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Austrian Additive Manufacturing Delegates Visit to TWI Rotherham
30/11/2016
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Agenda
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Introduction - TWI
TWI’s Mission
To deliver world class services in joining materials, and associated engineering technologies to meet the needs of Industry
Dedicated to Materials Joining
• £70m R&D per year
• Non profit distributing
• 800 staff
• >700 industrial members worldwide
• 70 years track record
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>800 confidential projects per year
150 ongoing industry-led research projects
25,000 training and examinations students per annum
5,000 new technical abstracts per annum
Representation on over 100 standards committees
Introduction - TWI
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2014 Structural Integrity Research Foundation
(SIRF) and new Integrity Research Centre (NSIRC) established in Cambridge
Major expansion of facilities in Cambridge
New purpose-built centres in Port Talbot, Wales and Kuala Lumpur, Malaysia
1979 The Robert Jenkins Laboratory for heavy and high-voltage equipment (electron beam, friction welding) opened by HRH The Prince of Wales
A Brief History of TWI
2015 1920 1970 1990 2010 1940 1930 1950 1960 1980 2000
1946 British Welding Research Association (BWRA)
established to take over the research activities of the Institute of Welding
Abington Hall purchased and research laboratories set up
The start of TWI in its recognisable form
1968 The Welding Institute formed by the merger
of BWRA and The Institute of Welding
1952 Purpose-built fatigue
laboratory erected
1966 The Ramsay Moon Conference
facility is built
1981 Purpose-built Training Centre opened in Cambridge
1984 The Welding Institute becomes a founding member of the Edison Welding Institute (EWI) in Columbus, Ohio, USA and seconds a team of specialists to set it up
1994 TWI achieves ISO 9001 accreditation
1990 ‘TWI’ adopted as trading name to reflect wider interests in joining, materials and engineering research and consultancy
1948 A founding member society of the
International Institute of Welding (IIW)
1923 Institution of Welding Engineers founded in London
1934 Institute of Welding formed by merger of Institution of
Welding Engineers and British Advisory Welding Council
1957 First metallurgical laboratory
built in Abington
1961 Engineering laboratory built – for fracture, pressure vessel and resistance welding research
Great Abington, Cambridge, 1969
Great Abington, Cambridge, 1958
1993 TWI South East Asia Centre opened in Kuala Lumpur, Malaysia
2010 TWI North America established in
Houston, Texas
The new TWI Technology Centre (Wales) building, 2014 New facilities in Abington, Cambridge, 2014
Abington Hall Stables, pressure vessel testing, 1948
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TWI - Industrial Sectors
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Cambridge
National Network
Port Talbot
Sheffield Middlesbrough
Aberdeen
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International Centres and Offices
North America China Central Asia
Middle East
Africa India
South East
Asia
Japan
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TWI Expertise
1. How to Join Materials Effectively
2. How do Joints Perform in Service
• Metals • Plastics • Ceramics • Composites • Welding • Adhesives • Fasteners • Surfacing
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Additive
Manufacturing Laser and sheet
processes, incl. laser welding and cutting
Friction and forge processes, incl. linear friction and friction stir welding
Electron beam welding
Adhesives and composites
Ceramics Brazing R&D developing
new technologies
Key Technologies and Expertise
Fitness-for-service assessment (FFS)
Risk-based inspection (RBI)
Advanced & specialist NDT/inspection
Fatigue & fracture testing & assessment
Testing in critical environments, e.g. sour (H2S), sweet (CO2), HTHP, H2
Software tools
Specialist training
Materials and failure mode characterisation
Materials/joints performance and degradation testing
Materials performance improvement for demanding service
Surface engineering
Welding engineering and fabrication
JOINING
ENGINEERING
MATERIALS
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TWI Service Delivery Overview
Core Research Programme Industrial contacts
Public funded projects
Single client projects
Exploratory Programme Far from market ideas generation
Advisory & consultancy services
Joint Industry Projects
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Member Products and Services
Technical helpdesk
R&D, consultancy
and manufacturing
support
Training and examinations
Information services
Technology transfer /
supply chain support
Online technical
knowledge
Software packages and development
Welding, AM, inspection and testing
Failure investigation
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Metallic Additive Manufacturing at TWI: An Overview
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Metallic AM Overview at TWI
Activity in AM since
1990’s
TRL 1-9 AM business
solutions offering
>£63Mn AM project
work (associated) in last 5
years
>£6Mn AM project
work (direct) during last
18 months
>£0.5Mn PA
TWI Core Investment
>25 live collaborative
projects underway
>35 AM Staff
directly in AM
NADCAP, ASTM-F42, AM-EC SP,
UK AM Strategy
Annual Industrial
AM Conference
at TWI
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AM Technology at TWI
Processing
Arc-based
EB-based
Powder-bed: SLM
Powder-fed: LMD
Thermal Spray
Materials
Metallurgical Analysis
Heat Treatment
Powder Quality & Recycling
HS&E Issues
Metrology Mechanical
Testing Standards & NADCAP
Numerical Modelling
Topology Optimisation
Process Modelling
Structural Integrity
Manufacturing Services
NDT
In- & post-process
Certification Validation
Prototypes Systems & Automation
Manufacture
Testing
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AM Technology Transfer Program: Working with TWI
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Additive Manufacturing Workshop
AM Product
Suitability Workshop
for Members
Concise AM Feasibility Report Business case for AM adoption
Guidelines for future activities supporting your product portfolio’s transition towards the adoption of AM technologies
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Additive Manufacturing Workshop
TWI
• CMG Officer
• Numerical Modelling Team
• AM/SLM Design Team
• AM/SLM Technician Rep
• Materials Group
• SSN, SMJ
• Welding Experts
• LAS, EBM , ARC
• Structural Integrity
• Reps – Static/Fatigue
• NDT Team Rep
• Manufacturing Services
Client
• Commercial Managers
• Design/FEA Engineers
• Materials Engineers
• Fabrication/Assembly Engineers
• Structural Integrity/Stress Engineers
• QA/QC Engineer
• Validation & Verification Managers
Recent Projects & Case Studies
AM Materials & Post-Processing
Current defects /Challenges
AM Knowledge & CRP Database
Ideas, New Product Introduction
Design for function & AM
Mechanical Performance Requirements
Pre-Production Trials and market needs Brainstorming
and Feasibility Exercise
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AM Technology Workshop
•Product suitability evaluation for AM
•Return on investment exercise
Topology
Optimisation
•Light-weighting
•Lattice sub-structures
•ATOM and TOSCA software
Design for AM
•Dimensional accuracy
•Machine Allowance
•STL Re-design for buildability
•Materialise 3-Matic STL Software
Material Selection
• Application based alloys
• Powder Characterisation
• Particle Size Range
• Morphology
• Flowability
Part orientation
• Critical surfaces & tolerances of features
• Post-processing needs
• Ease of support removal
• Minimal distortion
•Materialise MagicsRP
Support generation
•Solid supports & tree-like structures for build success
•Support Optimisation for heat dissipation to reduce Residual Stress
Process Development and Prototype generation
•Process parameters development
•Prototype Trials
•Destructive Tests
•Best Density &
•Surface Finish
Post Processing Activities
•Hot Isostatic Pressing
•Heat Treatments
•Surface Finish Improvement
•Cleaning of Parts
Manufacturing
•QA/QC
•Validation and Certification
•Full rate production
AM Product Evolution
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Product Selection for AM
Client’s Business Ranking
TWI’s Technical Ranking
Client’s Component Reference
Approximate SLM cost per
Component in £ (Including Heat Treatments and
HIPing) (Based on number of parts
nested in a build)
1 x Component 1 1000
2 x Component 2 2000
3 x Component 3 3000
4 x Component 4 4000
5 x Component ‘n’ 5000
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Outcome of Workshop
Concise AM product feasibility study List of recommendation/actions for AM Technology
adoption Down selection of most suitable parts for AM adoption
(business / technical aspects)
Next steps detailing new product AM introduction programme for selected products Guidance on IP and business exploitation
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Agenda
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Chris Dungey
Business Development Group Manager
Joining Technologies DD: +44 (0)7711 558 553 E: [email protected]
TWI Ltd Granta Park
Great Abington Cambridge CB21 6AL
UK
T: +44 (0)1223 899 000 F: +44 (0)1223 892 588 W: www.twi-global.com