Moireacute (UNCC) X X X

Pa

ss

ive

Acoustic X X X

Ultrasonic X

Interferometer X

Challenges and Path Forward

BIG Challenge = BIG Data throughput processingdistillation gono-go

storage

Global Imaging with 10MP camera 96 GB

Local sensing measurement every beam width gt80M data points

Path Forward Complete assembly and verify build conditions

(MayJune)

Install and test sensors (Summer)

Data processing (Fall)

Downselect viable sensors (Winter)

EWI is leading two other programs for in process sensing for L-PBF and L-DED

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Sensor Test Bed Development

and Build (EWI)

Sensor Matrix

Pro

ce

ss

Ob

se

rva

tio

n

Sensor

Defect Type

Pro

ce

ss

Devia

tion

Dis

tort

ion

Ge

om

etr

y

Be

d F

latn

ess

Me

tallu

rgic

al

Vo

lum

etr

ic

De

fects

Lo

ca

l

Photodetector X X

Spectrometer X X

High Speed Video Defect Generation Understanding

Thermal Imaging X X

Glo

ba

l

High Resolution Imaging X X X

Laser Line Scanner X X X

Thermal Imaging X X

Photogrammetry (UNCC) X X

Projection Moireacute (UNCC) X X X

Pa

ss

ive

Acoustic X X X

Ultrasonic X

Interferometer X

Challenges and Path Forward

BIG Challenge = BIG Data throughput processingdistillation gono-go

storage

Global Imaging with 10MP camera 96 GB

Local sensing measurement every beam width gt80M data points

Path Forward Complete assembly and verify build conditions

(MayJune)

Install and test sensors (Summer)

Data processing (Fall)

Downselect viable sensors (Winter)

EWI is leading two other programs for in process sensing for L-PBF and L-DED

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Sensor Matrix

Pro

ce

ss

Ob

se

rva

tio

n

Sensor

Defect Type

Pro

ce

ss

Devia

tion

Dis

tort

ion

Ge

om

etr

y

Be

d F

latn

ess

Me

tallu

rgic

al

Vo

lum

etr

ic

De

fects

Lo

ca

l

Photodetector X X

Spectrometer X X

High Speed Video Defect Generation Understanding

Thermal Imaging X X

Glo

ba

l

High Resolution Imaging X X X

Laser Line Scanner X X X

Thermal Imaging X X

Photogrammetry (UNCC) X X

Projection Moireacute (UNCC) X X X

Pa

ss

ive

Acoustic X X X

Ultrasonic X

Interferometer X

Challenges and Path Forward

BIG Challenge = BIG Data throughput processingdistillation gono-go

storage

Global Imaging with 10MP camera 96 GB

Local sensing measurement every beam width gt80M data points

Path Forward Complete assembly and verify build conditions

(MayJune)

Install and test sensors (Summer)

Data processing (Fall)

Downselect viable sensors (Winter)

EWI is leading two other programs for in process sensing for L-PBF and L-DED

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Challenges and Path Forward

BIG Challenge = BIG Data throughput processingdistillation gono-go

storage

Global Imaging with 10MP camera 96 GB

Local sensing measurement every beam width gt80M data points

Path Forward Complete assembly and verify build conditions

(MayJune)

Install and test sensors (Summer)

Data processing (Fall)

Downselect viable sensors (Winter)

EWI is leading two other programs for in process sensing for L-PBF and L-DED

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Post Process Inspection

MaterialGeometry Issues

Problem Statement for Geometry Geometric complexity of AM parts limits application of many

conventional NDI techniques

Objective Identify means to quantify inspectability based upon geometry and current state of the art

capability

Thick to thin ( Density Differences )

Embedded features

Thickness of the build layers (40 Micron)

Organic Part Design

National Additive Manufacturing Innovation Institute

Problem Statement for Materials Ultrasonic inspection limits of Ti-6Al-4V produced by certain AM

techniques reduced by complex microstructure

Objective Address reduced ultrasonic inspectability of heat treated Ti-6Al-4V

Process modifications

Improved Matrix Phased Array Ultrasonic Inspection

Needed for transition

If unresolved reliance on radiography and increase in inspection burden (additional costtime)

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Why is Complexity Important

Group 1- Simple

MachinesStructures

Group 2- Standard Part

but Joining reduction

( No Design For AM)

Group 3 ndash Embedded

Features ndash (No DFAM)

Group 4 ndash Organic

Structures (Full DFAM)

Group 5 ndash Lattice

Structures (Full DFAM)

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

The Additive Manufacturing

Consortium

Mission Accelerate and advance the manufacturing readiness of Metal AM technologies

Participation from Academia Government

and Industry

Present timely case studiesresearch

Execute group sponsored projects

Collaborate on Government funding opportunities

Forum for discussionshaping roadmaps

Goals

32

Current Members (2014) Rolls-Royce UT Aerospace Lockheed GE Aviation Woodward IHI Carpenter Powder

Products EOS LPW Technology Inc B6Sigma NCDMMAmerica Makes NC State University of Louisville University of Toledo NIST LLNL NASA

Summary ndash Metal AMEWIrsquos Role

Holistic view

Many AM process for metals each with different merits

Recognize that AM is an entire manufacturing chain which requires engineering support for technology transition and implementation

Much work to be done for manufacturing implementation especially for property data in-process monitoring and NDE

While everyone might be able to print a fork not everyone should print a rocket nozzleimplant etc

Evangelists (Education) Eg Run and organize MSampT AM Symposia (usually 40-50 papers)

Trusted Agent

Impartial objective equipment agnostic

Innovation

Eg sensor bed developmenttesting for in-process monitoring

Industry support

Supports clients in AM just as we support clients in materials joining

Operate the AMC

Questions

Shawn Kelly PhD

Senior Engineer Additive Manufacturing

Director Additive Manufacturing Consortium

skellyewiorg 6146885145

Ian D Harris PhD

Technology Leader Arc Welding

Founding Director Additive

Manufacturing Consortium

iharrisewiorg 6146885131

httpewiorgtechnologiesadditive-manufacturing

Questions

Shawn Kelly PhD

Senior Engineer Additive Manufacturing

Director Additive Manufacturing Consortium

skellyewiorg 6146885145

Ian D Harris PhD

Technology Leader Arc Welding

Founding Director Additive

Manufacturing Consortium

iharrisewiorg 6146885131

httpewiorgtechnologiesadditive-manufacturing

EWI is the leading engineering and technology organization in North America dedicated to advanced materials joining and

allied manufacturing technologies Since 1984 EWI has provided applied research manufacturing support and strategic

services to leaders in the aerospace automotive consumer products electronics medical energy amp chemical government

and heavy manufacturing industries By matching our expertise in materials joining forming and testing to the needs of

forward-thinking manufacturers we are successful in creating effective solutions in product design and production