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1 Jornada de fabricación aditiva de componentes metálicos IK4-LORTEK Additive Manufacturing in ITP María Sierra 27 Noviembre 2013 Materials & Processes Dept.
1
Jornada de fabricación aditiva de
componentes metálicos IK4-LORTEK
Additive Manufacturing in ITP
María Sierra
27 Noviembre 2013
Materials & Processes Dept.
COMPANY PRESENTATION
ADDITIVE MANUFACTURING
TECHNOLOGY ALREADY AVAILABLE IN ITP
CURRENT TECHNOLOGY DEVELOPMENT FOR NEXT COMPONENTS
FUTURE WORK
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INDEX
3
WHAT WE DO?
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ITP’S GLOBAL PRESENCE
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2012 2011 2010
Sales 581.497 € 518.526 € 482.981 €
EBITDA 93.970 € 105.466 € 88.165 €
Post-tax results 71.165 € 58.060 € 38.105 €
Material and non-material investments
82.177 € 69.944 € 71.000 €
R&D Investment 54.646 € 49.474 € 58.039 €
Capital and reserves 425.536 € 374.832 € 341.037 €
EBITDA against sales 16,16% 20,34% 18,25%
% R&D Investment/sales
9,40% 9,54% 12,02%
Sales/employee 198 € 185 € 180 €
Cost of labour/sales 24,80% 26,53% 27,71%
2012 2011
ITP 1.756 1.726
PCB 251 259
ITR 444 499
ITA 86 91
ITA Mexico 161 100
ITP Engines UK 149 138
Aeromaritime 89 94
Total 2.936 2.807
ITP Group Main Figures (in thousand euros)
Staff
SENER AERONÁUTICA 53,125 %
ROLLS-ROYCE 46,875 %
Participations
ITP IN FIGURES
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ITP’S UNIQUE EXPERTISE
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Trent XWB
Additional Information Airframe: Airbus A350 XWB -800, -900 & -1000
Thrust: 74,000 lb – 92,000 lb
Fan Diameter: 118 in
CIVIL – LARGE COMMERCIAL LPT
FROM THIS… TO THIS…
ADDITIVE MANUFACTURING - OVERVIEW
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NEAR 100% MATERIAL UTILISATION REDUCED MATERIAL COSTS. IMPACT
THE MANUFACTURE OF FUTURE AERO
ENGINE COMPONENTS (CURRENT BUY
TO FLY RATIOS RESULT IN MASSIVE
AMOUNTS OF WASTE)
SIMPLE/MINIMAL TOOLING REDUCED TOOLING COSTS
REDUCED TIME TO MARKET
NEAR NET-SHAPE CAPABILITY REDUCED ‘REMOVAL’ OPERATIONS
DESIGN FREEDOM INCREASED ENHANCED PRODUCT CAPABILITIES
REPAIR CAPABILITY INCREASED LOWER TOTAL LIFE CYCLE COST
ADDITIVE MANUFACTURING - OVERVIEW
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ADDITIVE MANUFACTURING - OVERVIEW
Capabilities Arc+ Wire
(SMD)
Laser/EB+
Wire
(EBWD)
Laser+blown powder
Laser Metal
Deposition (LMD)
Laser+ powder bed
Selective Laser
Melting (SLM)
Cost/kg Medium Medium Medium High
Build rate High High High Low
Filler usage
efficiency High High Low High
Fusion capability High Medium Medium Medium
Near net shape Low High High Very high
Capability of
avoiding cracking in
difficult to weld
materials
Low Low Low Medium
Deposit density Medium High High Very high
Suitablity for
complex parts Low Medium Medium High
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PRESENT NEAR FUTURE FUTURE
PR
OD
UC
TIO
N
Small-Medium Size Complex Non-Critical Components
SLM
Repairing Components made from Difficult to Weld Alloys (e.g. MAR-M-247)
LMD
Features and Repairs at Stressed Areas Non-Critical Components made from
Weldable Alloys (e.g. Inconel 718 and Ti) LMD
Non-Structural Features SMD
DEV
ELO
PM
ENT
BEN
CH
TES
T H
/W
LPT Blades SLM
LPT NGVs Instrumented or Not
SLM
Static Cast Components Instrumented or Not
SLM
Low Temperature Aerodynamic Rigs SLM
Instrumentation Rakes and Probes
SLM
ADDITIVE MANUFACTURING IN ITP - OVERVIEW
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ADDITIVE MANUFACTURING IN ITP - OVERVIEW
SMD, LMD AND EBWD VS FORGING
Cost savings of approximately 35-40%
SMD, LMD AND EBWD VS CASTING
Cost savings of approximately 10% or less Cost savings of approximately 10% or less
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INCO 718 SMD IN PRODUCTION FOR THB HANDLING LUGS
TECHNOLOGY ALREADY AVAILABLE IN ITP
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CONVENTIONAL MANUFACTURING SELECTIVE LASER MELTING
• DESIGN LIMITED BY MANUFACTURING (radius,
minimum thicknesses, profiles). Need to allow
adequate access to attach the tubes in position
and to provide access to the brazing filler
• CONSIDERABLE REWORKS or even scrap parts
due to brazing process
• LONG MANUFACTURING TIMES
(Machining, welding, brazing)
DESIGN ADAPTED TO MANUFACTURING MANUFACTURING ADAPTED TO DESIGN
• FREEDOM OF DESIGN → Aerodynamic profiles,
thickness and profiles distribution as required,
curved cavities 1 mm diameter
• INTEGRATED TUBES → No risk of reworks and
scraps because of tubes brazing
• ONLY ONE ITEM → Manufacturing time
reduced, less risk of reworks/scraps
TECHNOLOGY ALREADY AVAILABLE IN ITP
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TECHNOLOGY ALREADY AVAILABLE IN ITP
COMPARISON OF TIME DELIVERY VS COST
(REAL CASE FOR A SPECIFIC RAKE)
ADVANTAGE DISADVANTAGE
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COMPLEX DESIGNS ACHIEVABLE
• COMPLEX COOLING PASSAGES
• REINFORCING LATTICES
• INTEGRATED PRESURE TUBES
• LESS INTRUSIVE COMPACT DESIGNS
TECHNOLOGY ALREADY AVAILABLE IN ITP
AIRFOILS MADE FROM POLIMERIC MATERIALS FOR COLD RIGS
CURRENT TECHNOLOGY DEVELOPMENT - SLM
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CAST COMPONENTS
ONLY FOR FIRST BENCH TESTS
FIRST TRIAL
SECOND TRIAL
CURRENT TECHNOLOGY DEVELOPMENT - SLM
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VANES INSTRUMENTED OR NOT
ONLY FOR FIRST BENCH TESTS
CURRENT TECHNOLOGY DEVELOPMENT - SLM
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MILESTONE YEAR 1 YEAR 2 YEAR 3 YEAR 4
PERFORMANCE
VIBRATIONS
ENDURANCE
CYCLIC
THERMAL
INGESTIONS
CONTAINMENT
FLIGHT TEST BED
MINIMIZE DELAY IN THE
ENGINE TEST PROGRAM
1/1 1/2
2/1 2/2 2/3
3/1 3/2 3/3
4/1 4/2 4/3
5/1
6/1 6/2
7/1
8/1
MAIN ADVANTAGE OF A
REDUCED TIME DELIVERY
CURRENT TECHNOLOGY DEVELOPMENT - SLM
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LMD INCO 718 LMD Ti 6AI 4V LMD MM247LC
TBH FEATURES SEAL FINS REPAIR
GENERAL CASTINGS REPAIR
THIN SHEET REPAIR
CURRENT TECHNOLOGY DEVELOPMENT - LMD
PROPRIETARY INFORMATION – STRICTLY CONFIDENTIAL 22
Additive Manufacturing- Mechanical Properties
PROOF STRESS CLOSE TO FORGING: SLM PROCESS SAME AS FORGING WITH LOW
SCATTER
UTS BETWEEN CAST AND FORGING
ANISOTROPY CAN BE DECREASED CHANGING DEPOSITION PARAMETERS
FATIGUE DEPENDANT ON POROSITY, LACK OF FUSIONS AND SURFACE FINISH.
CREEP IN SLM LESS THAN FORGING DUE TO FINE MICROSTRUCTURE
0
1
YIELD(MPa)
Inco 718 Forging
SLM Plane XY
SLM eje Z
0
1
UTS(MPa)
Inco 718 Forging
SLM Plane XY
SLM eje Z
Inco 718 SLM Mechanical properties at 600ºC
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Additive Manufacturing- Mechanical Properties
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Additive Manufacturing- Mechanical Properties
Internal Surface Integrity Microporosity Lack of Fusion Defects
Reduced HCF from forging material.
Need of improving process capability to further reduce
defects
Need of determination of scatter band in
fatigue properties
Need of NDT development:
Laser ultrasonic testing in MERLIN
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SMD, LMD, EBWD BUILD RATES SLM BUILD RATE
CURRENT TECHNOLOGY DEVELOPMENT FOR NEXT COMPONENTS
TARGETS IN MERLIN TO INCREASE THE
DEPOSITION RATE MEETING QUALITY
REQUIREMENTS
Current build rate to
ensure full density in
commercial machines
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NEED TO DEVELOP
• COMPETITIVE BUILD RATES AND CAPACITIES
• TECHNIQUES TO BUILD DIFFICULT TO WELD HIGH TEMPERATURE SUPERALLOYS
• POWDER SUPPLIERS WITH SUITABLE QUALITY
• SUITABLE IN-PROCESS NDT TECHNIQUES
• POST PROCESSING METHODS TO ACHIEVE ACCEPTABLE INNER SURFACE FINISH
AND SURFACE INTEGRITY
FUTURE WORK
