Additive Manufacturing at EWI

Shawn Kelly, Ph.D. Technology Lead, Additive Manufacturing Director, Additive Manufacturing Consortium skelly@ewi.org 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 skelly@ewi.org 614.688.5145

http://ewi.org/technologies/additive-manufacturing/

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