Metal Additive Technology 101 Technology Choices and Applications Jeff Crandall Additive Manufacturing Research & Applications Senior Engineer Connecticut Center for Advanced Technology – Advanced Manufacturing Center PRESENTED BY
Why Additive Mfg? • Reduce time • Reduce waste • Reduce weight • Reduce cost
Why Additive Mfg? • Design for function Vs. manufacture • “Free” complexity
Why Additive Mfg? • Mass customization • Low volume – no tooling/fixturing/molds
Why Additive Mfg? • Unique materials
Additive Mfg Reality • High entry cost & learning curve • Doesn’t necessarily replace conventional manufacturing, BUT… • …it allows you to build things in new ways • Part/process certification
Additive Mfg Reality • QA/QC becoming real • The technologies are evolving quickly • Gaining momentum as a manufacturing tool • Early adopters are moving forward
The early adopters are moving forward………. “We are on the cusp of a step -change in weight reduction and efficiency – producing aircraft parts which weigh 30 to 55% less, while reducing raw material used by 90%. This game-changing technology decreases total energy used in production by up to 90% compared to traditional methods.” Peter Sander, Airbus
The early adopters are moving forward………. Airbus reports that using additive can reduce the weight of an airplane by more than a ton . They plan to print 30 tons of aircraft parts per month as soon as 2018.
The early adopters are moving forward………. “The lead time in engine development is dramatically reduced and the design freedom it offers as opposed to conventional casting and machining; both of which could be significant.” Simon Burr, Rolls-Royce
The early adopters are moving forward………. GE plans to build 25,000 LEAP engine nozzles with 3D printing.
The early adopters are moving forward………. The world’s largest and most technologically advanced manufacturers recognize the significance of additive manufacturing and are moving rapidly to secure their position in the industry. This includes their own capabilities and their supplier base.
Metal Additive Technologies • Powder Bed Fusion • Directed Energy Deposition • Binder Jet • Solid State
Powder Bed Fusion • Some of the manufacturers include: 3D Systems, Arcam, Concept Lasers, EOS, Renishaw, etc.
Powder Bed Fusion Laser or Scan Electron Beam Head Powder Layer Typical layer ~ 20 – 80 µ
Powder Bed Fusion Powder Layers
PBF – Build Characteristics • Very complex part geometries • Fine feature size, surface finish • Wide Range of Materials • Technology of choice for many new part builds. • medical, aerospace and other industries
Directed Energy Deposition
Directed Energy Deposition Heat Source: Laser or Electron Beam Metal Powder or Wire Typical layer ~0.010” - Melt Pool <0.100”
DED – Build Characteristics • Large Part Builds (e.g. 3’x3’x5’ & larger) • Huge Range of Materials • Build Morphology • Geometries • Wall thickness • Layer thickness • Surface finish • Near Net Shape
Directed Energy Deposition • New Part Builds • Repair & Modification • Small HAZ and dilution • Multi-material • functionally graded
Binder Jet • Powder Bed Process • Bake out the binder • In-fill with metal • OEM – EXOne
Solid-state • Ultrasonic • Additive Friction Stir Welding • OEMs: Fabrisonic, Aeroprobe
Solid-state • Metal foils ultrasonically welded together • Metal rods/powders • Lower build temperature • Bonds dissimilar metals • High build rate • Ability to embed electronics/fibers • Near Net Shape
New developing technologies • Plastic filament with embedded metal powder (Markforged, riZe, etc.) • Nano particle metals (ExJet)
Hybrid Machines • Combine additive and subtractive capabilities • Other hybrid machines in daily use (Mill-Turn) • One & Done • Technology flexibility • Optomec, DMG, Mazak, Hybrid Mfg Technology and many others • New or retrofit existing
• 316L Stainless • Total build time = 4.75 hrs. • No rough machining • Multiple parts per tool
I’m considering getting into metal additive. What’s the next step? • What do you want to do and why? • What material(s)? • Fully understand the total commitment and associated cost.
PBF DED Build new parts Y Y Build highly complex parts with extreme part Y N geometry and very fine part structure Build parts smaller than a microwave Y Y Build parts larger than a microwave M Y Add modifications to existing parts N Y Repair existing parts N Y Use one or two materials Y Y Use a wide variety of materials M Y Make graded/multi-material parts N Y
Equipment & Other Considerations • Size & capabilities of the build chamber • Materials selection and availability • Support equipment • Explosion proof vacuum cleaner, vacuum pumps, powder recovery, gas systems, shop equipment, exhaust systems • Safety • Metal powders, respirator program, cryogenics, gases
Post Process Considerations • Remove part from the build plate • PBF – clean up the support structures • Critical dimensions / surface finish – Near Net Shape (Design with the end in mind) • Heat treatment, stress relief, HIPping
Consider using a service bureau before investing in equipment. Find out: • Who is going to embrace the technology? • How are you really going to use it? • Does it really make business sense? • Strategic long-term sense? • Is there customer demand or interest?
• Powder • Manufacturing process (Gas Atomized/PREP/Milled/Spheroidized) • Morphology & chemistry • Flow rate • Layer thickness • Packing density • Reuse
• Build environment • Cover gas or vacuum/inert enclosure • Oxygen level • Heat source • Laser (power, beam size, wavelength) • EBM • Friction • Substrate • Dimensions, material, cleaning/prep, temperature
Process Parameters • Layer Height ( 20µ - 2+ mm) • Packing density/method (PBF) • Hatch Spacing & Orientation • Write / Travel Speed • Powder Flow Rate (DED) • Laser Power
Varying Parameters – ten layer test coupons Ti- 64 “As Built”
Ti 6-4 As Built
Ti64 - Additive Tensile Test Ti 6-4 200000 180000 Tensile 160000 Test 140000 120000 100000 80000 60000 40000 20000 0 0 1 2 3 4 5 6 7 8 9
Ti 6-4 Fatigue Test
450 430 Ti 6-4 410 Hardness 390 Thin Base / Thin Deposit Test 370 1-P-1a 1-P-1b HV 500 350 1-P-1c 1-P-2 330 1-P-3 310 290 270 AM Build HAZ Base - Build Plate 250 0.05 0.025 0.005 0.005 0.01 0.015 0.02 0.03 0.05 0.07 Distance From Fusion Line (in)
Takeaways • There are tremendous efforts underway to: • Develop QA/QC/Process Monitoring /Control/Documentation • Speed the certification process • Understand and control the basic science of the technology.
Takeaways • The real power of additive is to build things in new ways that are difficult or impossible to do with conventional technologies. To rethink how something is made and how the power of additive technology can be employed to make it better, lighter, faster or cheaper.
Takeaways • The technology, equipment & materials are evolving very rapidly. • Try out the technology before you invest. • Additive is here to stay and will continue to grow as a manufacturing & repair tool.
The early adopters are moving forward……….
Thank you! Jeff Crandall jcrandall@ccat.us 860.282.4201 www.ccat.us
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