additive manufacturing at ge aviation · 2012-09-28 · • rapid tooling for production and...

imagination at work

Additive Manufacturing at GE Aviation

TRAM 2012 Chicago, Il

2 Global Joining Forum 2012 imagination at work

ADDITIVE MANUFACTURING (AM),

n – process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing and freeform fabrication

*ASTM E2792-009 Standard Terminology for Additive Manufacturing Technologies

LENS Process, Sandia National Labs

Definition:


Benefits of Additive Manufacturing

•Reduced time to market

•Reduced manufacturing leadtimes and costs

•Improved buy:fly

•Enabling design capabilities

•Novel/Hybrid materials

•Weight reduction

•Sustainability

• Separate efforts initially.

• Typical AM applications:

• Plastic and metal models for design

validation.

• Rapid tooling for production and

inspection.

• Rig testing and engine testing.

• Now coordinating amongst the divisions

through our GE Global Research

Center.

• At Aviation:

• Low rate initial production 2015.

Across the corporation… Aviation

Appliances

Healthcare

Energy


Fan

Metal Leading Edge

Blisk

Structures

Compressor case

Combustion case

HPT case

LPT case

Combustion

Liners

Fuel nozzles

HPT/LPT

Blades

Vanes

Shrouds

Installations

VSV bushing

Heat shield

Tubes & brackets

Assemblies

Booster/Compressor

Blades

Vane Segments

Candidate AM Applications for Aviation

imagination at work

Advanced

Technology

Enhanced

Technology

Additive Manufacturing Maturation

Basic

Technology

• Limited Supplier Base

• Internal Standards vs. Industry

Specifications

• Limited Design Methodologies

• Metals

•Productivity Enhancements

•Design Allowables (mechanical

property database)

•Increased Build Volume

•Process Monitoring and Control

•Enabling Design Paradigm

•Topology Optimization

•Complete design freedom

•Polymer Composites

$$ $$$$ $$$$$$

•Autonomous Processes

•Novel Materials

•Adaptive Process Control

•Process Intelligence

•Hybrid Materials

•Rapid Qualification

•Ceramic/Nano Composites

Start

Technolo

gy D

evelo

pm

ent

10 years

10 years 20 years

2013 2015 2005

MRL 6 MRL 0 MRL 9 MRL 3


Additive Manufacturing Methods

By Heat Source

Additive Mfg

Whole Features

Welding

Inertia, Flash,

Stud, other…

Layering Processes

By Methodology

Laser Electron Beam

(EB)

Plasma

Transfer Arc

(PTA)

Gas Tungsten

Arc

(GTA)

Powder

Feed Powder

Bed

Wire

Feed


Direct Metal Additive Processes

Material -Feed Powder-Bed


Material-Feed


20+ years and going strong

•Production for surface

enhancement

•New-make Repair

• MRO

Parts flying today.

Laser and Electron Beam Additive Manufacturing

Powder and Wire Feed Processes

•Feature and whole part

•Simple geometry

•High dep rate


Making the Business Case

• Many structural parts evaluated for AM in terms of cost savings.

• No cost benefit found

• Material savings offset by processing costs and additional post processing steps: Straightening

Heat treat

Inspection

• Potential carbon tax benefit.

Machining Fact:

•Average Buy:Fly = 8:1

•87% of raw material ends up as chips on the floor.


Powder Bed


Direct Metal Laser Melting (DMLM)

Part

Laser Beam

Powder

Leveler

Laser Window

Shield

Gas

Powder

Collector

Powder

bed

Build Platform

DMLM Part


Direct Metal Additive Properties

Better than cast, approaching wrought.

Tensile

Fatigue

Cast

Spec

Min Cast

Wrought

Spec

Min

3 DMLM

1

2 4 5 6

Wrought

Bulk material properties.


Major Gaps and Challenges

•Rapid Qualification

•NDI

•Materials Database

•Specifications

•Supply Chain

•Design Rules

General Process Specific

•Surface Finish

•Process Speed

•Distortion

•Build Volume

•Applicable Materials

•Process Monitoring and Control

DMLM Fact:

• Melt pool is 0.003” wide and traveling at 1 yard/sec

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Poor Surface Finish and Subsurface Porosity Reduce Life…

LCF

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Throughput - Simple Case Study P

art

Num

ber

Type

Layer

Spacin

g

(um

)

Quantity

/Build

Build

Tim

e (

hrs

)

Build

Cost

($/P

art

)

Quantity

/Build

Build

Tim

e (

hrs

)

Part

Build

Tim

e

(hrs

/part

)

Build

Cost

($/P

art

)

First P

art

Cost

($)

100th

Part

Cost

($)

2152M85 Casting 20 1 8.5 1.04 9 36 4.0 0.49 1 0.16

40 1 4.3 0.53 9 18 2.0 0.24

5151T61 Casting 20 1 10 0.52 12 50 4.2 0.22 1 0.07

40 1 5 0.26 12 25 2.1 0.11

ER4024 20 1 20 0.27 9 50 5.6 0.07 1 0.02

40 1 10 0.13 9 25 2.8 0.04

DMLM Single-Part

Build

DMLM Nested Build Conventional

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Higher laser power…

Cost Reduction Through Increased Throughput…

Dual

laser/scanhead.

…higher throughput.

Courtesy SLM-Solutions GmbH

2X improvement

without having to

requalify process or

material.

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Reduced part count.

Reduced number of braze cycles.

Reduced number of welds.

Cost Reduction Through Consolidation

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Distortion -> Stress Management Iterations increase leadtime and cost.

Mitigation strategies add time and cost.

Very repeatable.

Predictable?

Where to next?


Lightweight Structures

Composites

MMC, PMC, CMC

Lattice Structures

• Recent study

indicates that over

90% of energy

footprint of an aero

engine part comes

from use in service.

Topology Optimization

Courtesy Within Technologies Ltd


Status of Additive Mfg GE Aviation

• AM metal components are bill-of-material for advanced engine programs.

• Base of applications is expanding as technology is excepted and exploited by design engineers.

• Major issues remain in terms

of surface finish, dimensional tolerances and throughput (and more).


Near-term Needs

• Proven, robust manufacturing processes (FTY=1)

• Healthy supply chain

• Improved business case

• Mechanical property database for common alloys

• Continued integration between design, equipment and manufacturing

imagination at work

additive manufacturing at ge aviation · 2012-09-28 · • rapid tooling for production and...

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