Additive Manufacturing of Titanium Alloys at Honeywell Aerospace

Daira Legzdina / Rob Adams / Donald Godfrey

ITA Conference Atlanta October 10, 2012

BP12-228-0 HONEYWELL PROPRIETARY: This copyrighted work and all information are the property of Honeywell International Inc., contain trade secrets and may not, in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All Rights Reserved.

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Page 1

Outline • What is Additive Manufacturing (AM)

– Pros and Cons

• Honeywell AM processes for titanium alloys

– Direct Laser Metal Sintering (DMLS) – Electro Beam Melting (EBM) – Ion Fusion Formation (IFF)

• AM challenges and

opportunities for Aerospace

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Additive Manufacturing (AM) – What Is It? • ASTM definition: Additive Manufacturing AM:

– “Process of joining [melted] materials to make objects from 3D model data, usually layer by layer, as opposed to subtractive manufacturing methods...”

• Many process variations with advantages and disadvantages – SLS, DMLS, EBM, laser consolidation, LAM, POM

• AM is affecting manufacturing market at an

accelerating rate – AM global market 2011 estimated $2.5B – 8,000 AM systems forecast 2011 sales – $400K to >$1M price range for metal

AM systems – “Personal” AM systems (e.g., 3D

thermoplastic printers) start at ∼ $1K

Powder

Sintering

Part

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Additive Manufacturing – Pros and Cons • AM is a game changing technology for:

– Difficult to manufacture components • Internal passages • ‘un-machinable’ shapes • Difficult to manufacture materials (e.g. TiAl)

– High value added and long lead time items – Legacy items – Prototype parts where design has not been finalized – Functionally graded materials – Hybrid fabrication-cast or wrought base with AM

added features – Repair of high cost components – High buy-to-fly ratio

• Conventional: 15 – 20 to 1 • AM: 2 to 1

• Challenge areas for aerospace: – Cost for materials property data bases – Qualification and certification costs

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Page 4

Direct Metal Laser Sintering Process (DMLS) • Energy source:

– Laser 200 – 400 watts

• Atmosphere: – Shield Environment

• No Built-in powder preheat

• Build speed:

– Slower than Electron Beam Melting but has better surface finish

• Typical dimensional accuracy for Ti-64 +/- 0.005

Powder Part

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Page 5

Electron Beam Melting (EBM) • Energy Source: Electron beam • Atmosphere: Vacuum • Pre-heating is available • Build Speed:

– Faster than DMLS – Surface finish not

as good

Photos Courtesy of Arcam Corporation

Filament

Anod

Focus Coil Deflection Coil

Electron Beam Powder Container

Vacuum Chamber

Building Table

Grid Cup

EBM Process Build Chamber

Heat Shield

Powder Distributor

Build Table

Powder Container

Electron Beam Gun

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Page 6

AM and Titanium Gain Foothold in Medical Industry Hip Joint Knee Joint Acetubular Cups

Photos Courtesy of Morris Technologies Inc.

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Page 7

DMLS & Ti-64 Moving into Aerospace

• Possible parts – Actuators – Valve Bodies – Heat Exchangers – Compressor Blades – Compressor Vanes – Shrouds

Photos Courtesy of Morris Technologies Inc.

Ti-64 Swirlers

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Page 8

DMLS – Ti-64 • Static properties equal or better than Ti-64

wrought material • LCF life is DMLS Ti64 is equal to Ti-64 MA

– Better than Ti-64 cast

Cycles to Failure St

ress

LCF Wrought Ti-64 MA Cast Ti-64 MA DMLS Ti-64 Annealed

DMLS Ti-64 Actuator

Tensile

Temperature, °F

Stre

ngth

, (ks

i), o

r El

onga

tion

(%)

700 0

160

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TiAl Additive Manufacturing Opportunities in Aerospace • TiAl has approx. half the density of Ni Alloys

– Offers significant weight savings

• Possible parts – Compressor Cases/Combustor Plenums – Compressor Flow Path Static Components – Compressor Blades – Compressor Vanes – Diffusers – Exhaust Nozzles – Heat Exchangers – Impeller Shrouds – LPT Blades – TOBI(s) – Valve Bodies

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DMLS-Titanium Aluminide (TiAl) • DMLS has no ability to pre-heat powder

– Not suitable for low ductility materials

• Not possible to optimize build parameters

– High energy end shows cracking – Low energy end shows porosity

(insufficient fusion)

• Heating stage needed for materials with low ductility

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Page 11

Electron Beam Melting (EBM) – TiAl • Ongoing build optimization studies

– Optimizing build parameters to eliminate internal porosity

– Improving as-built surface finish

Sample Condition

YS (ksi)

UTS (ksi)

Elongation (%)

As HIPed As HIPed As HIPed HIP+HT HIP+HT

72 72 74 69 68

78.5 90.5 82 92 92.5

1.2 2.2 0.9 2.3 3

500x

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Page 12

Ion Fusion Formation (IFF) • Energy source is arc

– Uses very high temperature inert gas to fuse the material

– Electrical power generates the high temperature in the gas within a small chamber with a variable orifice

• Wide range of both orifice size and heat input • Match deposition rate with size and heat input

• Deposition material can be wire or powder

• No chamber-free form deposition • Build Envelope: 4ft X 4ft X 6ft

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Page 13

Ion Fusion Formation (IFF)

• Open architecture • Wire and powder feedstock

– Any material – Large diameter wire, multiple heads –

high build rate • Easy maintenance • No build supports • Varied thermal management

capability – not just speed

• Free form builds-no size restrictions

Ion-Fusion Deposited Ti-6Al-4V Cylinder

• Use of wire deposition requires post machining • Low power control/fine feature equipment

currently not installed • Multi-axis build and thermal management

capability complicates programming while providing more flexibility

Advantages Disadvantages

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Ion Fusion Formation (IFF)–Ti-64 • Requirements – ASTM B367

– UTS 130 ksi min – YS 120 ksi min – Elongation 6% min

Add gray portal

• As-deposited – Average – UTS 131 ksi – YS 123 ksi – Elongation 12%

• STA–Average – UTS 160 ksi – YS 142 ksi – Elongation 8%

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Ion Fusion Formation (IFF) – Repair and Overhaul • Free form fabrication allows build freedom • Housing repair for Honeywell Repair and Overhaul

U-gap for Localized Repair

Reference Point

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Page 16

AM Challenges and Opportunities for Aerospace

• A game changing technology potentially suitable for

– Difficult to manufacture components – High value added, long lead time items – Legacy items – Possibility of functionally graded materials

• Challenge areas for aerospace

– Build envelope limitation – Cost for materials property data bases – Qualification and certification costs

• Develop databases in MMPDS • Use of modeling and simulation

• Additive manufacturing consortium has been formed to address the needs for technology maturation

• ASTM F-42 committee for standardizing AM technology an developing industry standards

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Page 17

Summary

• Additive Manufacturing (AM) using Titanium Alloys has a future in Aerospace Manufacturing

• AM is gaining acceptance on a global scale

• Technology’s largest barrier to entry into Aerospace Marketplace is machine size (build envelop is too small)

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Page 18

Thank You!