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CSIRO MANUFACTURING CSIRO Collaboration and Innovation : Metals Industry Manufacturing Keith McLean Director, CSIRO Manufacturing June 26 2018
CSIRO MANUFACTURING
CSIRO Collaboration and Innovation : Metals Industry Manufacturing
Keith McLean Director, CSIRO ManufacturingJune 26 2018
About CSIRO
McLean Copper to the World June 2018
5000+staff
3000industry partners
across 80+ countries
Top 1%of global research agencies
$1.3 Billion research
organisation
1800+Australia’s
largest patent holder
50+ research
centres across Australia, Chile, France and USA
The Commonwealth Scientific and Industrial Research Organisation (CSIRO) has delivered solutions for the environment, business and society for over 100 years.
Annual benefits from CSIRO
research
>$6 Billion
Research portfolio provides
estimated return
>5:1
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THE DEEP SPACE COMMUNICATION COMPLEX MANAGED BY CSIRO IS ONE OF THREE DEEP SPACE NETWORK STATIONS AROUND THE WORLD.
Our role
CSIRO uses applied science and research to solve problems and make a difference to the economy, society and the environment.
We also manage important research infrastructure like the Australia Telescope National Facility (pictured), the Marine Research Vessel (RV Investigator) and the Pawsey Supercomputing Centre.
Our mission
Projects and teams – creative, entrepreneurial, collaborative teams tackling big challenges through science, technology and innovation
Customer value – delivering value through innovative solution for customers in industry, government and community
Impact delivery – creating new economic, environmental and social impact for Australia
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Create value for customers
through innovation
that delivers positive
impact for Australia
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Collaboration
We work with
of RDCs
We’ve workedwith
of 200 CRCs
Customers (20% of ASX 200)
FEDERALSTATE
& LOCALGOV’TS
SMEs with 100+ researchers in
business projects
ALLAUSTRALIANUNIVERSITIES
international partners from 80+ countries
EXCELLENT SCIENCEMASSIVEIMPACT
from offshore sources
Producer of research relevant
to Australia’s Strategic Priorities
LARGEST
139
3000 1200 150 $140m
90%
3D PRINTED BONES FOR CANCER PATIENTS
Agriculture and FoodData61EnergyHealth and BiosecurityLand and WaterManufacturingMineral Resources Oceans and AtmosphereAstronomy and Space ScienceResearch InfrastructureResearch CollectionsEducation
CSIRO focus areas
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CSIRO Manufacturing
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3D PRINTED BONES FOR CANCER PATIENTS MANUFACTURED AT OUR STATE OF THE ART FACILITY, LAB22
Australian manufacturing is changing focus from heavy industry to high tech products based on sustainable, advanced manufacturing processes. Our science and engineering skills, equipment and international connections are helping Australian manufacturers be globally competitive.
Research programs
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Metal industries
We help organisations capture opportunities in the face of a changing metals industry, through innovative sustainable processes and high performance alloys and technologies.
Materials Industries Program Capabilities
Alloy and Powder Technologies
Innovative Additive Manufacturing
Surface and Functionality Technologies
Modelling Technologies
Future Metals
“Powder to Product”
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Metal Industries
Defence, Space and Aerospace
Metals
Key Value Chain Horizontals: Titanium, Lithium
Secondary Value Chain Horizontals: Scandium, Magnesium, Cobalt/MMOs
Mining and Rail Metals
Energy and Resources Metals
Medical Metals
Industry Sector Focus
• Defence, Space, and Aerospace Metals
• Energy and Resources Metals – including energy storage, renewables, corrosion, and related applications, and the link with Lithium and other battery materials
• Medical Metals –prosthetics, dental, and related technologies.
• Mining and Rail Metals
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Titanium Powder Making
Current Economics of Additive Manufacturing Powder Feedstock
Ti Sponge~$15/kg
GA Ti Powder
Final AM Product
>$400/kg
• Morphology: spherical or near spherical• PSD: < 45 μm for SLM & CS
<106 μm for EBM• Purity: low O%, H%
Powder requirement for Powder bed fusion processes
Batch-continuous rod feeding system
Rotating rod (electrode)
Chamber
Induction coil
Gas jets
Powder collection
Courtesy ALD Corporate Brochure; EIGA
A Need to Develop a Low Cost Additive Manufacturing Powder Making Value Chain
Novel Titanium precursor
PMTMetal
Powder
Titanium precursor
Kroll process Melting Casting/Forging Mill productGas
atomization
Traditional powder value chain
Additive Manufacturing
CSIRO’s AM Powder value chain
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There ARE “other” Titanium Processes
Armstrong Process – Cristal - USA
FFC Process – Metalysis - UK
CSIR - SA
Hydride DeHydride
ADMA
China
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..but they all require shaping and sizing for Additive Manufacturing
~$15/kg
AM PowderMorphologyrequirements
New Powder Manipulation Technology PMT®
50
25
>1000 600 –1000
400 –600
250 –400
150 –250
100 –150
75 –100
45 –75
25 –45
< 25
ColdSprayLaser AM
WeightWt %
Particle Size (mm)
Powder after PMT processing
Sponge Titanium morphology has been directly manipulated in solid-state to achieve powder, size & distribution suitable for Cold spray and powder bed AM processes
Sponge TitaniumBefore PMT
Before PMT
After PMT
EBM AM Arcam
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PMT of Ti takes place in solid-state and in a safe environment
PMT Morphology & PSD Requirements for AM
>250 µm 150 - 250 µm 106 - 150 µm
75 – 106 µm 45 – 75 µm 25 – 45 µm
PMT can be automated to produce a particular morphology & PSD range
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Economics of Low cost AM Powder Feedstock
Ti Sponge~$15/kg
GA TI Powder$>400/kg
CSRO PMT® ~$50/kg
Final Product
>$400/kg
~$65/kg
3D printing 101
LAB22 Powder Bed Additive Manufacturing Systems
Arcam A1 & Q10+
Concept Laser M2 Voxeljet
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LAB22 Blown and Spray Powder Systems
Optomec LENS LaserTech 65 Cold Spray
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Why is 3D printing so exciting?
Design Freedom
Mass customisation
Low lead time
Anyone can be a “maker”
Transport and storage
Breaking of supply chains.
Customised frames: Bastion and Flying Machine
Three Conditions Together Made the Product Marketable Design Change for Every Customer Possible
Off-The-Shelf Tubing
The Novelty
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3D Printing Won’t Keep you Up at Night
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3D Printed Sand Mould (Voxeljet) for CastingAlbins was asked by Thales Bendigo to deliver a prototype steering pump bracket for the Hawkei within one week.
Albins asked the CSIRO if they could make a casting mould within two days.
HawkeiProtected Mobility Vehicle
http://research.csiro.au/metals/add-manufacturing/aus-innovation/voxeljet-sand-3d-printer/case-study-rapid-prototyping-for-the-hawkei-protected-mobility-vehicle/
Delage 1914 Grand Prix Type S
Parts consolidation in combination with topology optimisation
Optimisation Part reduction.
• Nozzle component 20 parts to a single unit
• 900 components to 16, over the complete engine redesign.
An Epiphany Of Disruption: GE Additive Chief Explains How 3D Printing Will Upend ManufacturingNov 13, 2017 GE Reports
Geometry controls performance
Conflux Technologies CSIRO flow works
Cold Spray AM Technology
Blown powder processes: Cold spray
Cold spray Technology
sub
stra
te
P0, r0,T0
Throat, M=1
M>1M<1
np
ng
Solid state deposition – no melting, therefore no solidification defects
No need for vacuum chamber or protective atmosphere
Deposition rates of kilograms per hour (~10 kg/h)
Cold Spray Additive Manufacturing
(*) A. Vargas-Uscategui, P.C. King S. Gulizia. Cold Spray as a Powerful Additive Manufacturing Technology for Metal Powders. (2017) APICAM, Melbourne (Australia).
Titomic
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Thank youCSIRO Manufacturing
Keith M. McLean B.Sc.(Hons); Ph.D.; FBSE; FRACI
+61 (03) 9545 [email protected]
CSIRO MANUFACTURING
