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
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
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
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
MalargüeESA sites
OfficesESA Ground Station
ESA Ground Station + Offices
ESA sites + ESA Ground Station
www.esa.int
Andrew Norman | 18/06/2019
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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 6
Early Design Phases
Materials and Processes/Failure Investigation
Flight Acceptance/Operations
Full Scale Testing Support
Design for Demise
Vibro-Acoustic Environment Prediction/Launcher Coupled-Multibody Analysis
Detailed Stress Analysis
Materials, Structures and Mechanisms
Andrew Norman | 18/06/2019
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
o
Space Debris / Demisability
Dust, Micrometeoroids
Asteroids and Comets
Space Junk
Controlled Break-up / Demisable
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 8
Why adopt Additive Manufacturing for Space Applications ?
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 9
Why Additive Manufacturing for Space hardware?
o Challenges for Space Materials and Processes:
o Why Additive Manufacturing ?
ALM addresses majority of above challenges
Applied to many materials => metals, polymers, composites, ceramics
Dimensions: few micrometers to meters
Significant gains in performances
Environmentally friendly
Low Mass
Small Production Series
Very High Reliability
Small Geometries
Very High Performances
Challenging Material Procurement
Andrew Norman | 18/06/2019
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 Processand materials selection
Designing forAdditive Manufacturing
Andrew Norman | 18/06/2019
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 of 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
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 1As built part
Designing for AM(Alloy design)
Designing for AM (topology / properties)
Starting to Design for AM
Re-thinking Materials Selection
Simple reproduction of existing parts
Andrew Norman | 18/06/2019
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 = 1-324 targeted at TRL = 3-6
Co-funded 4 PhD Studies
Total = 25.1 MEuros
Andrew Norman | 18/06/2019
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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 15
Injectors
Mirrors
Mirrors
Chambers
Bellows
Examples of Manufactured Parts
Wave Guides
ThrustersBrackets
Optical Bench
Brackets
NozzlesBracketsBolts
Flex-Pivots
CoilsBrackets
Tank Hemispheres
Andrew Norman | 18/06/2019
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 16
Re-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 17
Starting to Design for AM
Single Part Wave GuidesRe-thinking Materials Selection
Simple reproduction of existing parts
Designing for AM(Alloy design)
Designing for AM (topology / properties)
Radio Frequency
3D print it in a single piece
Reduce misalignments and errorsare removed
Andrew Norman | 18/06/2019
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 18
ISCAR Secondary Bracket for Ariane 5 ECARe-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 19
Reaction Wheel Bracket for Exomars TGORe-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 20
Reaction Wheel Bracket for Exomars TGORe-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 21
Bellows (Going Small)Re-thinking Materials Selection
Simple reproduction of 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 more reliable and cost effectivemanufacturing process => AM
Characterizing the performance and the reliability of the bellows
Andrew Norman | 18/06/2019
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 22
Athena Optical Bench (Going Large)Re-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 23
Alloy DesignRe-thinking Materials Selection
Simple reproduction of 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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 24
End-to-End Manufacturing
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 ProcessingProcessingMaterial SupplyDesign
End-to-End Additive Manufacturing
Andrew Norman | 18/06/2019
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
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 27
Additive Manufacturing: In Orbit and On Planet
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
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
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
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
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
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
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 power
• Testing in representative conditions (vacuum, temperature, reduced gravity, dust, radiation) is more challenging
Andrew Norman | 18/06/2019
ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/05/2018 | Slide 35
Future Challenges on Earth
Functionally Graded Material4D 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