Additive Manufacturing for Space Applications: On Earth, On Orbit - - PowerPoint PPT Presentation

▶
additive manufacturing for space applications on earth on
SMART_READER_LITE
LIVE PREVIEW

Additive Manufacturing for Space Applications: On Earth, On Orbit - - PowerPoint PPT Presentation

Dec 21, 2023 193 likes •573 views

Additive Manufacturing for Space Applications: On Earth, On Orbit and On Planet Andrew Norman A.D. Brando, J. Gumpinger, B. Bonvoisin, A. Makaya, L. Pambaguian, T. Rohr, T. Ghidini European Space Agency, Materials and Processes Section

slide-1
SLIDE 1

ESA UNCLASSIFIED - For Official Use

Additive Manufacturing for Space Applications: On Earth, On Orbit and On Planet

Andrew Norman

A.D. Brandão, J. Gumpinger, B. Bonvoisin, A. Makaya, L. Pambaguian, T. Rohr, T. Ghidini

European Space Agency, Materials and Processes Section Noordwijk, The Netherlands

Engineering Integrity Society, MTC, 18 June 2019

slide-2
SLIDE 2

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 2

Outline

 Introduction to the European Space Agency  Why Additive Manufacturing for Space Applications  Manufacturing on Earth (The ESA Journey)  End-to-End Manufacturing Process  Additive manufacturing on orbit and on planet  Conclusions

Andrew Norman | 18/ 06/ 2019

slide-3
SLIDE 3

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 3

European Space Agency Today

 Over 50 years of experience  22 Member States  Eight sites/ facilities in Europe, about 2300 staff  5.6 billion Euro budget (2018)  ESA is a procurement agency  Over 80 satellites designed, tested and operated in flight

February 2018 Andrew Norman | 18/ 06/ 2019

slide-4
SLIDE 4

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 4

ESA Locations

Washington Houston Kourou Maspalomas Santa Maria New Norcia Perth Moscow Oberpfaffenhofen ESOC (Darmstadt) EAC (Cologne) Salmijaervi (Kiruna) ESTEC (Noordwijk) ECSAT (Harwell) Toulouse Brussels ESA HQ (Paris) Redu Malargüe

ESA sites Offices ESA Ground Station ESA Ground Station + Offices ESA sites + ESA Ground Station

www.esa.int

Andrew Norman | 18/ 06/ 2019

slide-5
SLIDE 5

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 5

European Space Research and Technology Centre (ESTEC)

 Materials support to the missions  Run technology programmes  Testing / Evaluation Facilities  State-of-the-art laboratories  Equipment dedicated to space  Access to external test houses

  • Materials level
  • Component level
  • Spacecraft / Satellite level

Andrew Norman | 18/ 06/ 2019

slide-6
SLIDE 6

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 6

Early Design Phases Materials and Processes/ Failure I nvestigation Flight Acceptance/ Operations Full Scale Testing Support Design for Dem ise Vibro-Acoustic Environm ent Prediction/ Launcher Coupled-Multibody Analysis Detailed Stress Analysis

Materials, Structures and Mechanisms

Andrew Norman | 18/ 06/ 2019

slide-7
SLIDE 7

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 7

Surviving in Space

Ground Storage / Launch Phase

Stress corrosion cracking Red plague corrosion Vibration and Shock Zero Gravity Telecom ~ 75,000 thermal cycles CTE Mismatch Expulsion of volatiles (Cd / Zn) Cold Welding Outgassing of volatiles

+ 150˚ C

  • 150˚ C

Thermal Environment / Vacuum Radiation / Charged Particles

Ultraviolet Rays High Energy Electrons Solar Protons Atomic Oxygen

e

  • Space Debris / Demisability

Dust, Micrometeoroids Asteroids and Comets Space Junk Controlled Break-up / Demisable

slide-8
SLIDE 8

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 8

Why adopt Additive Manufacturing for Space Applications ?

slide-9
SLIDE 9

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 9

Why Additive Manufacturing for Space hardware?

  • Challenges for Space Materials and Processes:
  • W hy Additive Manufacturing ?
  • ALM addresses majority of above challenges
  • Applied to m any m aterials = > metals, polymers, composites, ceramics
  • Dim ensions: few micrometers to meters
  • Significant gains in perform ances
  • Environm entally friendly

 Low Mass  Small Production Series  Very High Reliability  Small Geometries  Very High Performances  Challenging Material Procurement

Andrew Norman | 18/ 06/ 2019

slide-10
SLIDE 10

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 10

ESA Approach to Additive Manufacturing

 Funded a number of activities across Europe  Fundamental Studies  Manufacture of Demonstrator Parts  End-to-end process (including qualification and standardization) Simple part reproduction Rethinking Process and materials selection Designing for Additive Manufacturing

Andrew Norman | 18/ 06/ 2019

slide-11
SLIDE 11

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 11

Designing for AM (Alloy design) Designing for AM (topology / properties) Starting to Design for AM Re-thinking Materials Selection Simple reproduction

  • f existing parts

How it all started at ESA

 Failure in a Water On/ Off Valve on the ISS  Unit was returned to ESTEC for root cause analysis  Complex design  Thick and thin wall  Welded parts Would it be possible to manufacture the part as a single piece using the new technology of 3D printing ??

Andrew Norman | 18/ 06/ 2019

slide-12
SLIDE 12

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 12

How it all started at ESA

 Simple reproduction of the same part  substituted stainless steel by titanium  Ti6Al4V powder available at manufacturer  40% mass benefits  Part count reduction to 1

As built part Designing for AM (Alloy design) Designing for AM (topology / properties) Starting to Design for AM Re-thinking Materials Selection Simple reproduction

  • f existing parts

Andrew Norman | 18/ 06/ 2019

slide-13
SLIDE 13

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 13

ESA Funded Activities in Europe

46 Activities to date 16 Countries 18 targeted at TRL = 1-3 24 targeted at TRL = 3-6 Co-funded 4 PhD Studies Total = 25.1 MEuros

Andrew Norman | 18/ 06/ 2019

slide-14
SLIDE 14

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 14

ESA Funded Activities in Europe

 Improved understanding of the End-to-End manufacturing process  Experience in a wide range of techniques and materials  Manufacture and test a number of demonstrator parts  Developing a property database (static and dynamic)  Developing a company database (Europe wide)  Developing a defect catalogue  Create appropriate standards (qualification)

Andrew Norman | 18/ 06/ 2019

slide-15
SLIDE 15

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 15

I njectors Mirrors Mirrors Cham bers Bellow s

Examples of Manufactured Parts

W ave Guides Thrusters Brackets Optical Bench Brackets Nozzles Brackets Bolts Flex-Pivots Coils Brackets Tank Hem ispheres

Andrew Norman | 18/ 06/ 2019

slide-16
SLIDE 16

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 16

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Mirror for the Tropomi Instrument (Sentinel 5)

Designing for AM (Alloy design) Designing for AM (topology / properties) Starting to Design for AM

 Pair of aluminium mirrors set up to form an optical cavity.  Printed in Ti6Al4V using SLM  Requirement of same final coating and optical performance)

Original design Material: AA6061 Mass = 284.6g NiP coating New design Material: Ti-6Al-4V Mass = 127.7g NiP coating 56% Mass Saving

Andrew Norman | 18/ 06/ 2019

slide-17
SLIDE 17

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 17

Starting to Design for AM

Single Part Wave Guides

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Designing for AM (topology / properties)

 Radio Frequency  3D print it in a single piece  Reduce misalignments and errors are removed

Andrew Norman | 18/ 06/ 2019

slide-18
SLIDE 18

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 18

ISCAR Secondary Bracket for Ariane 5 ECA

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Starting to Design for AM Designing for AM (topology / properties)

 Part of the Future Launchers Preparatory Programme (FLPP)  Critical secondary structure on the Ariane 5 ECA  Preparation of Bracket qualification for serial production  In flight demonstration on A5 (Pilot) Maturation for A6

Andrew Norman | 18/ 06/ 2019

slide-19
SLIDE 19

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 19

Reaction Wheel Bracket for Exomars TGO

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Starting to Design for AM Designing for AM (topology / properties)

Trace Gas Orbiter

Andrew Norman | 18/ 06/ 2019

slide-20
SLIDE 20

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 20

Reaction Wheel Bracket for Exomars TGO

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Starting to Design for AM Designing for AM (topology / properties)

Conventional AM Saving Weight 1114g 456g 60% Buy-to-Fly Ratio 56kg 0.84kg 97% Costs €8000 €3800 53% Lead Time Weeks Days

Andrew Norman | 18/ 06/ 2019

slide-21
SLIDE 21

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 21

Bellows (Going Small)

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Starting to Design for AM Designing for AM (topology / properties)

 Failures occurred on welded Ti64 bellows  Artes 5.1 activity to investigate a potentially m ore reliable and cost effective manufacturing process = > AM  Characterizing the performance and the reliability of the bellows

Andrew Norman | 18/ 06/ 2019

slide-22
SLIDE 22

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 22

Athena Optical Bench (Going Large)

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Designing for AM (Alloy design) Starting to Design for AM Designing for AM (topology / properties)

 3m diameter optical bench  Ti-6Al-4V Elevated cell structure with 20 rows  1062 mirror module pockets  Prohibitive cost of conventional manufacturing (forging + machining)

Andrew Norman | 18/ 06/ 2019

slide-23
SLIDE 23

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 23

Alloy Design

Re-thinking Materials Selection Simple reproduction

  • f existing parts

Starting to Design for AM Designing for AM (topology / properties) Designing for AM (Alloy design)

 Current aluminium alloys limited to Al-Si(Mg) or SCAMALLOY  Need to develop new alloys which can take advantage of AM

  • Modification of conventional alloys: AA7075+ X
  • New alloys based on Al-Cu and/ or Al-Zn
  • Metallic Glasses / Bulk metallic glass
  • Alloys with unusual crystallographic structures
  • High entropy alloys
  • Shape memory alloys

Andrew Norman | 18/ 06/ 2019

slide-24
SLIDE 24

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 24

End-to-End Manufacturing

slide-25
SLIDE 25

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 25

Qualification  Optimisation  Orientation  Support Structure  Software Tools  Simulation  Supply Chain  Quality  reproducibility  Handling  Recycling  Scan strategy  Power / Speed  Atmosphere  Position  No Parts  Heat Treatment  Surface Treatment  Cleaning  Hipping  SCC Performance  Standards  Tensile / Fatigue  NDI Post Processing Processing Material Supply Design

End-to-End Additive Manufacturing

Andrew Norman | 18/ 06/ 2019

slide-26
SLIDE 26

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 26

Remaining Challenges for Earth Manufacturing

 Set up robust, repeatable AM end to end process

  • Powder feedstock control
  • SCC
  • Cleanliness
  • Residual stresses
  • Effects of defects

 Combination and interaction of these within the design process

 Standardisation tries to tackle these challenges

Andrew Norman | 18/ 06/ 2019

slide-27
SLIDE 27

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 27

Additive Manufacturing: In Orbit and On Planet

slide-28
SLIDE 28

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 28

Additive Manufacturing in Orbit

 On demand production of spare parts  CAD files can be stored on Earth, information sent remotely.  Already a Fused Deposition Printer on the ISS  Wire fed metal printer for 2020

Andrew Norman | 18/ 06/ 2019

slide-29
SLIDE 29

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 29

Additive Manufacturing in Orbit

 Use of 3D bio-printing to support medical treatment of long-duration space expeditions and planetary settlements.

Andrew Norman | 18/ 06/ 2019

slide-30
SLIDE 30

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 30

Challenges for AM in orbit

  • Micro gravity
  • Offgassing
  • Particle release (powders  wires)
  • Limited power availability
  • Metals
  • Post processing
  • Recyclability

Andrew Norman | 18/ 06/ 2019

slide-31
SLIDE 31

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 31

Additive Manufacturing on Planet

 Using a Mg-based Binder (D-Shape process)  Remote 3D printers using regolith (1.5 ton demonstrator manufactured)  Validate the concept by producing a representative section of the lunar base.

Andrew Norman | 18/ 06/ 2019

slide-32
SLIDE 32

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 32

Additive Manufacturing on Planet

 Process to lunar regolith using only concentrated solar energy, without involving any binder  Feasibility demonstrator

Andrew Norman | 18/ 06/ 2019

slide-33
SLIDE 33

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 33

Science Museum Display

 Could we 3D-Print habitats on the moon  On display until October 2019

Andrew Norman | 18/ 06/ 2019

slide-34
SLIDE 34

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 34

Challenges for AM on planet

  • Wide variations of feedstock (composition, grain size)
  • Limited availability of pow er
  • Testing in representative conditions (vacuum, temperature,

reduced gravity, dust, radiation) is more challenging

Andrew Norman | 18/ 06/ 2019

slide-35
SLIDE 35

ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 35

Future Challenges on Earth

Functionally Graded Material 4 D Printing Advanced Alloy Design (Al, Ti)  In-line process monitoring  End-to-end process control  Repair strategies / NDI Alternative AM Processes  Ultrasonic Bonding  Cold Spray  Hybrid 3D Printing Joining Technologies  Additive to Additive  Additive to Non-additive  Metals to non-metals

Andrew Norman | 18/ 06/ 2019

slide-36
SLIDE 36

ESA UNCLASSIFIED - For Official Use

Thank you for attention

Andrew.norman@esa.int www.esa.int