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GKN Aerospace Additive Manufacturing Rob Sharman – Head of Metallics Technology Societe Generale 2014
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Additive Manufacturing Terminology
The ASTM definition:
“The process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining”
EBM EBFFF
3D-Printing SLS
SLM D
MD
DM
LS
FDM ALM
SLA
LENS
LD
W
WAALM
Polyjet
LC
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High geometric complexity enables next generation small prismatic components. Accurate but near-net
parts and claddings
High material fusion rate and deposition technique enable large scale near-net shape parts or grow-outs
Deposition of powder fused using laser in a chamber to produce
part
LASER
(POWDER)
Free deposition of wire fused using
plasma arc to produce part
PLASMA
(WIRE)
Deposition of wire fused using electron or laser beam in a chamber to produce
part
EB
(WIRE)
LASER
(WIRE)
Laser or electron beam selectively fuses powder on a bed in a chamber to produce part
LASER
(POWDER)
EB
(POWDER)
PICTURE
DESCRIPTION
APPLICATIONS
DEPOSITION POWDER BED
DESIGNATED ICON
Powder / binder system requiring
down-stream consolidation
BINDER
(POWDER)
Net-shape parts achievable at
automotive rates
Additive Manufacturing
Fraunhoffer ILT
Arcam
TWI
Cranfield University
GKN Aerospace Höganäs Digital Metal®
TWI
GKN Aerospace GKN Aerospace
Cranfield University
Cranfield University
SMALL PUDDLE DEPOSITION
• Lower material throughput deposition systems
• Focus on Ti and Ni alloys
• Nearer net-shape add-ons and prismatic pre-forms
• Engine component fabrication, component repair and grow-outs (cost & performance)
• Broad range of medium-size engine and structures components; fabrications
LASER P/BED
• Lowest material thru-put
• Ti, Ni and steel alloys
• Nearest-net
• Intricate hi-value components
• Engine parts and small inserts
EB P/BED
• Low material thru-put
• Ti6Al4V
• Highly net-shape
• Small – medium prismatics
• Structural brackets, engine parts and fabrications
INDIRECT P/BED
• Low material thru-put
• Cast-able alloys
• Highly net-shape
• Complex castings and inserts
•Engine parts and fabrications
LARGE PUDDLE DEPOSITION
• High material throughput deposition systems
• Focus on Ti
• Large-scale pre-forms
• Initial cost-driven introduction
• Applications including large aero structure components
EB P L L L EB B
Virginia Tech
GKN Aerospace
Fraunhoffer ILT
Sciaky
Reis Robotics
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History & Lifecycle of Technology Adoption
Composites
1930 1950 1940 1970 1960 1980
NC Machine Invented
Robotic process reaches
manufacturing maturity
Applied across multiple
industries
Fiberglass Patented
Carbon Fiber production
begins
All fiberglass aircraft; H-301
Dragonfly
CNC Machining (Subtractive) Over 40 Years!
Over 40 Years!
2000 1990 2010
787 commercial aircraft first
flight
Metallic AM
Entire history of AM!
Gartner Hype Cycle
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Ti Growth in Airframe Applications
Growth in use of Ti in Aerostructures
Of particular note in recent years has been the rapid growth of Ti and its alloys in airframe applications
This has been predominately linked to the growth in CFRP due to the better compatibility of Ti alloys (galvanic corrosion and thermal expansion) with CFRP
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AM within Processing Portfolio
AM ONLY
Delivery Drivers Cost Drivers Performance Drivers
AM IN COMPETITION WITH OTHER TECH
L EB
Powder Bed Deposition
L EB P L
DEPOSITION
POWDER BED
DEPOSITION
Norsk Titanium EADS GKN
Data Release DfM
Complete
Tooling Ready
1st Article Production
< 95 WEEKS
< 12 WEEKS AM
Conventional
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AM Adoption
Cost Reduction - Aero
Niche/High Performance - Aero & Auto
Near net pre-forms Added features Improved functionality/performance
1
Introduction of both new materials and processes is challenging
Conservatism and healthy cautiousness are barriers to initiatives
Step-wise approach is implicitly required
“INITIAL” phase
Generally cost-driven implementation
Allows both GKN and customer (and supply chain) to acquaint themselves with challenges and opportunities
“NEXT” phase
Builds on “INITIAL” phase
Allows all parties to fully exploit AM technology benefits
PR
IMA
RY
S
EC
ON
DA
RY
DERIVATIVE SIMILAR NEW
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Generic Conventional Component
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Generic Conventional Component
Mat’l = 4.85kg Swarf = 4.08kg
Mat’l = 1.08kg Swarf = 0.31kg
Part = 0.77kg
Machining Route to Man’f AM Route to Man’f
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Generic Conventional Component
~5 x less feed stock
~13 x less swarf
Conventional design (not yet optimised for weight)
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The possibilities and benefits are exciting Unlocks Materials Science
Only uses the material you need - uses less material
Design no longer constrained by conventional manufacturing processes
Allows design for functionality
Speed and flexibility of development
A revolutionary set of technologies – not evolutionary
Phased introduction is implicitly required Secondary derivative structure before primary optimised
Need to pin variables to gain acceptance
Process and material are now linked like never before
Big challenge to the industry in evaluation How to certify
New and novel QA techniques required
AM Current R&D Programmes GKN Additive Manufacturing
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GKN Investment and Growth in Additive Manufacturing
GKN sees additive manufacturing as a high priority technology
GKN is investing and expanding our portfolio in AM across the business, leveraging our expertise across divisions
GKN is expanding and establishing new Centres of Excellence in additive manufacturing, building on existing capability to build a global network:
Powder bed - Filton (UK)
High rate Deposition - St Louis (USA)
Fine Deposition - Trollhatten (Sweden)
Materials - New Jersey (USA)
Operating across the whole value chain, from raw material, design, process and application
Partnered with key academic institutions, customers and suppliers
Understand the criticality and potential of design, and GKN is developing the skills and design toolbox to take advantage of the disruptive nature of additive manufacturing