Laser Additive Manufacture Research in Aerospace in Australia
M. BrandtAdvanced Manufacturing Precinct, RMIT University
• Motivation • Research capability• Examples of additive manufacture research • Summary
AKL 14May 7-9, 2014 – Aachen, Germany
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Motivation
Australian aerospace industry comprises of
• Civilian – overseas companies with established local manufacturing presence such as Boeing
• Defence – Airforce one of the three pillars and plays a major role in our defence strategy. Just recently Australian government has signed a 12 billion dollar deal to purchase some 80 F35s from Lockheed Martin.
Motivation: repair and restore legacy and new components
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• Legacy systems: Metallic aircraft components and structures experience damage, wear and corrosion damage in service due to operating environment. This results in the need to replace them which impacts the cost of ownership.
• Potential cost saver in sustainment costs(US DOD 2009 Report on the Annual Cost of Corrosionestimate for Air Force to be 31% of maintenance cost) + wear + impact damage)
• New systems: Components designed to tight specifications so need to develop repair technology to keep them in service.
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Why laser additive manufacture components
Subtractive manufacturing process -Ti
Additive manufacturing process- Ti
• Short lead time• Less material waste• Complex geometry• Light weighting • Manipulation of
structure – manufacture fordesign
• Cost• worn/damaged and corroded
profiles can be restoredto their original shapeand performance integrity
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Laser based additive technology in Australia
• Laser cladding established commercially since 2000• Powder bed more recent around 2006 but only one operator• Research capacity increased significantly since 2011
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Institution - Research Systems and lasers QuantityMonash University, Melbourne, Victoria Trumpf system 1
Concept Laser X line 1000R 1EOS (280) 1
RMIT University, Melbourne, Victoria SLM 250HL 1Trumpf system 1
Deakin, Geelong, Victoria SLM 125 1
Swinburne University, Melbourne, Victoria Trumpf POM DMD, 1University of Western Australia (UWA), Perth, Western Australia ReaLizer 100 1University of Wollongong, Wollongong, New South Wales ReaLizer 50 1CSIRO, Melbourne, Victoria Laserline 1
10Institution - GovernmentDepartment of Defence, Canberra, Australian Capital Teritory SLM 250 1
1Institution - CommercialRace Dental, Sydney, New South Wales EOS 250 1Breasight, Sydney, New South Wales EOS 250 2Amaero, Melbourne, Victoria, EOS 280 (On order) 1
Hardchrome Engineering, Melbourne , Victoria IPG and Laserline 2Brenco, Melbourne, Victoria Laserline 1Jarvie, Newcastle, New South Wales Rofin and Laserline 2Laser Bond, Sydney, New South Wales Laserline, Rofin 2
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Lasers and systems for AM - 2014
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Monash Centre for Additive Manufacturing (MCAM) Houses some of the worlds most advanced Additive
Manufacturing equipment.
Working with Microturbo (Safrongroup) manufacture small engine components – well advanced
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Amaero – company spun-off by Monash AM CentreComponents supplied to Microturbo
Casing with internal diffuser
An engine component
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RMIT Advanced Manufacturing Precinct – opened in 2011
• World class $25m research and teaching facility with focus on additive manufacturing to assist local companies transition to new manufacturing
• Complements other advanced materials and manufacturing facilities at RMIT
• Unique in Australia – covers both metal and polymer based technologies together with high-end CNC machines (One stop shop for Industry)
Our Capability:Additive manufacturing technologies at AMP
Metal systems:• Selective Laser Melting machine - 250HL • Laser: 400 W Fibre laser• Preheat: 200 deg C• Volume: 250 x 250 x 350 mm
–(100 x 100 x 100 and 50 x 50 x 100)
• Layer thickness: up to 100 microns
• In the process of purchasing a second system
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Metal System:• TRUMPF 3 in 1 laser system• Laser source: Disk laser • Beam delivery : Fibre• System: 5 axis plus rotary• Working volume: 1500 mm x 1800mm x 750 mm • Capability: cutting, welding, additive with powder and wire
Our Capability:Additive manufacturing technologies at AMP
Substrate
Clad layer
HAZ
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• Materials and manufacturing optimisation• Powder alloys and properties• Porosity, lack of fusion, roughness• Structure/ property optimisation• Tolerances• Repeatability• Maturity level – certification• Design
Opportunities: major scientific challenges with laser AM technology
Lack of fusion
On the platform Off the platform
Our Research Focus:
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Aerospace, Automotive, Bioengineering, Defence and Sports
Design
• Topology optimisation algorithms
• Self supporting structures algorithms
AM Systems
• New additive system •Modification/improvement of existing systems
Materials and manufacture
• Process optimisation• Structure optimisation• Process control• Alloy development• Modelling
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Examples of current additive aerospace research activities at RMIT
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Project: Repair technologies for current and nextgeneration defence aircraft platforms
Aging Aircraft
FatigueCorrosion
WearFretting
To develop and certify repair technologies for current and next generation aircraft and in particular direct metal deposition technologies so that these components can be returned to service in a safe, timely and cost effective manner.
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Strategy
SPD – Supersonic Particle Deposition, HVOF – High Velocity Oxygen Fuel LC – Laser cladding
Application
Material
Corrosion Protection
Wear Resistant Substrate Geometry restoration
Structural Restoration
Structural Enhancement
Magnesium Alloy SPD, HVOF SPD, HVOF, SPD, HVOF, SPD, HVOF, SPD, HVOF,
2024 Al Alloy SPD, HVOF SPD, HVOF, SPD, HVOF, (LC) SPD, HVOF, (LC) SPD, HVOF, (LC)
7075 Al Alloy SPD, HVOF, (LC) SPD, HVOF, (LC) SPD, HVOF, (LC) SPD, HVOF, (LC) SPD, HVOF, (LC)
High Strength steels (low Carbon>260ksi
SPD, HVOF, (LC) HVOF, LC LC, (HVOF) LC, (HVOF) LC, (HVOF)
Stainless Steels SPD, HVOF, LC LC, HVOF LC (SPD,HVOF) LC (SPD,HVOF) LC (SPD,HVOF)
Titanium Alloys SPD, HVOF, LC SPD, HVOF, LC LC, (SPD, HVOF) LC (SPD,HVOF) LC (SPD,HVOF)
Inconel Alloys N/R SPD, HVOF, LC LC, (HVOF) LC (SPD,HVOF) LC (SPD,HVOF)
Defence Materials
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DMTC Project 4.1 Repair technologies for current and next generation aircraft systems
1. FA 18 landing wheels –Al 2xxx and Al 7xxx series (research phase – issues with fatigue)
2. High strength steels – 4340 and Aermet(research phase – issues with fatigue)
3. Engine mount - Ti-6Al-4V alloy(certification started - issues with fatigue)
4. FA 18 Rudder Anti-rotation bracket – 17 – 4 PH(application certified)
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The repair of ultra high strength steels
AISI4340 and Aermet (>1900MPa)
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Static Strengths (Al)
0
100
200
300
400
500
600
700
800
Sta
tic S
tren
gths
, MP
a
Substrate(AA7075)
Treated LC(Al-Si powder)
Treated LC(Mixed powder)
σUTS (min)∗
σ0.2 (min)∗
* MMPDS-4 (MIL-MDBK-5J)
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Fatigue Properties (Al)
0
2
4
6
8
10
12
14
16
18
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Fat
igue
Life
, Blo
cks
Slot cross-section
Note: * number of blocks under a spectrum loading
Substrate (grind-out)
Al-12%Si (T6)
5.18*4.35* 3.85*
Mixed powders (Not heat treated)
14.10*
Mixed powders (Heat treated T6)
~10%
> 15*
Substrate (No grind-out)
• Laser cladding repair of critical components satisfactory for sliding wear
• When used for repair of components experiencing fatigue more work needs to be done to understand the effect of interface between the clad layer and parent metal.
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Cladding repair findings
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Project: Laser Direct Manufacture of Small Scale High Value JSF Type Components
To investigate, the manufacture of small scale high value JSF components using SLM technology.
Focus on Titanium parts– Machining of Titanium can
represent 40 to 50% of the cost of a titanium part for an air vehicle
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• Built samples for metallurgical, tensile and fatigue tests• Examined porosity using CT scanner
Sample properties
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Pore due to
entrapped gas
Pore due to lack
of fusion
Front/side view
Front/side view
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Effect of SLM processing on porosity – Ti64
• Distribution– Primarily along the planer
inter-layer boundaries– Stand-alone pore or inter-
connected pores
• Affected by – Layer thickness– Laser scan speed– Hatch spacing– Laser power
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Mechanical Properties (as manufactured): Higher Strength and lower elongation
Spec Cond. Yield Stress, σ0.2
(MPa)
Ultimate Stress, σUTS
(MPa)
Young’s Modulus, E
(GPa)
Elongation (%)
Baseline 1039 1098 109 21.4
SLM; Horizontal 1029 1197 116 8.3
SLM: Vertical 958 1122 111 8.1
AMS4928R[1] 862 931 - 10
AMS4999[2] 800 896 - 4
[1] AMS 4928R – Titanium Alloy Bars, Wire, Forgings, Rings, and Drawn Shapes 6Al-4V Annealed, Jan 2007.[2] AMS 4999 – Titanium Alloy Laser Deposition Products 6Al-4V Annealed, Feb 2002.
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Comparison of Fatigue Properties – as manufactured and machined
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Topology Optimisation
• Evolutionary algorithm
• Begins with Full Mesh
• Removes material according to stress and deflection constraints
• Provides insight into topographically optimal geometries
Software: Optistruct, Abaqus ATOM, Topostruct
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Optimisation
Topographically optimal
CAD Equivalent
•Internal gussets usedto allow manufacture ofoverhang features.•Truss-like morphologywith hollow elements.•Bulkhead features toprovide compressivestrength.•Annular reinforcementto resist local buckling.
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Large scale reinforcement
required at annular feature
Minor reinforcement
required to assist
manufacture
Inclination angle modified to allow
support-free manufacture
Staircase effects
SLM Manufacture
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Manufactured part – door bracket
40-60% Mass
reduction (depending on loading)
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Current work on lattice structures -Internal Structure Design and Optimisation
• Lattice type internal structure is automatically generated conformal to the volume obtained from 3D comparison
• Loads applied are simulated and are applied to the lattice along with boundary conditions
• The structure is then optimised to meet allowable stress and buckling criterion
• Provisional patent lodged
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Message
• Laser additive manufacture growing globally and in Australia and will be playing a key role in the aerospace industry in the future due to its versatility and its specific process advantages.
• LMD established for repair and restoration of components and structures depending on use. More research needs to be done on the effect of fatigue.
• SLM being explored for a range of components.
•The R&D base in the area has also expanded and the establishment of a national centre in 2014 with focus on additive manufacture will further accelerate this growth
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RMIT AM group – colleagues and PhD students
Prof. M. BrandtProf. Ma QianProf. Mark EastonDr. Ming YanDr. Shoujin SunDr. Martin LearyDr. Stefanie FeihDr. Joe ElambasserilDr.Wei XuDr. Maciej MazurMr. Martin VcelkaDarpan Shidid – PhD studentStephen Sun – PhD studentInam Inam – PhD studentNicholas Orchowski – PhD student
