impacting product development and support through additive ......our global footprint product line...

Caterpillar Non-Confidential

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Impacting Product Development and Support through

Additive Manufacturing

Thierry Marchione, Caterpillar Inc.

AGENDA:

•Different matrix, different road map

•Gap assessment and mitigation

•Present applications

•Moving forward

Manufacturing Technology & Solutions

Caterpillar Non-ConfidentialManufacturing Technology & Solutions

OUR GLOBAL FOOTPRINT PRODUCT LINE

END MARKET

Construction Mining

Equipment

Diesel & Natural

Gas EnginesIndustrial Gas

Turbines

Diesel-Electric

Locomotive

3 Million+Products at Work

Around the World

98,400Full-time

Employment*

We Provide Solutions

that Help Our Customers

Build a Better World

171 DealersServing 192 countries*

500,000+Connected Assets*


A different matrix for AM

AM

success

Light weighting

Product

Performance

Supply chain

High volume/ High cost

Low volume/ Low cost High volume/ Low costAM

success

Light weighting

Product

Performance

Supply chain

Robustness

Durability

Emission regulation

Tooling

Lead time

Sourcing issue


A different matrix for AM

Material

MFG

processes

Product

MFG

practices

Aerospace

Composite Injection molded polyurethane

Safety

fabrication

Caterpillar


2014 - 2016

2016 - 2020

Optimized products

Gages, jigs and fixtures, tooling

Metal prototypes, legacy and non-critical service parts

Performance parts, first-fit applications

Advanced applications (e.g., structural)

Desktop

deployment

A different Road Map for AM

MicroFoundry







AGENDA:




•Moving forward



Gaps analysis

Material properties “The Cornerstone”

Digital technologies

“The Enabler”

Process capabilities & control “The Maker”

Post processing & QC “The Healer”

“As Designed” “As Manufactured”


Topology Optimization

Surface Optimization

Thermal Simulation

FEA comparison

Down selectionfor 32 solutions

Digital technologies

FEA validation

Test Bench

Manufacturing Challenges


Material development

1. Single layer, single bead test

2. Single layer, surface

3. Volume build

4. Scanning strategy

5. Cracking mitigation

6. Component check

“IP safe haven” H10, M2, 8620, Haynes 230, Hastelloy X, Waspalloy, MarM247 and 17-4 refined

Compliance to specification to establish

Simulation software and fundamental simulation in WIP

Developed semi-empirical model based on operator tangible parameters


100x – As Printed 100x - Anneal 100x – HIP 100x - Wrought Alloy

Yield Strength (MPa) Ultimate tensile (MPa) Elongation (%)

Horizontal As-Printed 686.5 ± 25 808.1 ± 15 5.7 ± .3

Horizontal HIP 526.2 ± 10 941.3 ± 10 31.6 ± 3.8

Vertical As-Printed 640.6 ± 10 835 ± 40 11.8 ± 1.2

Vertical HIP 521.5 ± 10 902.3 ± 40 28.4 ± 10

Wrought Alloy 390 ± 10 860± 10 47.7± 10

As-Printed (HRC) 32.7

HIP (HRC) 27.2

Wrought Alloy (HRC) 16.0

HIP Microstructure

Material development Haynes 230


Post processing & QC

PLAN for dimensional stock

QC difficult on internal feature

(Eddy current , CT Scan and/or ultrasonic)

REDESIGN for post-operation finishing


Increase deposition rate (technology or/and parts classification)

Reduce volume material (lattice, TO and Hybrid)

Heat treat trade off

Plan for finishing

Low cost material ???

Market trend

Survey other technologies

Saving cost with PBF

Slow

Slower

Moderate

Fast







AGENDA:




•Moving forward



Supply chain mitigation: Gas Turbine Fuel Swirler

ORIGINAL

CASTING

Benefits: Reduce leadtime: 9 monthS to 6 weeks

Cost reduction 35% (32-step process to 14 steps)

Better quality

Enable redesign for better durability and performance

Inspiration for development additional production


Supply Chain Mitigation: AT Legacy Suspension Valve

Background: Part 7U6910 made obsolete by the supplier without notification. Based on sales, part still required

Manufacturing options : Machine from solid: Expensive, special cutting tools needed, Long lead time

Additive Manufacturing: Allows more complex forms, minimizes post processing

Validation: Test underway on customer machine that had long back order

Material: 17-4PH, Stainless Steel or 8620


Developing “Next Generation” Reciprocating Engine Components

The Bold Goal: Increase life of reciprocating engine part by 2.5X

from 8,000 hours to 20,000 hours

Previous efforts w/ traditional manufacturing & materials Minor improvements

No line of sight to life goal

A new approach required Rethink operating mode and temperature behavior

Results: Nickel alloys fully developed (Haynes 230, Waspalloy, Inconel 718 and tested for high temperature

operating condition)

Top 3 concepts are being tested on engine

Parts will be fully validated as part of NPI process including typical engine NPI validation process of 20K hours / first overhaul interval


Large Engine Sea Water Pump Bracket

Objective: Develop a design process that utilizes Optimization Software, Materials and Additive Manufacturing processes

Why Print : Avoid high tooling cost for low volume components

Enables Improved Performance: Optimized Natural Frequency

Increased Fatigue Life

Radical weight reduction for cost mitigation

Next Steps: Back-to-back part testing

Material: 17-4PH, Stainless Steel, Inconel 625

Processes challenge: Sand printing, PBF, and DMLS

Consider hybrid manufacturing







AGENDA:




•Moving forward



CRAM Cost Reduction efforts for Additive Manufacturing

SCAM duplication of Supply Chain application for Additive Manufacturing

MAM pursuing Material development specific material for Additive Manufacturing

DDAM Digitally Differentiated product merging by using digital thread for


Moving forward

impacting product development and support through additive ......our global footprint product line...

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