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CSIRO Titanium Technologies and Additive Manufacturing Chad Henry | Additive Manufacturing Operations Manager

12 February 2014

Transforming South Australia’s Manufacturing Sector

Agenda

Titanium Technologies Theme - TiRO

- Lab 22 – Metallic Additive Manufacturing – Arcam E-Beam Melting (EBM)

- Strategy and Roadmap

- Capabilities and Examples

- Thermal Assisted Machining

ore to more

Titanium Technologies - from ore to moremore Titanium Technologies - from ore to moremore

Titanium Titanium TechnologiesTechnologies

MetalMetal

ProductionProduction

Metal to Metal to

ProductProduct ManufacturingManufacturing Special ProjectsSpecial Projects

TiRO

Alloys Process

Novel Alloy Design

Project 21

BMG Prod/Proc

Sheet

Plates

Bars

Billets

Shaped Billets

Wire

Extrusions

Powder (for AM)

Cold Spray

Laser Assisted Machining

Additive Manufacturing

Lab 22

Modelling and Simulation

Online / In Situ Measurement

Victorian Productivity Network

Royal Australian Mint

SIEF Aero-engine Project

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The TiRO™ process

Christian Doblin | TiRO™ Project Leader

Same overall chemistry as Kroll

TiCl4(g) + 2Mg(l) → Ti(s) + 2MgCl2 (s)

TiRO is continuous 2 stage process cf. Kroll batch process

• Lower capital cost • Greater process intensity • Reduced energy requirement • Very high yield

TiRO is a “non equilibrium” process • No melting of Ti occurs

TiRO produces powder directly • Cost comparable to Ti sponge

Has the potential to produce Ti alloys directly

The TiRO™ Process Mg

TiCl4

Ti Powder

MgCl2

Intermediate product (MgCl2/Ti composite)

Fluidised Bed Reactor

Vacuum Distillation Separator

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CSIRO Lab 22 Metallic Additive Manufacturing

Chad Henry | Lab 22 Operations Manager

Additive Manufacturing is...Additive Manufacturing is...

Resource efficient and Sustainable energy efficient

reduces waste

layer-by-layer processing to make 3D objects directly from CAD files, as opposed to using subtractive methods like traditional CNC machining.

9National Aeronautics and Space Administration

Langley Research Center

Metal Additive Manufacturing Landscape Today

Must Understand ... One Size Does Not Fit All

Material

Build Volume

Rate

Design and Unitization

Unique Shapes/Details (free)

Surface Finish

Inspection

Laser vs.

E-Beam vs.

Solid State

Powder Bed vs.

Powder Spray vs.

Wire Fed

Product Requirements Manufacturing Processes

Production

Prototyping (form, fit, function)

Tooling

Shop Aids

All For ...

Ti

Ni

Al

Australian Metallic Additive Manufacturing RoadmapAustralian Metallic Additive Manufacturing Roadmap

Database for Production

•

Database for Production

•Ti 6Al 4V

Low Cost Feedstock

Distortion Control Management

In Situ Inspection Methods

Microstructure Manipulation

Additional Material Data

•

Additional Material Data

•Titanium, Steel or ?

Novel Titanium Materials

Electron Beam

Wire Fed Powder Bed

•

Database for Production

•Ti 6Al 4V

Ex Situ Powder Bed

Powder Manipulation

In Situ Modelling & In Situ Modelling & Management

In Chamber Inspection In Chamber Inspection Methods

Microstructure Microstructure Manipulation

Novel Titanium Novel Titanium Materials

Additional Materials

Decrease final Component Cost

Increase the Application Space

Additive Manufacturing ... The 2+1 Strategy

Modelling and Simulation

Feedstock and Powder

New Material Development

Distortion Management

Novel Sources

Physical Modification

The AX - Powder Flow

Industry Engagement

AM Network

Build, Consult, SIEF

Casting, Welding

Cold Spray, TiRO and Alloys,

Processing

Arcam - Electron Beam Melting (EBM) - Powder Bed - Vacuum - Elevated Temp - Low Distortion - Excellent Properties - Model A1 - 200mm x 200mm x 180mm - Materials - Ti and Ti Alloys - CoCr - Nickel Alloys (Inconel) - Steel Alloys - Others??? - CSRIO Level 3 Training

E-Beam AM Equipment

Lab 22 Lab 22 –– ArcamArcam ImagesImages

Lab 22 Lab 22 –– ArcamArcam ImagesImages

Lab 22 Lab 22 –– ArcamArcam ImagesImages

0

500

1000

1500

2000

0

500

1000

1500

2000

Future Today

50% of the cost in operation is labour 20% is depreciation (i.e. Cost of the unit)

If the equipment cost comes down and labour gets more productive Powder becomes the mostly costly component of AM

$ $

Operational Cost Considerations of Additive Manufacturing – Why work on materials?

Where is “Cheap” Titanium Powder???

Armstrong Process – Cristal

FFC Process – Metalysis

TiRO

Alloys

CSIR

New Zealand

Hydride DeHydride

ADMA

China

The powder is median size d50 of 67 µm with a very narrow distribution for Arcam.

SEM of Titanium Powder

Particle Diameter (µm.)

Volume (%)

0

10

20

30

0

10

20

30

40

50

60

70

80

90

100

1.0 10.0 100.0 1000.0

Volume distribution of Arcam powder size

Powder for Additive Manufacturing Fusion Systems

Powder, Particles and Aggregate

Size

Size Range

Flow

Density

Alter Either or Both: - Improve the Inexpensive Powder - Alter the AM Equipment Operating Parameters

CSIRO Powder ManipulationCSIRO Powder Manipulation

CSIRO TiRO Metal

Other Available Powders

Powder Modification Powder Modification -- SizeSize

50

25

>1000 600 – 1000

400 – 600

250 – 400

150 – 250

100 – 150

75 – 100

45 – 75

25 – 45

< 25

Arcam EOS Cold Spray

Weight pct

Particle Size in mm

Before

After

Titanium Technologies and Lab 22 Achievements

• Over 270 people through Lab 22 • MPs - Adam Bandt, Julie Bishop, Anna Burke, Greg Combet

• EVP of the Lockheed Martin F-35 Joint Strike Fighter Program, Tom Burbage

• 60 people attended and participated in the Lab 22 Open House Workshop

• 45 people from SEMIP toured

• TiRO Produced in the Saleable Pilot Plant

• Lab 22 Chosen to be a Preferred Service Provider for Arcam EBM

• Additive Manufactured (AM) Fish Anchors Implemented

• Flying Machine Bicycle

• AM Mining Drill Bit Holders Implemented

• AM Bugs and AM Orthotic Horse Shoes

• AM student projects

• Sophie’s Dragon, Toothless

• The Titanium Challenge

Topology and Design Optimisation

Same Performance ... Less Weight

Iteration 1 Iteration 6 Iteration 9 Iteration 13

Iteration 16 Iteration 20 Iteration 25 Iteration 29

Rapid Design Iteration

Manufacture all of the design candidates at once in a single build.

Inexpensive physical testing was employed to make decisions.

SIEF AeroSIEF Aero--engine AM Demonstration w/ Monash Uengine AM Demonstration w/ Monash U

I like big bugs ...

Plasma Giken PCS-1000

Cold Spray Technologies - Equipment

CGT Kinetiks 4000

Meltless Additive ManufacturingMeltless Additive Manufacturing

Cold Spray

Additive Manufacturing Repair Coatings

Near Net Shape

Ti Pipe Seamless Continuous

Ti Bike Frame

Ti Coupler

Composite Dies

Defects Repair

Corrosion Resistant

Electroplating Replacement

Design Modification

Wear Resistant

Biofowling

Composite Coatings

Bulk

Billet

Forging Pre forms

Reclamation

MaterialsMaterials

Metals & Alloys: Ti, Ni, Fe, Cu, Al, Sn Ceramics + Metals: Al + TiB2 Polymers

Cold Spray for PreCold Spray for Pre--formsforms

Continuous Billet ProductionContinuous Billet Production

CSIRO has the capability to produce 45 kg/hr of product via cold spray

Thermally Assisted Machining of TitaniumThermally Assisted Machining of Titanium

Titanium Technologies Theme 2013

Page 32 | CSIRO Titanium Technologies | August 2012

Future Ti TechFuture Ti Tech

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Additive Manufacturing Network

Delphine Cantin | The AMN Project Leader

The Additive Manufacturing Network The hub for all things additive.

GOAL – Market globally Australian additive manufacturing capability, for both technology R&D and production for profit in industry. - Publish who has what equipment and corresponding capabilities. - Create confidence in global customers investigating Australian potential. - Collaborate efficiently for new Australian business, creating greater total revenues in which to participate. - Connect those with a need to those with a solution.

GOAL – Facilitate communication within Australia on additive manufacturing. - Use a network infrastructure, including focused working groups, to conduct regular face-to-face and web meetings. - Understand others’ roadmaps and strategies. - Coordinate and be efficient on resolving issues. - Achieve a comprehensive and non-redundant R&D project portfolio within the country. - Accelerate the deployment of technologies to industry.

MISSION – Coordinate additive manufacturing for Australia.

MISSION – Coordinate additive manufacturing for Australia.

The Additive Manufacturing Network is ... - Public with participation from academia, industry, and government welcome. - To be self governed once established. - Well poised to be a self supporting national asset.

The Additive Manufacturing Network The hub for all things additive.

Per the mission statement: co·or·di·nate (verb) - The act of harmoniously combining and interacting items to function effectively.

For further information, please contact: Delphine Cantin CSIRO Gate 7 Normanby Road, Clayton 3168 VIC Australia +61 (03) 9545 2761 (office) delphine.cantin@csiro.au

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Thank you CSIRO Titanium Technologies Theme - ore to more

Chad Henry

Additive Manufacturing Operations Manager - Lab 22

Titanium Technologies Stream Leader

+61 3 9545 7844

chad.henry@csiro.au