Additive Manufacturing at EWI
Shawn Kelly, Ph.D. Technology Lead, Additive Manufacturing Director, Additive Manufacturing Consortium [email protected] 614.688.5145
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Advanced Manufacturing Technologies at EWI
Innovate, mature, commercialize Materials Joining and Manufacturing technology for industry
─ Laser processing ─ Nondestructive evaluation ─ Numerical modeling and simulation ─ Plastic and composite fabrication ─ Resistance welding ─ Ultrasonic joining ─ Weldability and mechanical testing;
metallurgical analysis
─ AcousTech™ Machining ─ Additive Manufacturing ─ Advanced arc welding ─ Automation, sensors, controls ─ Brazing and soldering ─ Dissimilar materials joining ─ Friction processing ─ Hot forming
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Buffalo Manufacturing Works Dedicated to making Western New York a nationally-recognized hub of advanced manufacturing innovation
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Buffalo Manufacturing Works Technical Focus Areas
Flexible Manufacturing
Materials & Testing
Machining & Finishing
Additive Manufacturing
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A Holistic View of Additive Manufacturing Process Chain
Final Part
3DP Process
CAD File
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Additive Manufacturing Supply Chain
Final Part Material
Properties
Path Planning
Finishing
Thermal History
Inspection
Qualification & Certification
AM Process Dimensional Control
Heat Treatment
CAD File
Material Process Control
Residual Stress
Process Sensing
Process Selection
Blue boxes are being addressed at EWI presently 7
EWI’s Approach to Additive Manufacturing Technical challenges rooted in EWI’s expertise in
materials joining.
AM/3DP is another tool in the toolbox
AM is more than the ‘printing’ process…many of the conventional manufacturing steps apply.
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EWI is enabling broader adoption of Additive Manufacturing by industry through the development,
demonstration, and innovation of critical technologies along the AM process chain.
Merge EWI Expertise and Capabilities with Client-Driven Needs Expertise
─ Additive Manufacturing ─ Laser Welding ─ Arc Welding ─ Materials Science, Welding
Metallurgy ─ Non Destructive Inspection ─ Machine Controls and Automation ─ Machine Design ─ Design for Additive Manufacturing ─ Modeling
Capabilities ─ L-PBF – EOS M280 ─ EB-PBF – Arcam A2X ─ EWI Design and Built
─ L-PBF – Sensor Test Bed ─ Arc-Directed Energy Deposition ─ Laser Directed Energy Deposition
─ X-Ray CT ─ Powder Characterization ─ Powder Production
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In Process Quality Control
Post Process Inspection
Materials and Process
Development
Support Design Allowable Database
Generation
Advancements for
Manufacturing Machines
Design for Additive /
Technology Application
EWI AM Focus Areas
AM Activities in Columbus and Buffalo Columbus • Materials: Metals • Processes: L-PBF, Arc-DED, Laser-
DED • Equipment: EOS M280, L-PBF Sensor
Test Bed, L-DED and Arc-DED Robotic Workcell
Buffalo Manufacturing Works • Materials: Ceramics, Polymers • Processes: EB-PBF, Material Extrusion,
Vat Photopolymerization, Large DED, Hybrid, Binder Jetting
• Equipment: X-Ray Computed Tomography, Powder Production, Powder Characterization.
Joint Site Activities • Process Development • Heat Treatment and Mechanical Performance • In Process Inspection • Post Process Inspection • Process/Equipment Improvements • Design for AM • Operate the Additive Manufacturing Consortium
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Additive Manufacturing Technology Pillars
PBF • Laser • Electron Beam
DED • Arc • Laser
Metals
Ceramics/Polymers In Process Sensing Post Process Inspection
Design for Additive / Tech. Application
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EWI Capabilities – Powder Bed Fusion
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Laser PBF EOS M280
Electron Beam PBF Arcam A2X
400W Laser 200°C Heater upgrade
EWI Capabilities – Large Scale AM
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3x3
Arc Deposition of Ti-6Al-4V Ultrasonic Additive Manufacturing
Understand process physics.
Large robotic/CNC capability.
Proven machine integration capability.
Laser Power to 20kW
> 1m x 1m x 1m work envelope 2m x 2m x 1m work envelope
> 1m x 1m x 1m work envelope
Additive Manufacturing Equipment in Buffalo
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Planned AM Investments in Buffalo
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Ceramics Hybrid
X-Ray CT Powder Spheroidization
Large DED
The Additive Manufacturing Consortium
Mission: Accelerate and advance the manufacturing readiness of Metal AM technologies
Participation from Academia, Government,
and Industry Present timely case studies/research Execute group sponsored projects Collaborate on Government funding
opportunities Forum for discussion/shaping roadmaps
Goals:
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Current Members Full Members Aerospace – Engine (5) Aerospace – Airframe (2) Aerospace – Systems (1) Heavy Industry (1) Non-Profit R&D (2) Suppliers Powder (3) AM Equipment (1) AM Ancillary Equipment
(1) AM Technical Service
Providers (2) Research Partners Government (3) University (4)
Nickel Alloy 625 Project Objective: Develop manufacturing process
controls Understand process variables as
a foundation for database development.
Funding to Date: 273K AMC / 160K Gov’t
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AMC Data
Current Task: Refine heat treatment to
minimize anisotropy Develop high temperature
mechanical property data.
Deliverables to Date: Manufacturing Plan Room and Elevated Temperature
Property Study across multiple L-PBF machines
Heat treatment development
Nickel Alloy 718 Project Objective: Identify proper heat treatment
for L-PBF 718. Room and elevated tensile and
creep data.
Funding to Date: 212K
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Current Task: Refine Heat treatment Generate additional high
temperature creep/fatigue data Investigate alloy modifications
Deliverables to Date: Heat treatment evaluation Room and elevated temperature
tensile data Creep data
As-built
SR+ST+Age
625/718 Database Roadmap
•Generate data on •powder recycling impact and best practice •chemistry heat to heat variation
Material Issues
•CY17, generate data on •Wall thickness •Surface finish/orientation
Design Issues
•CY16, Generate data on: •LPBF (EOS, Concept, 3DS, Renishaw) •EB-BPF (Arcam)
Phase 2.2: Machine Issues
•CY14-15, Generate data for • Improve HT schemes •Understand impact of HT
Phase 2.1: Heat Treatment Optimization
•CY12-13 •Demonstrate plan •Establish SOA perf. data
Phase 1: Manufacturing Plan, Foundational Data
Design Allowable Database Generation
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Monel 400 Project Objective: Develop process parameters for
L-PBF Monel 400 Evaluate mechanical and
corrosion properties
Funding to Date: 63K AMC
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Current Task: Develop process parameters for
L-PBF Monel 400 Evaluate mechanical and
corrosion properties
Deliverables to Date: Identified process parameters
leading to >99.98% density Produced coupons for heat
treatment and mechanical testing, and weldability
Aluminum Alloy Development Project
Objective: Identify process/alloy changes
to achieve 6xxx/7xxx aluminum alloy properties
Funding to Date: 75K AMC
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Current Task: Review AM, welding, casting, PM
literature to identify potential process and alloy modifications
Develop test plan Feasibility study
Deliverables to Date: Project starting July 2015
CY16 AMC Project Themes
Continue to build upon current body of work in 625 and 718
Incorporate NDI into project execution
Cross-platform validation of PBF machines and powder suppliers
Investigate needs for larger/productive/manufacturing robust machines.
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EWI In Process Sensing Activities
In Process Sensing for L-PBF ─ Developed and built a sensor test bed ─ Developing in process monitoring baselines for LPF ─ Investigate integration issues on EOS M280
In Process Sensing for L-DED’ ─ Leading in process sensing task for L-DED repair applications ─ Developing methods to quantify powder flow rate in process.
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EWI In Process Sensing Roadmap
Near 0-2 years
• Machine producer integration • Supplier integration • Existing sensor development • Informing production
Mid 3-5 years
• Certifying production • New sensor techniques • Robust algorithm development • Standards
Far 5+
• Closed Loop control implemented
• Corrective actions taken
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EWI Post Process Inspection Activities Refining Microstructure of AM Materials to Improve
Nondestructive Inspection(NDI) ─ Identified EB-DED Ti-6Al-4V Process Changes leading to a UT-
Inspectable microstructure; and Identified UT inspection equipment changes to improve inspection.
NDI for complex PBF components ─ Identify applicable techniques ─ Determining current capabilities of X-Ray CT of complex PBF components
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Geometry/Complexity Impact
EWI Post Process Inspection Roadmap
Near 0-2 years
• Evaluate Current Capability • Modify AM process, Inspection
Process, Geometry
Mid 3-5 years
• Integration of in process and post process inspection
• Improvement of inspection processes
Far 5+
• Develop new inspection techniques
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Material and Process Development Activities EWI is an EOS Material
Development Partner Develop core process
conditions. Evaluate performance,
heat treatment, etc. Develop surface finish
conditions. Transition to client
machine or service provider.
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Alloys Developed at EWI Ferrous Alloys
4140 SS: 316L, 420, 2205
Ni-base alloys Inconel 625 (transfer to sensor test bed) Monel 400, K-500, C-276
Zircaloy-4 Tungsten Stellite-6
EWI Material Development Roadmap
Near 0-2 years
• Development of conventional alloys,
• Heat treatments, recycling issues, etc on current machines
Mid 3-5 years
• Continued development on current machines.
• Controlled microstructures • Process specific alloys
Far 5+
• Designed microstructures
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Machine Development Activities
Development of Arc DED Processes
Development of Laser DED process
Workcell development and identify CAD to part.
Part specific AM systems for high volume.
Innovation for productivity improvements for high volume AM.
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3x3
Arc Deposition of Ti-6Al-4V
> 1m x 1m x 1m work envelope
EWI AM Machine Development Roadmap
Near 0-2 years
• Process modifications (powder, speeds, powers, scan strategies, etc) achievable with current machine technology to achieve XXx increase in speed
• Establish Arc and Laser DED Workcell
Mid 3-5 years
• Development of new application specific machines…XXXx increase
Far 5+
• High volume production machines
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EWI’s Role Holistic view
─ More than the 3D Printing Process ─ Requires Manufacturing support to be true additive manufacturing
Evangelists (Education) ─ Another tool in the tool box ─ Understand application of conventional manufacturing.
Trusted Agent
Innovation
Industry support ─ EWI supports clients in AM just as we support clients in materials joining ─ Operate the AMC
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Questions Shawn Kelly, Ph.D. Technology Lead, Additive Manufacturing Director, Additive Manufacturing Consortium [email protected] 614.688.5145
http://ewi.org/technologies/additive-manufacturing/
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