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Materials Selection for Additive ManufacturingK. Rogers,

Technology Leader, Additive Manufacturing

GE Center for Additive Technology Advancement

August 10, 2016

Key additive manufacturing facilities

2

GE Healthcare AM COE, Milwaukee, WI

(PBFAM metals & polymers, direct write)

GE Global Research, Niskayuna, NY

(DMLM, laser cladding, polymers, ceramics, AM

design)

GE Corporate Center for Additive Technology

Advancement, Pittsburgh, PA(DMLM, EBM, polymers, sand binder jetting, laser cladding)

GE Power Advanced Manufacturing Works,

Greenville, SC(DMLM, polymers, AM design)

GE Aviation, Auburn, AL(LEAP fuel nozzle production

DMLM)

GE Aviation Additive Technology Center,

Cincinnati, OH(DMLM, EBM, polymers,

AM design)

GE Power AM COE, Baden, Switzerland(DMLM, polymers)

GE Oil & Gas, Talamona, Italy

(DMLM production)

GE Aviation, Avio Aero, Turin, Italy

(EBM)

GE Oil & Gas, Florence, Italy

(DMLM, polymers)

AM Technologies at GE

15 µm 200 µm 500 µm

Large-scale features

• Turbomachinery applications• Test hardware• Limited production since 2014

• Repair & feature addition; reduced buy-to-fly

• LRIP casting; NPI acceleration• In use

U/S probes Functional metal, ceramics & polymer partsCommercial polymer & metal machines

Large low volume functional metal partsCustom built machinesFoundry of the future enabler

Macro-scale featuresMicro-scale features

• Ultrasound probes• Integrated circuitry• Direct-written CBM sensors

• Direct ceramic deposition• Direct written sensors

• DMLM & Electron beam• Commercial polymer AM

• Spray technologies• Laser & EB cladding• Sand casting mold and core

CBM Sensors

Ceramics printing

Direct write

Mission Statement

This will be the flagship center for GE additive manufacturing where we will be on the forefront of implementing industrial applications for the benefit of all GE businesses. This site will be a hub of innovation and promote training and development in both design and applications for this breakthrough technology

Center for Additive Technology Advancement

Project Details

• First multi-modal US site

• ~50 employees

• 125,000 sq ft

• $39M Corporate investment

• April 2016 Opening

Pittsburgh, PA

Technology readiness level

• Part & process design tools

• Next generation equipment

• Material development

• Develop, prototype, scale & mature

• Should-be cost development

• Low rate initial production

• Large scale output

• Proven technology

• Standard routers & quality plans

Develop ImplementInvent

GRCCATA

Business

1 3 7 10

Applying additive technology

5

Repairs & ServicesCrankshaft repair

Design prototypesNPI applications

Low rate initial productionComplex geometries

Lighter weight parts/ efficiency

ProductionLEAP fuel nozzle

Flex tips

ToolingBoth metal & polymer tooling applications

IndustrializationMachine change-over reduction

In process monitoring

Identify

Develop

Industrialize

Globalize

Product offering

differentiationUnique concepts that leverage non-traditional solutions for customers

Additive supply chain

GE Supply Chain... Delivering REAL Production Parts

250K+

parts by

2020…

and growing!

T25 Housing Flex Tip

Materials Selection (Traditional)

Materials Selection (traditional)*

Problem solving process

1. Analysis of the Materials Requirements

– Service/use conditions and use environment

2. Screening of Candidate Materials

– Compare needed properties with a large 40000+ alloys to select a few materials that look

promising

3. Selection of Candidate Materials

– Analyze candidate materials in terms of tradeoffs of product performance, cost,

fabricability, and availability

» Best material for the application

4. Development of Design Data

– Determine the key materials properties for the selected material and process to obtain

statistically reliable measurements

– ASTM / AMS specifications

*George E. Dieter, Engineering Design A Materials and Processing Approach, McGraw-Hill, 1983 9

Relations between failure modes and mechanical properties, Smith & Boardman, “Metals Handbook 9th ed., vol 1, ASM international, Metals Park, OH 1980 10

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LCF

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Contact Fatigue

Fretting

Corrosion

SCC

Galvanic Corrosion

Hydrogen Embrittlement

Wear

Thermal Fatigue

Corrosion Fatigue

Materials Selection: Interrelationship of design, materials and processing

11

Design

service conditions function

Cost

Processing

Equipment Selection

influence on properties

cost

Materials

Properties

availability

cost

Product Reliability

Example: Paperclip

12

TRADITIONAL MATERIALS SELECTION EXAMPLE

1. Materials Requirements1. Elasticity

2. Strength

3. Wire diameter, clip design, etc.

Too much opening force

Too little clamping force

Permanent bend

MODULUS

YIELD STRESS

Materials Selection (Additive)

LASER POWDER BED PROCESS I.E.. SLM / DMLM


Can you print me a valve controller body out of a soft

magnetic material like 430 Ferritic Stainless or Nickel

Iron alloy?

14

We have several MIM & conventional machining

quotes and need some next month

Yes, But…...

Magnetic properties?

• Never heard of 403 stainless in DMLM additive…

weldable but prone to cracking – Possible?

• 50% Nickel–Iron alloys? Does anyone make

powder?

• Binderjet?

15

Yes, But…

Magnetic properties?

• Never heard of 403 stainless in DMLM additive…

weldable but prone to cracking – Possible?

• 50% Nickel–Iron alloys? Does anyone make

powder?

• Binderjet?

16M300 Maraging steel, magnetic

permeability in test

17

Can you print me a bedplate out of grey iron?

IMAGE: GE Reports

Yes, But…...

Lets do some math

• 30000 Lb casting

• @ 10 lbs per hour for WAAM (www.waammat.com)

= 3000 hours or 2.9 parts per year!

18

19IMAGE: GE Reports

How many do you need this decade?

Title or Job Number | XX Month 201X 20

People can have the Model T in any color, as long as it’s black”-Henry Ford

You can have any alloy you want….

Andy Snow, GE Aviation October 2015 21


As long as it’s CoCrMo!

Materials Selection Compared (metals)

Traditional Data Sources• ASM Metals Handbooks

• SAE Handbooks

• Structural Alloys Handbook

• Grey and Ductile Iron Handbook

• Steel Castings Handbook

• Woldman’s Engineering Alloys

• Mil Standards

• Aerospace Materials Standards

Additive Data Sources

22


• Senvol Database – 400 alloys

• Senvol Indexes - 2?

• Manufacturer data sheets – 100?

Limited data available

COMING SOON:

ASTM standardsSME AMS standards

How to really do materials & process selection (Additive)


Process Selection (Additive)

24

Production Vs Prototype

Material Type (Polymer, Metal, Ceramic)

• Part Size (<400mm)• Production

rate/volume• Tolerances• Feature size• Surface Finish

High level materials requirements

Preliminary AM selection

• Part orientation• Build Time

• Cost

Final AM selection


• Topology optimization• Shorten NPI manufacturing time• Eliminate process steps• Reduce outsourcing• Design performance improvements• Product design freedoms• Reduce assembly costs• Design CNC machining fixtures on the additive part• Incorporate datum features into the part design• Reduce prototype lead times and costs• Reduce inventory• Build internal passages into almost any geometry• Change multiple part assemblies to be designed as one part

geometry• Eliminate welds in an assembly

Additive Advantage

IMAGE: GE Reports





26


Material Selection (Additive)





– Compare needed properties with the 359 metal results to select a few materials that look

promising

27


Senvol database search 8 Aug 2016 5PM EDT http://senvol.com/5_material-search/

http://senvol.com/5_material-search/






– Compare needed properties with 359 metal results to select a few materials that look

promising


– Analyze candidate materials in terms of tradeoffs of product performance, cost, and

availability


28


Use Casting Data as an approximation

29


Additive materials property data (CTE, YS, HCF) is “typically” between cast and wrought data

• LCF, FCGR , toughness, creep, environmental effects unknown







4. Development of Design Data

– Determine the key materials properties for the selected material and process to obtain statistically reliable measurements

– Machine parameter optimization

– Support Structure & design optimization

ASTM / AMS specifications

30


CATA Additive Materials - DMLM

Current– CoCrMo

– Stainless steels - 316L, 15-5PH, 17-4PH

– Nickel Superalloys – IN718

– Haynes 188

– Maraging steel

Near Future – Aluminum – A205

– Nickel Superalloys - Haynes 282

31

GE Proprietary Information

Summary & the additive future

• Feasibility of production AM established @ GE

• Game changing, high performance product

• Industrialization of supply base & GE

businesses via CATA

Keys to success:

• Materials & process selection

• Design data development

…..Exciting times to be in AM

“We are standing in front of a potential revolution in manufacturing.”

Michael IdelchikVP of Advanced Technologies, GRC

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