Additive Manufacturing

Oak Ridge, Tennessee November 19, 2013

Amy Elliott

Graduate Researcher Manufacturing Demonstration Facility

SPARK

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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