additive manufacturing applications in aerospace
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Additive Manufacturing applications in
Aerospace, Automotive, Robotics and beyond
JGIF 2015
Tokio, 9th of November 2015
Joachim Zettler – Airbus Apworks GmbH
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Airbus APWorks
Who we are:
Founded in 2013 as a 100% subsidiary of Airbus Group, APWorks is familiar with modern manufacturing
processes, including proven concepts and lightweight design from the aerospace technology. With a high focus
on design, materials and serial production, APWorks optimizes parts for weight, structure, cooling and RF
efficiency. Working in close cooperation with Airbus, we develop high quality materials, and advanced
qualification processes for serial production.
Our aim:
Making innovative and high quality aerospace concepts accessible for customers across all industries.
Additive Manufacturing in der Luft- und Raumfahrt
Founded in 2013
100% subsidiary of Airbus Group
A perfectly harmonized triad for 3D printing
Design Materials Serial production
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Quality Assurance
Additive Manufacturing
Additive Manufacturing in der Luft- und Raumfahrt
APWORKS OFFER
Process & Post Process
AM
Value Chain
End of Part‘s Life
AM Design
AM VALUE CHAIN
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Destructive testing
NDT (non-destructive testing)
Metrology
Validation on testing
Quality Assurance
Additive Manufacturing
Additive Manufacturing in der Luft- und Raumfahrt
APWORKS OFFER
Process & Post Process
AM
Value Chain
End of Part‘s Life
AM Design
AM VALUE CHAIN
Build design & preparation
Detailed design, optimization
Process selection
Part concept
Repair
Material prodcuction & qualification
ALM process
Heat & pressure treatment
Machining of interfaces
Surface treatment
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Quality Assurance
Additive Manufacturing
Additive Manufacturing in der Luft- und Raumfahrt
APWORKS OFFER
Process & Post Process
End of Part‘s Life
AM Design
APWorks controls each phase of the AM value chain with customized services generating superior results:
• Concept Development & Consulting
• From prototyping to large scale part production
• Powder Sales of high quality Aluminum powder
• System integrator
AM VALUE CHAIN
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Re-cap: ALM Deposition Process Types
Additive Manufacturing in der Luft- und Raumfahrt
Additive Manufacturing Processes
Directed DepositionPowder Bed
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Forging / Investment Casting
Data
Release
Up to 95 wks for large/complex parts
DFM
complete
Dies / Pattern
complete
First
Production
article
AMOpportunity for design changes or risk mitigation~12 wks
Programme Risk Mitigation
Titanium Price
Motivation for Technology Adoption
Additive Manufacturing in der Luft- und Raumfahrt
QUALITYCOST
TIME
• New Material
Compositions
• Weight Savings by
Topology Optimisation
• Unique Geometric
Capability for
functional applications
• Material Price Volatility
• Material Waste in Manufacturing
Titanium Plate 90% Waste
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ALM value chain in more detail
Design optimization
Additive Manufacturing in der Luft- und Raumfahrt
Existing design
Design interpretation
modelled as solid
Further FE
analysis
Further loop
of Topology
optimization if required
AM VALUE CHAIN
Data used to create optimized
design interpretation
21
34
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Structure
simulation
ALM value chain in more detail
Detailed design, optimization, design for manufacture (DFM)
Additive Manufacturing in der Luft- und Raumfahrt
antenna pattern
distortion Cooling efficiency
Aerodynamic
efficiencyStructure efficiency
Although not yet
applied to ALM
applications; AGI
has capability for
RF simulation
Design for
manufacture
Design rules to applied on their own or in conjunction with optimisation
AM VALUE CHAIN
DETAILED DESIGN, OPTIMISATION, DFM
RF
simulation
Thermal
simulation
Flow
simulation
Application of design rules (design for
manufacture)
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Scalmalloy® ALM parts have properties in the range of high strength 5XX Al-Alloys
ALM value chain in more detail
Scalmalloy®
Additive Manufacturing in der Luft- und Raumfahrt
Typical Values Scalmalloy® AlSi10Mg TiAl6V4
0.2% Offset Strength (MPa) 450 210 860
Tensile Strength (Mpa) 490 350 910
Specific Strength 184 129 205
Elongation (%) 8 3 10
Vickers Hardness HV0,3 177 119 320
Fatigue Limit 3E7 cycles (MPa) 300 97 600
Density (g/cm3) 2.67 2.70 4.43
AM VALUE CHAIN
MATERIAL
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ALM value chain in more detail
Process & Postprocess
Additive Manufacturing in der Luft- und Raumfahrt
EOS M270
EOS M280 SLM 125 HL ARCAM A2 EBM
Available Metallic Materials:
• Titanium (TI6AI4V)
• Stainless Steel (316, 17-4, 15-5)
• Aluminum (AISi10Mg, Scalmalloy, Silmagal)
• Cobalt Chrome
• Inconel
EOS M290
EOS M400 (08/15)
MATERIALS & MACHINES
AM VALUE CHAIN
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ALM value chain in more detail
Influence of surface roughness on fatigue data (Ti6Al4V, schematic)
Additive Manufacturing in der Luft- und Raumfahrt
• Surface roughness
strongly influences
fatigue life
• Fatigue of specimens
with as built surface
not improved by HIP1,E+081,E+04 1,E+05 1,E+06 1,E+07
Cycles to failure [ 1 ]
400
600
800
1000
200
0
Ma
xim
um
str
es
s [
MP
a]
Wrought
Cast
Powder bed
+ HIP + milled
Powder bed
+ milled
Powder bed + with
and without HIP +
as built surface
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• Static/dynamic tensile
• Fatigue crack propagation
• Fracture toughness, JIC, etc.
• Corrosion(salt spray, SCC etc.)
• Fracture analysis(SEM, XPS, XRD etc.)
• AFGROW, DoE, ANOVA etc
ALM value chain in more detail
Destructive testing
Additive Manufacturing in der Luft- und Raumfahrt
Analysis of traveler
samples
AM VALUE CHAIN
DESTRUCTIVE TESTING OF TRAVELER
Testing of inbuild
traveler samplesCross reference against extensive APWorks
database
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µCT testing of a cube:
Detection & characterization of
voids (Voxel size: 46 µm)
Detection & characterization of flaws Analysis in reference to effects of
defects catalogue
Residual Stress Measurements
• X-ray diffraction (XRD)
with portable system
• Destructive hole drilling
method
ALM value chain in more detail
Non-Destructive Testing
Additive Manufacturing in der Luft- und Raumfahrt
AM VALUE CHAIN
NDT
Defect characterization: (µ-) Computed Tomography
Defects: Ultrasonic
Defects: X-Ray
Residual stress
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Application Selection Strategy
Additive Manufacturing in der Luft- und Raumfahrt
STRUCTURE DESIGN CHANGE
Derivative
STRUCTURE
CATEGORY
NewSimilar
Principal
Significant
Secondary
Powder Bed Tooling
Wire Feed
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Weight Saving through Design Freedom: ‘Bionic’ Brackets
Additive Manufacturing in der Luft- und Raumfahrt
836
MPa
429
MPa
0.89
KG
0.35
KG
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Weight Saving through Design Freedom
Additive Manufacturing in der Luft- und Raumfahrt
Homogenized stress distribution
Increased stiffness
44% Weight saving
Material: Al2024 Material: AlMgSc
255
G
142
G
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Weight Saving through functional integration
Additive Manufacturing in der Luft- und Raumfahrt
30% decrease in time to market
More efficient pipe routing
45% Weight saving
Material: SS Material: Ti64
820
G
451
G
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ALM vision
Thank you for your attention
Additive Manufacturing in der Luft- und Raumfahrt