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Additive Manufacturing
Oak Ridge, Tennessee November 19, 2013
Amy Elliott
Graduate Researcher Manufacturing Demonstration Facility
SPARK
2 SPARK – Additive Manufacturing
Manufacturing Demonstration Facility
MDF
Additive Manufacturing
Carbon Fiber & Composites
Lightweight Metals
Processing
Low-Temperature
Material Synthesis
Transient Field Processing
Roll-to-Roll Processing
www.ornl.gov/manufacturing
Manufacturing Demonstration Facility: a multidisciplinary DOE-funded facility dedicated to enabling demonstration of next-generation materials and manufacturing technologies for advancing the US industrial economy
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Intro. to Additive Manufacturing (AM)
“Additive Manufacturing will become the most important, most strategic, and most used
manufacturing technology ever.” Wohlers 2012
Topics to Discuss: • Principles of AM • Powerful Applications of AM • AM Thrust Areas at MDF • Unique AM Capabilities at MDF
CAD Model to Physical Part
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Additive Manufacturing (AM)
“Additive Manufacturing will become the most important, most strategic, and most used
manufacturing technology ever.” Wohlers 2012
CAD Model to Physical Part Topics to Discus: • Principles of AM • Powerful Applications
of AM • AM Thrust Areas at MDF • Unique AM Capabilities
at MDF
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Principle 1: Complexity is Free
Withinlab.com
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 2: Variety is Free
goyaldiecast.com
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 3: No Assembly Required
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
replicatorinc.com
www.austechexpo.com.au
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Principle 4: Zero Lead Time
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc. Makepartsfast.com
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Principle 5: Zero Skill Manufacturing
Makerkids.ca
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 6: Zero Constraints
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
Bathsheba.com
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Principle 7: Compact, Portable (Affordable) Manufacturing
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 8: Less Waste
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 9: Infinite shades of Materials
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 10: Precise Replication
Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc. Makerbot.com
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Enabling Next Generation Robotics Additive Manufacturing
Army PETMAN program Bluefin Robotics • Team with Boston Dynamics to develop a fully
anthropomorphic android for in situ testing of chemical and biological PPE – ORNL role: Arms and hands – Requirements: Integrated sensing
(chemical), perspiration, thermal management and control (hydraulics)
– Part complexity would not be possible with conventional machining
• Develop a neutrally buoyant titanium manipulator arm – Able to float – Integrated fluid passages
and wire ways
Anthropomorphic Hydraulic Arm for Boston Dynamics Petman Program
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Enabling Next Generation Robotics Additive Manufacturing
• Titanium made using E-beam AM (operating pressure 3000 psi) • Integrated pump, fluid passages and pistons with mesh for weight reduction
Curved fluid passages
Pistons integrated into structure
Integrated motor and pump
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Enabling AM of Aerospace Brackets Collaboration with Industry
• Bleed Air Leak Detect (BALD) Brackets – Buy to Fly Ratio of 33:1 – AM can reduce to 1.5:1
• ARCAM Parts HIPed (900oC, 15ksi, 2 hours)
• Decrease Cost by Over 50%
Property Minimum Value Maximum Value Ultimate Tensile Strength, (ksi, MPa) 132 910 152 1,048 Elongation, % 12 22
Over 60 Tensile Specimens Tested Within a Matrix of Processing Conditions
As-Deposited As-HIPed
Pores
Consistent with data from ARCAM
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Enabling AM of Turbine Blades Science to Application
Headquartered in Cincinnati, OH
• Largest number of AM machines worldwide
• 18-yrs experience in laser deposition
• Works with every major aerospace company in US
Critical to widespread adoption of technology
Profilometry map illustrating distortion
• Optimized internal cooling structures are desired for maximum efficiency
• AM can produce geometries not possible with conventional processes
• Decrease manufacturing costs while maximizing performance
Laser AM creates large residual
stress leading to distortion
laser AM of turbine blade
Understanding link between residual stress and additive manufacturing
Utilizing neutron science to impact industry
turbine blade
Reconstructed image using neutron tomography
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Additive Manufacturing (AM) Thrust Area Goals
Leveraging key resources at ORNL to accelerate technology implementation • Developing advanced materials
– Titanium alloys, Ni superalloys, stainless and ultra high-steels
– High-strength, carbon-reinforced polymers • Implementing advanced controls
– In-situ feedback and control for rapid certification and quality control
• Understanding material properties and geometric accuracy
• Exploring next-generation systems to overcome technology barriers for manufacturing – Bigger, Faster, Cheaper
– Integrating materials, equipment and component suppliers with end users to develop and evolve the supply chain
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Neutron Characterization of AM Unique Capabilities
laser AM of turbine blade
• Successful Inter planer spacing measurements on complex geometry
• Developing capabilities for residual stress mapping
• In-situ measurement during processing, HT, mechanical testing
Residual Stress Measurements
Neutron Imaging and CT • Neutrons offer higher contrast and better
resolution than x-rays • Resolution Capabilities
• Currently at HFIR: 50 µm • Proposed VENUS: 10 µm
• Ability to study micro/macro cracking phenomena related to residual stress during processing
Reconstructed image using
neutron tomography
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Neutron Characterization of AM Unique Capabilities
• 210 Images around 180 degree rotational axis
• Currently 50-75 µm resolution at HFIR, VENUS is targeting 10 µm
• Developing methodology to perform stress mapping with tomography
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MDF Metal-based Systems Additive Manufacturing
• Developing in-situ characterization, feedback and control
• Heated powder bed • Expanding range of
materials (Ti64, 718, 625, CoCr)
• Precision melting of powder materials
Electron Beam Melting
• Simultaneous additive and subtractive process for manufacturing complex geometries
• Solid-state process allows embedding of optical fibers and sensors
Ultrasonic Additive Manufacturing
• Site-specific material addition
• Application of advanced coating materials for corrosion and wear resistance
• Repair of dies, punches, turbines, etc.
Laser Metal Deposition
• Unheated powder bed • Wide range of material
choices (316L, 17-4PH, H13, Al, Ti, 718, 625)
• 9.8 x 9.8 x 11.8 inch build volume
• Precision melting of powder materials
Laser Powder Bed
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MDF Polymer-based Systems Additive Manufacturing
• Development of high-strength composite materials for industrial applications
• Precision deposition of thermoplastic materials
• Multi-material deposition
Fused Deposition Modeling
• Deposition of multiple materials, integrated structures, and material gradients
• High resolution, complex geometries, and smooth surface finish
Photopolymer Multi-head Jetting
• Large build volume • Currently 8 x 8 x 8 ft • Expanding to 20 x 10 x 10 ft
• Pellet to part manufacturing • 10-20 lbs per hour throughput • Amorphous & semi-crystalline materials
Big Area Additive Manufacturing (BAAM)
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Big Area Additive Manufacturing (BAAM)
ABS
CF-ABS
Large scale deposition system • Unbounded build envelope
• High deposition rates (~20 lbs/h)
• Direct build components
• Tools, dies, molds
Carbon fiber material reduces warping out of oven
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SSAM Lab Small Scale Additive Manufacturing
Great for: • Geometric Modeling • Small Fixtures • New AM Material Development • New AM Sensor Development
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Carbon Fiber FDM Composites
CF-ABS
2x strength
4x stiffness
ABS ABS
CF-ABS
ABS
CF-ABS
• Compounded filament printed on Solidoodle 3 (modified) • 10-15% CF by weight
Dramatically reduced curl
Lindahl ACCE Poster (2013)
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Multi-function Material Systems Manufacturing Systems
Optomec/Neotech/FAPS
Integrate Functionality into Structure • Electrical Circuits • Sensors • Communication • Energy Generation • Energy Storage
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Key Principles of Additive Manufacturing
Complexity is Free Variety is Free No Assembly Required
Less Waste Infinite Shades of Materials Zero Constraints
Others: Zero Lead Time, Compact and Affordable, Low-skill, Precise Replication
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Discussion
Amy Elliott elliottam@ornl.gov (865) 946-1577