certification of laser powder additive manufactured components for industrial adoption in the energy...

Copyright TWI Ltd and Lloyd's Register Group Services Ltd 2015


Joint Industry Project Launch Event 29 September 2015

Certification of Laser Powder Additive Manufactured Components for Industrial Adoption

in the Energy and Offshore Sectors



What are we going to cover

Item Presenter

1 General introduction Luke Morsillo

2 TWI introduction Ian Norris

3 Lloyd’s Register Energy introduction Andy Imrie

4 Current state of the art in additive manufacturing Roger Fairclough

5 Presentation of the Project Outline proposal Ian Norris, Amanda

Allison, David Hardacre

Short 5 minute coffee break and virtual slideshow

6 Discussion of technical content, timeliness, duration and

likely support of the proposal, including general Q&A All

7 Any other business Luke Morsillo



Acronyms and abbreviations

We’ll use a number of different phrases

within this presentation

• AM/3DP/ALM: Additive Manufacturing

• NDE: Non-Destructive Examination

• NDT: Non-Destructive Testing

• LMD: Laser Metal Deposition

• SLM: Selective Laser Melting

• JIP: Joint Industry Project

• DOE: Diffractive Optical Elements



What’s the purpose of the launch event

Discuss the questions and

commentary on the technical

content, benefits and

deliverables of the project

• We encourage open

discussion on how relevant

the project’s aims are to your

organisation and the

industry.

Establish the timeliness of

the project

• We are looking to the

participants today to provide

a gauge of how mature AM

is within the industry.

Establish the likely support

for the project

• We’ll be following up 1:1 with

each of you in the next week

to discuss next steps.



Revolutionary technology does not automatically

result in saleable products overnight

• Barriers include legal, safety, reliability & repeatability.

• International standards and regulations are there to overcome these.

• ISO and ASTM standards are in development now but are years away from adoption.

These are the challenges that designers and manufacturers now face

Our project aims to forge a path to market, remove barriers, provide

expert guidance

And finally…the project




Project outline

The objectives of this project are to assist industry with the wider

adoption of AM technology by…

Identifying the priority measurement and standard compliance challenges of the Energy and

Offshore sectors.

Undertaking certification of a range of representative parts selected by the project sponsors.

Creating protocols that address the specific material and process needs of each sponsor.

Setting an example framework for certification and providing valuable information and data for

AM standard development across industries and research fields.

1

2

3

4



Benefits to sponsors

Certified parts that meet industrial requirements for quality, safety, and consistency, and

which are qualified ready for market introduction.

Improved knowledge of AM processes and practises to ensure repeatability and

reproducibility and facilitate the certification of future parts.

Decreased cost of certification by leveraging expert processing and certification knowledge

and experience from both TWI and LR Energy.



TWI introduction

Dr Ian Norris, JIP Product Manager (TWI)




Mission

To provide authoritative and impartial expert

advice, knowhow and safety assurance

through engineering, materials and joining

technologies.



Over 700 Industrial members in

60 countries

Over 800 staff

£80M turnover

• Non profit distributing

Over 24,000 trainees/ year

Membership based Research

and Technology Organisation

Established 1946

TWI – serving our members




UK network

Port Talbot

Middlesbrough

Cambridge

Aberdeen

Rotherham

UK network



Worldwide network



TWI – technology engineering

• Research, Development, Technical support

and consultancy in all welding & joining

processes:

• Arc, EB, Laser, solid state, adhesive

etc.

• Innovative solutions to joining materials:

• Metals, plastics, ceramics, composites.

• Surface Engineering:

• Spraying, coating, surface

modification.

• Metallurgy & corrosion expertise.

• Structural Integrity.

• Failure analysis:

• Creep, fatigue & fracture testing.

• Design and manufacturing engineering.

• Training and certification.




Support for industry

• Helpdesk Technical support

• [email protected]

• Over 15,000 visitors to TWI

technical centres

• Over 800 confidential, Single

Client Projects

• 20 Joint Industry Projects

• £4M Core Research

Programme

• 65 Collaborative Programmes



Knowledge transfer

• Website technical information

• Best practice guides

• Member reports

• Published papers

• More than 1,000 FAQs

• Knowledge summaries

• Weldasearch

• TWI and industry news

• Conference and events

• Social networking



Our team today

We help our clients to Amanda Allison Amanda has a BEng(Hons) in Materials Engineering and is currently employed

as a Project Leader in the Laser Additive Manufacturing (LAM) section of TWI

Ltd. Her key responsibilities include: promoting advancements in Additive

Manufacturing technologies; preparing technology and innovation proposals and

managing UK and EC funded technology and innovation projects.

Ian Norris Ian is the Product Manager for Joint Industry and Single Client Projects at TWI.

He is a metallurgist with a background in laser, EB and friction processing for

applications in the power generation, marine, construction, aerospace and oil

and gas sectors. His current role involves working together with technical

experts on development of timely project proposals to address industry needs.

Roger

Fairclough

Roger is a Principal Project Leader in the Joining Technologies Group at TWI,

based at the Technology Centre in South Yorkshire and involved with a range of

technologies but particularly Additive Layer Manufacture using lasers. He has

over forty years experience within UK engineering industry, having worked in the

mining, power generation, R & D and steel manufacturing sectors.



Lloyd’s Register Energy introduction

Andy Imrie, Business Development Manager (LR)




Where we started

Our heritage is genuinely historic

• Formed in 1760 in Edward Lloyd’s coffee house to

examine and ‘classify’ merchant ships according to

their condition.

We have 250 years of global marine history.

• The world’s first ship classification society and this

remains our core activity today.

…and over 100 years serving other industries

across society from energy, rail, food safety to

power and manufacturing.



What we do

We help our clients to

Improve safety and reduce environmental incidents or near misses.

Ensure successful delivery of major capital projects and activities: safely & on target.

Ensure the design and manufacture of critical equipment complies with specifications and standards.

Extend asset life and manage end of life.

Raise asset productivity, efficiency and increase uptime of critical equipment.

Support adoption of innovation and new technology and extend skills base.




Lloyd’s Register Energy at a glance

20

No1 We are the no.1 provider of verification services to offshore operators in the UK by market share.

80% We inspect 80% of the world’s offshore oil rigs. In fact, we’re the leading provider of independent risk management services to the drilling industry.

World leaders on codes and standards

We are one of the largest providers of ASME Authorised Inspection services by market share in the world.

0 shareholders

We are financially and politically independent and our services are truly impartial.

We pioneered RBMI software

The industry’s first reliability-based mechanical integrity (RBMI) software which has radically advanced the maintenance and management of rotating and instrumentation equipment.

90% Fewer inspections points required by our risk-based inspection management software system, RBMI, compared to a traditional programme. And the risk of failures is reduced by 80-95%.

Up

to

100%

Owned by the Lloyd’s Register Foundation, a UK charity dedicated to research and education in science, technology and engineering.




The sectors we support - Energy

We improve the safety, reliability and performance of assets, people, systems and processes across

the energy industry, helping our clients to solve the most demanding technical, regulatory and

commercial challenges.

Downstream

Upstream

Power

Oil and Gas

Renewables Thermal Power

Nuclear Power




We provide assurance to manufacturers, vendors and operators that their equipment, materials and

components comply with statutory requirements, regulations and standards.

This reduces the potential risks to employees, the environment and our clients’ businesses and

reputations.

The sectors we support - Manufacturing

Components Materials Equipment




Experience at every manufacturing stage

We help our clients to

• Global design

appraisal

capabilities.

• Processes to verify

and validate that

designs reflect

detailed

specifications.

• Capabilities to

validate all aspects

of material

properties.

• Extensive

experience with

EN standards,

including EN

10204:2004 Type

3.2 certification

and EN 1090.

• Witnessing of

NDE, heat

treatment, forging.

• Certification to

global codes and

standards.

• Ability to certify

weld procedures

and qualifications

to all major codes.

• Traceability of

components.

• Witness/

verification of

assembly

procedures.

• Snagging and

package

inspections.

• SUT, SIT, FAT

witnessing.

• Site receipt

testing.

• Manufacturing

record book

review.

• Issue certification.

Design Raw Materials Manufacturing Assembly Testing MRB




A world leader in certification to internationally recognised standards

One of the world leaders in certification of

businesses and products to internationally

recognised standards

• ASME, API, EC Directives/CE marking, IBR,

MHLW, MOM, NC-14 and DOSH.

LR also supports the development and evolution

of standards and codes through its involvement

in technical committees and working groups

• BSI, ASME, EU




Our core team is supported by our Global Technology Centres

We are operating with strong representation

from our two Global Technology Centres in

Singapore and Southampton

• Both centres work towards positioning LR

and our clients at the forefront of technology

to ensure that people are safe and that

essential assets perform as required.

• Our primary focus is on supporting

innovations for energy and shipping.

• We’ve grown a global research and

development network that spans across

academia, industry and government.

AM is one of the key technologies mapped

to our smart supply chain innovation

programme



Our team today

We help our clients to David Hardacre David is the Technical Lead on the Additive Manufacturing project for LR Energy.

He is a Chartered Mechanical Design Engineer with over seventeen years’

experience. He holds the role of Lead Specialist for LR Energy, performing

independent design calculations for a wide range of equipment to recognised

standards and regulations.

Andrew Imrie Andy works as part of the Energy Business Development Group responsible for

the upstream, downstream, power and manufacturing businesses. He is at the

forefront of identifying trends within the marketplace and maintains a strong

focus on facilitating and delivering collaborative innovation and technology

projects.

Luke Morsillo Luke is the project manager and analyst for all additive manufacturing projects

and activities within Lloyd’s Register Energy. Luke has several years

background in project and business management and analysis, with a strong

focus on information systems and technology.



Current state of the art in additive manufacturing Roger Fairclough, Principal Project Leader (TWI)




TWI’s AM activities

Additive Manufacturing

Repair

Surfacing and Coating

Prototyping

Legacy Parts

Small Batch Production

Customised Products

Salvage Parts

OEM

R&D

Activities

Part

Production

Activities



Additive manufacturing technology

Powder bed deposition

Selective Laser Melting (SLM)

Nozzle powder delivery

Laser Metal Deposition (LMD)



Selective Laser Melting (SLM) capability

Micro SLM50 Realizer SLM100

Renishaw AM250 Rapid Part System 1kW



Design optimisation for additive manufacturing

Used to create designs that

exploit AM processes

Introduce complex

geometries

(sub-structures and lattices)

Multiple-part assemblies

combined into single builds



Topology optimisation

Courtesy of GE



Structural efficiency can be improved by enabling optimised topology that could not normally

be achieved by machining or casting.

A collaboration between the following organisations: TWI Ltd, University of Exeter, EADS UK,

Bombardier Aerospace plc, TISICS Ltd and Materialise UK. The Project was managed by TWI Ltd

and partly funded by the TSB under the Technology Programme ref: “AB183A”. TP No:

TP11/HVM/6/I/AB183A.

Selective Laser Melting (SLM) Topology



Traditional “Machining” process flow

AM process flow

Issue Material

Turn Gun Drill

Thread Drill

Sculpture Mill

Proximal Milling

Digital Milling

Bend and Bow

Glass Bead

Anodise

QA QA QA QA QA QA QA

Post Processing

Heat Treatment

Finishing

AM Build

Build Parameter

Machine

Powder

Supports

Design Optimisation

QA?

AM and “traditional” approaches P

art

Desig

n

Fin

al In

sp

ecti

on



TWI LMD hardware overview



Robotic LMD Capability Manipulation

New

TRUMPF

5.3/8kW

Disk

Laser

KUKA

KR30

(HA)

Robot

Cell

REIS

RV60-40

Robot

Cell



Oil and gas flange

• Standard flange

manufactured in SS316

and clad internally and

on the raised face with

Inconel 625 using In625

powder and laser

deposition.

• This is an alternative to

the manufacture of the

flange in solid Inconel

625, which significantly

reduces the materials

costs.

Standard flange in SS316 material

Flange laser deposited with In625 and

final machined to finished dimensions

Flange with laser deposited In625



Repair of hydraulic pump shafts

• Deposited like for like material of a

Ni-Cr-Mo Steel.

• Able to both maintain a tight control

on costs without compromising

quality.

• Reduce lead times for their repaired

units.



EC Project

Aims

• Deposition procedures for combustion chamber parts.

• Material IN718.

• Reduce time to manufacture

(2-3 months -> 6 hours).

Challenges

• Complex shape.

• Thin wall (0.8mm), Ra (15-25µm).

• Large aspect ratios i.e. thin wall (0.8mm) vs. overall build height

(~100mm) 300mm dia.



Lead time reduction



Lead time reduction

The MERLIN project has

received funding from the

European Union's Seventh

Framework Programme for

research, technological

development and demonstration

under grant agreement no

266271.



Inline LUT NDT Inspection



Diffractive Optical Elements (DOE)

Conventional LMD using

‘Gaussian’ Profile

DOE based LMD (Theoretical optimal)

TSB/Innovate UK: SCAMPER



Beam profile



Integrated Manufacture



Concept for in-situ repair

IN-SIDE project:

• Automation of repair by machining and LMD tools

integration.

• Combination of 3D scanning with CAD/CAM

software.

• Automatic tool path generation of all repair tools.

• Development of an integrated mobile robotic LMD

system incorporating laser safety.

• Optimisation of LMD repair process:

• Reduce cracking in Stellite 6 deposits.

• Investigate alternative repair materials

(martensitic SS).

• Reduction of part distortion.



Repair of vintage aircraft landing gear

Crack indication under

NDT

Build internal sleeve

LMD repair welding into

sleeve

Final repair after

machining bore



Turbine Shaft Cladding

• Over a period of 5 years we have worked with an industrial gas turbine

manufacturer to develop laser deposition processes for the cladding of

bearing journals on a range of industrial gas turbine shafts to combat

wear and corrosion.

• The shaft materials include Ni alloy and martensitic stainless steel and

the cladding material is a NiCrMo high tensile steel.

• There are strict limits for defects (porosity, cracks) and min hardness

levels and max Cr levels to achieve.

• Heat input is restricted to reduce dilution and hence Cr content in the

deposit.

• TWI has produced Weld Procedure Specifications for the different

materials and developed process control systems to ensure deposition

quality and consistency.

• The work is being carried out using our Trumpf laser deposition system

and integrated rotator



LMD vs conventional processing

• Alternative conventional processes:

• Metal Spraying

• Arc welding – MMA, MIG, TIG, Plasma Transfer Arc

• Ability to achieve technical specification:

• Surface chrome content

• Surface and interface hardness levels

• Full traceable record of deposition- parameters/heat input etc.

• Benefits include:

• Full fusion/high bond strength to substrate

• Low heat input, low dilution, low distortion

• Small HAZ

• Least effect on substrate

• Good surface finish

• High accuracy

• High repeatability



Presentation of the Project Outline proposal Amanda Allison, Principal Project Leader (TWI)

Dr Ian Norris, JIP Product Manager (TWI)

David Hardacre, Technical Leader (LR)




What is a joint industry project

• Opportunity to develop cutting edge

technology supported by industry.

• Topic of mutual interest to a number of

clients.

• Issues relating to safety and integrity.

• Development of codes and standards.

• Generic process development.

• Generation of materials properties data.

• Results confidential to Sponsor Group.



The proposal process

Launch Meeting

• Presentation of outline

proposal.

• Establish the timeliness of

the proposed project.

• Obtain input on the technical

content, deliverables and

benefits.

• Establish the likely support

for the project.

Launch Follow Up

• Prepare and issue full

proposal.

• Participation Agreements

(PAs) to potential sponsors.

• Individual discussions as

required.

Project Start

• When agreed number of

Sponsors have returned

PAs.

• Kick-off meeting.

• Agree work plan for first 6

months.



Project organisation

Sponsor meetings

• 6 month intervals.

• Report results to date and review progress.

• Plan work for following period.

• Final meeting.

• Overview of project results.

• Implementation and future plans.

Reports

• Bi-monthly progress updates.

• 6 monthly ahead of meetings or deliverables based.

• Final report drawing together all results.

• Reporting is done via a secure project website.



Revolutionary technology does not automatically

result in saleable products overnight

• Barriers include legal, safety, reliability & repeatability.

• International standards and regulations are there to overcome these.

• ISO and ASTM standards are in development now and will tackle a number of the challenges

facing the AM community:

• CAD model translation.

• Powder size and quality.

• Recyclability of powder.

• Variability between AM machine models.

• Support structures.

• Build parameters.

These are the challenges that designers and manufacturers now face

Background




We created this joint industry project to…

Forge a path to market

Remove barriers

Provide expert guidance




Project outline

The objectives of this project are to assist industry with the wider

adoption of AM technology by…

Identifying the priority measurement and standard compliance challenges of the Energy and

Offshore sectors.

Undertaking certification of a range of representative parts selected by the project sponsors.

Creating protocols that address the specific material and process needs of each sponsor.

Setting an example framework for certification and providing valuable information and data for

AM standard development across industries and research fields.

1

2

3

4



The case study technologies

Powder bed deposition

Selective Laser Melting (SLM)

Nozzle powder delivery

Laser Metal Deposition (LMD)



Our approach



Benefits to sponsors

Certified parts that meet industrial requirements for quality, safety, and consistency, and

which are qualified ready for market introduction.

Improved knowledge of AM processes and practises to ensure repeatability and

reproducibility and facilitate the certification of future parts.

Decreased cost of certification by leveraging expert processing and certification knowledge

and experience from both TWI and LR Energy.



Discussion and Q&A




Any other business




Next steps




Our timeline

Contracts Kick-off and project delivery

Oct-

15

Nov-

15

Dec-

15

Jan-

16

Feb-

16

Mar-

16

Apr-

16

May-

16

Jun-

16

Jul-

16

Aug-

16

Sep-

16

Oct-

16

Nov-

16

Dec-

16

>>

2017

Follow up

1:1 by our

team Discussions on project scope

Finalisation

of Project

Outline

w/e 04-Oct w/e 11-Oct w/e 18-Oct w/e 25-Oct w/e 01-Nov w/e 08-Nov



Get in touch

JIP Co-ordinator

Luke Morsillo

Email: [email protected]

Technical Lead

David Hardacre


JIP Co-ordinator

Kirsty Jones


Technical Lead

Amanda Allison


Find out more at: www.lr.org/additive-manufacturing

Find out more at: http://www.twi-global.com/services/research-and-

consultancy/joint-industry-projects/
