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CLIC WORKSHOP 20133

HIGH GRADIENT DAY – 31/01/2013

TECHNICAL CAPABILITIES – MECACHROME France

PRESENTATION sandrine.lecureuil@fr.mecachrome.com & al

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MECACHROME OVERVIEWMECACHROME OVERVIEW

Mirabel

Tanger

Aubigny sur Nère

Vibraye

Sablé-sur-Sarthe

Amboise

Ville Saint Laurent

Tunis

Toulouse

10 sites:

Headquarters : Amboise 8 production sites 1 R&D center 1 engineering center Aeroengines Aerostructures Automotive

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Division AerostructuresMECACHROME / MECAHERS

5 production sites: Amboise, Toulouse, Mirabel, Tangier, Tunis (France / Canada / Morocco / Tunisia) Equipments: 75 CNC machines

Division Aero Engines & EnergyMECACHROME

2 production sites: Aubigny sur Nère, Vibraye - France Equipments: 155 CNC machines Special process : 75 machines

Division AutomotiveMECACHROME

1 production site: Sablé sur Sarthe - France Equipments: 127 CNC machines 51 robots & 49 special machines

Production capabilities – Mecachrome / MecahersProduction capabilities – Mecachrome / Mecahers

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Iron cast blocks

AUTOMOTIVE

Main Customers :• Aerolia

Key Technologies :• B E• UGV machining• Spot stamping• Riveting

WP - Landing gear bay

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Main customers• RENAULT

Key technologies:•Iron cast Machining•Vermiform•Burn in• Assembly

Large Cases and Disks (1,2-2,5 m)

Main customers :• Rolls Royce• Snecma• ECF

Key technologies:• Combined milling/turning

machine (ITV)• Ceramic milling• High-pressure turning (with

double railhead ram)

Typical parts– Mecachrome Typical parts– Mecachrome

AERO STRUCTURES AERO ENGINES

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RADIO FREQUENCY QUADRUPOLE - MachiningRADIO FREQUENCY QUADRUPOLE - Machining

RFQ IPHI Photo CEA Saclay

Collaboration : CEA IRFU / MECACHROME

Scope: Machining, Assembly

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5-axis CNC turning milling machine Technical characteristics:

X axis travel 350 mmY axis travel 150 mmZ axis travel 300 mmB and C axis travel 360 degrees

Swing capacity up to 20‘’ Air bearing Turning spindle 10,000 rpm Air bearing Milling spindle 60,000 rpm

Precision34 picometers resolution rules (0.034 nanometers)Incremental programming 0.01 nanometerAxial and radial spindle error ≤ 25 nanometersB axis axial and radial error ≤ 100 nanometers

Shape defect ≤ 0.15 μm on diameter 75 mmSurface finish Ra ≤ 3.0 nanometers

NANO MACHINING / NANO MACHINING / MECACHROME R&D CenterMECACHROME R&D Center

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NANO MACHINING / NANO MACHINING / MECACHROME R&D CenterMECACHROME R&D Center

Our structures have been tested at CERN on 22 February 2012.

Beyond the dimensional control, these are measures which demonstrates our expertise in

achieving accelerating cavities.

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Results :PV = 0.807 µmRa = 0.002 µm

RmS = 1,72 nm

Results :PV = 0.335 µmRa = 0.001 µm

RmS = 1,92 nm

Aluminum mirror for satellite application on its support delivery

Copper disk - accelerating structure

NANO MACHINING / NANO MACHINING / MECACHROME R&D CenterMECACHROME R&D Center

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Working on cutting parameters to avoid grain pullout

SEM inspection capabilities / SEM inspection capabilities / MECACHROME R&D CenterMECACHROME R&D Center

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Innovative Manufacturing - Additive manufacturing processInnovative Manufacturing - Additive manufacturing process

The powder bed is melted in a vacuum chamber No moving parts, electron beam scanning faster than a laser beam The high energy beam melts the powder producing 100 % dense parts in controlled thermal conditions Homogeneous focusing on the entire Build surface Build reports are generated for each batch with monitored data during the entire cycle

ALM = Parts are manufactured using CAD data by the addition of material, layer by layer

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Innovative Manufacturing - Additive manufacturing processInnovative Manufacturing - Additive manufacturing process

Advantages and limitations of the process:

Achieves close to the raw scores (as a foundry), but with similar characteristics on a forged (excellent health matters).

No residual stresses and distortions.

Material: Titanium Alloy TA6V (sheet material available).

2 build configurations (size max.): 200 x 200 x H 332 mm or Ø 300 mm H x 210 mm.

Geometric Tolerance: + / - 0.2 mm

Minimum thickness : 1.2 mm

Important roughness Ra ~ 12 microns (possibility of improvement post processing).

Freedom of design (concept parts embedded, network structure of ...) not achievable by any other process …

Benefits achievable by design optimization (design around functionality -> gain of material).

Short production cycle, production time is independent of the complexity of the parts.

Machining is limited to functional areas, drilling … leading to a much reduce material removal rate

Much lower environmental impact than the traditional method, only the material needed is consumed

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Matrix Reinforcement

Ball Milling

Can or die filling

SPSHIP Extrusion

Thermal treatment, machining….

Part

Advanced Materials Advanced Materials : : Powder Metallurgy – Metal Matrix compositePowder Metallurgy – Metal Matrix composite

Metal powder (Matrix) Reinforcementt

Composite powder

Dense material

From powder to advanced materialFrom lab scale to industrialization

Know-how : ball milling, Spark Plasma Sintering ( on-site installations)

Hot Isostatic Pressing, Hot extrusion (sending subcontracting)

Examples of development:Steel-TiC, Ti-TiC, Al-SiC, ODS-steel, …

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Advanced Materials Advanced Materials - - Spark Plasma Sintering : on-site installationSpark Plasma Sintering : on-site installation

Main advantage:Short cycle time

- Conservation of fine microstructures (nanomaterials, metal matrix composites ...)- Ability to consolidate "difficult" materials (tungsten carbide, ceramics transparent ...)- simple, reliable and process to industrial

scale SPS microstructure is finer than HIP (Hot Isostatic Pressing) microstructure

Assembly of steel matrix composite

with steel

Processes: consolidation of powder (reactive or not), assembly / coating (solid / solid, solid, powder, solid)Materials: Metals, ceramics, composites (metallic and polymeric), FGM (density, composition)

Under pressure and pulse energized, the temperature can instantly rise to 2000 above the ambient temperature, ℃resulting in the production of a high quality sintered compact in only a few minutes.

Our machine is the world largest unit the diameter can

reach 350 mm

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PEM ELECTROMACHINING / PEM ELECTROMACHINING / MECACHROME AubignyMECACHROME Aubigny

The PEM process is an electrochemical cavity-sinking erosion process with vibrating electrodes

Technology on progress – unit operationnal in March 2013

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Coating / Coating / MECACHROME VibrayeMECACHROME Vibraye

DLC

Substrat

An adherent film, hard and thin

High hardness (approaching that of diamond (> 2500 Hv)

Relatively low deposition temperatures (<300 ° C)

An extremely low coefficient of friction

High resistance to wear, shock and scratches

Limitations : plasma interaction with the substrate can lead to inhomogeneity's deposits parts of complex geometry.

PECVD : Plasma Enhanced Chemical Vapor Deposition

Process for chemical vapor deposition assisted by plasma, used to deposit thin films on a substrate from a gaseous state (steam). Chemical reactions take place in the process after creating a plasma from the gas reactor. The plasma is generally created from this gas by radio frequency or by an electrical discharge between two electrodes.

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Thank you very much for your attention

sandrine.lecureuil@fr.mecachrome.com

Loic.guillonneau@fr.mecachrome.com

marc.noyer@fr.mecachrome.com

www.mecachrome.com