160615 metal am for aerospace and high-end applications (marc de smit)
TRANSCRIPT
Metal-AM for Aerospace and high-end applications
R&D for future certification excellence
NLR MAMTeC , 2016 Marc de Smit
NLR, MAMTeC 2016
Content
• Short introduction NLR & MAMTeC
• Application metal AM in Aerospace
• Challenge of metal AM certification
• NLR Certification activities
• Next steps
>95
639 employees
Innovative, engaged and practical
One-stop-shop
€ 73 M revenue
Global player with Dutch roots
For industry and government
Extremely high client satisfaction
Amsterdam, Marknesse, Schiphol 95 years young
Active in 33 countries 74% Dutch, 23% EU
and 3% international
For civil and defence
NLR in brief
NLR, MAMTeC 2016
NLR, MAMTeC 2016
Manufacturing Technology Centre (MAMTeC)
• Thé Metal AM Technology Centre in NL
– Unique combination of knowledge, experience and facilities
– Independent
– Non profit
– Qualification/Certification track record
NLR, MAMTeC 2016
What we deliver
• One-off products, prototypes or small series
• Metal-AM Development & optimisation
• Mechanical testing
• Support in making Metal-AM business case
• Compare Metal-AM with conventional
• Support with certification of Metal-AM products
• Support with implementation of Metal AM technology
NLR, MAMTeC 2016
Examples of MAMTeC projects
• Research for Dutch Defence
• Parts for wind tunnel models
• Space applications
• Prototyping for various applications
• Process development new materials
• Process development Multimaterial AM
Application metal AM in Aerospace is growing
• Aerospace OEM’s increasingly use AM for functional aircraft components
• FAA cleared first 3D printed part to fly in a commercial jet engine
NLR, MAMTeC 2016
Challenge of metal AM certification
NLR, MAMTeC 2016
• Fatigue is the predominant failure mode
• Good understanding is essential for production of structural parts
Failure Mechanism % Failures
(Aircraft components)
Fatigue 55%
Corrosion 16%
Overoad 14%
Stress Corrosion Cracking 7%
Wear/Abrasion/Erosion 6%
High temperature corrosion 2% Source: Finflay S.J., Harrison N.D., Why aircraft fail, Materials Today, p. 18-25 Nov 2002
Challenge of metal AM certification
NLR, MAMTeC 2016
• Fatigue is the predominant failure mode
• Good understanding is essential for production of structural parts
NLR, MAMTeC 2016
Challenge of metal AM certification
• Multidisciplinary
– Laser processing
– Powder metallurgy
– Materials science
– Post processing
– Testing
– Modelling
– ...
NLR, MAMTeC 2016
Challenge of metal AM certification
• Approval for aerospace is based on assessment of risks
– Non critical components
– Sub-critical components
– Critical components
– System level risk assessment
Source: Gorelik M., AM in context of Structural integrity, ASIP 2015 Conference
Challenge of metal AM certification
• Effect of variations in material and AM-process parameters on design values
• A lot of variations are possible
NLR, MAMTeC 2016
Challenge of metal AM certification
Examples of risk factors in AM
• Powder Control
• Variation in microstructure
• Surface quality
• Internal defects
NLR, MAMTeC 2016
Effect of variations
Granulomorphometry
– Particle size distribution
– Particle Shape
Composition
– Chemical composition
– Moisture content
– Oxygen & Nitrogen pick-up
– Pollution
NLR, MAMTeC 2016
NLR, MAMTeC 2016
Challenge of metal AM certification
Examples of MAMTeC activities
• Track record in Cert & Qual of composites in Aerospace
• Evaluation & Validation of process monitoring systems
• Development of AM bracket for NH90
• Development of Qualification and process certification methodologies for AM in PPS programme
Melt pool monitoring
• Melt Pool Control module is installed in Q4 2015
– Fast single-point IR emission measurements at two wavelengths
– Data presented as 2D maps of thermal energy.
– Sampling rate of ~ 14kHz.
– Challenge= find relation between system output and defects
– Future= Dynamic adjustment of laser output power to achieve closed-loop power control
NLR, MAMTeC 2016
NLR, MAMTeC 2016
Ladder mount brackets for NH90 on tail section
• Defence Technology Project
• Design optimisation
• Certification & qualification
• Supply chain & Logistics
NLR, MAMTeC 2016
Ladder mount re-design Ti6Al4V alloy - weight reduction 42 %
12.8 cm³ 7.4 cm³ (wt. red. 42%)
NLR, MAMTeC 2016
Metals for Additive Manufacturing Programme
• Four years programme on Metal-AM for high tech applications
• NLR & TNO Initiative
• Public-Private Partnership with international participants
Technical objectives
• Efficient AM processing parameter optimisation
• Database with design values
• Post-processing ; Powder removal, heat treatments, surface finishing
• Metal-AM Design guide lines, methods and tools, for AM manufacturing
• Material qualification and process certification methodologies for AM
• Technology demonstrators
NLR, MAMTeC 2016
NLR, MAMTeC 2016
Efficient AM processing parameter optimisation • Automatic generation of sample matrices
• Variation of Laser power, scan speed, Hatch distance, layer thickness
• Automated analysis & evaluation based on porosity & roughness
NLR, MAMTeC 2016
Static, creep & dynamic testing
• Impact of variables Inc718 are investigated
– Particle size distribution
– Variations in Mn & Si content
– Variation in Nb, gamma prime & precipitate former
– Atomising gas environment (O & N)
– 4 Different heat treatments
NLR, MAMTeC 2016
Metal-AM Design guide lines, methods & tools
NLR, MAMTeC 2016
Next steps @ MAMTeC
• Expanding AM capabilities to new technologies and new materials
• Examples:
– Multimaterial Additive Manufacturing
– Additive manufacturing of large structures
– AM-Repair concepts
NLR, MAMTeC 2016
Multi-material additive manufacturing
Graded Sharp MMC
NLR, MAMTeC 2016
Multi-material additive manufacturing
• Sharp transition
• Build with metal A on substrate metal B
NLR, MAMTeC 2016
Multi-material additive manufacturing
Graded materials
• Single line scanning
• Analysis of cross-sections
• Elemental maps with EDX to investigate mixing of elements
Fe
NLR, MAMTeC 2016
Multi-material additive manufacturing
Graded materials
• Full material samples with graded transition
• Homogenization heat treatment
• Cracks are present in region above transition in SS316
Fe
NLR, MAMTeC 2016
Multi-material additive manufacturing
Graded materials
• Graded transition can be made
• Optimisation required
• A lot of mixed powder waste
• Cert. & Qual.?
• Combination with deposition
NLR, MAMTeC 2016
Metal Matrix Composites AM
• High material performance in extreme environments
• Complex parts with high hardness and wear resistance
• Minimum finishing of difficult to machine materials
• High specific strength and specific stiffness
• Low coefficients of friction and thermal expansion
NLR, MAMTeC 2016
Metal Matrix Composites AM
• SiC, TiC, Al2O3, Y2O3
• Challenges:
– Powder flow behaviour
– Cracking
– Solution/reaction
• Set up PPS for continuation of development
NLR Marknesse
Voorsterweg 31, 8316 PR Marknesse, Netherlands
Fully engaged Netherlands Aerospace Centre
p ) +31 88 511 4234 e ) [email protected] i ) www.nlr.nl
Questions?