metal additive manufacturing ksb am consulting and

© Copyright KSB SE & Co. KGaA 2021

Metal Additive ManufacturingKSB AM Consulting and Manufacturing: Support for the Nuclear Industry to gain the benefits of Metal AMChristine Burow August 25, 2021

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Outline

1. KSB Group and Additive Manufacturing (AM)

2. Additive manufacturing examples

3. Quality Assurance for additive manufacturing

I AM @ KSB I August 2021 I

KSB Group 15,600 employees 100+ countries Sales revenue 2019

€ 2,400 million

1. One of the leading global producers of pumps, valves, motors and related service offerings, for nuclear industry and many other industries

2. Expertise in metal additive manufacturing

• For internal product development and production

• For external clients for any application

3 I AM @ KSB I August 2021 I

4

Outline

1. KSB Group


3. Quality Assurance for additive manufacturing


How can adoption of additive manufacturing be accelerated?

- Wait or start? Our experience is sooner the start, sooner and greater benefits

- AM will continually evolve, when is it ready enough?

- AM is an additional tool, not a replacement for conventional

- Need experience with AM to be widespread within the organization and across organizations

- Overcome inertia

- Study, but then try a part, learn and repeat


BENEFITS of additive

manufacturing

INERTIA from the existing

systems, procedures and

approaches

What to do?

Watch and wait for everything to

be ‘done’

Start

Interest in AM

AM business case:48-hour impeller

Challenge: • Nuclear power plant needed

an impeller urgently

Solution: • AM part delivered in 48 hours

AM quality management process already in place

CAD designed, printed by LPBF, machined, tested and delivered

Benefit• Traditional manufacturing

would have taken much longer and cost much more


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Challenge• Framatome wanted to leverage additive manufacturing for

fuel assembly components with complex geometries for fuel assembly program

• How to source components that meet their high-quality standard requirements

Solution• Close partnership with KSB to develop program to qualify

AM part suppliers• They will qualify KSB AM department as an approved

supplier for Framatome’s fuel assembly parts by LPBF

Benefits• With quality assurance program in place, Framatome can

confidently gain the performance benefits of complex designs, which can only be cost-effectively produced by additive manufacturing


AM business case:Reduced manufacturing cost for complex geometry Fuel assembly components

Upper tie plate grid

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Additive Manufacturing for Fuel Pump Development

Additive manufacturing:• Design phase: product development – samples for testing design concepts• Testing phase: prototype production• Manufacturing: each component will be assessed for optimal manufacturing strategy - AM

will be considered alongside forging and casting• Manufacturing considerations: materials, design complexity, specs, standards, …


Chemical industry exampleImportance of close cooperation with customers

Development of partnerships

Testing of LPBF impeller in comparison with cast impeller at BASF, Ludwigshafen

Successful multi-year field test


AM business case:Cost saving from complexity

conventional housing with welded cooling jacket topology optimized design (CAD: Siemens NX)

production tolerances with offsets for areas tobe machined (red)

fully assembled pump

Challenge: • European chemical plant

needed a more efficient pump for a high temperature acid application

Solution: • AM can produce parts with

complexity not possible with other manufacturing processes

• Design for additive: Topologyoptimized spiral pump housing

• Pressure boundary part


Chemical plant customerbenefits with new pump housing:

• stiffness enhanced with exo-skeleton

• optimized flow of force

• weight-optimization: 57 %(30 kg → 13 kg)

• all-over cooling / heating

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Photos: Additively manuctured pump housing with integrated cooling

Designed for additive manufacturing: New and betterperforming design which cannot be casted

Pump housing printed in one piece on a laser powderbed powder fusion machine at KSB‘s additive manufacturing centre in Pegnitz, Germany

Developed in partnership with the customer

Pumped installed at a chemical plant in Europe

AM business case:Cost saving from complexity


machined machined

additive manufactured (SLM)additive manufactured (SLM)

AM business case:Cost saving from AM serial production

Challenge: • KSB was externally sourcing a

316L machined part, a mechanical seal flush connection

• Needed a lower cost part without compromising quality

Solution: • AM can produce quality parts

for serial production at a lower cost

• Weight reduced 208g to 130g• 84% cost savings


Mechanical seal flush connection 92 parts per build job on

the EOS 400-4 Produced in-house with

84% costs savings Several 100 parts / year

AM business case:Cost saving from AM serial production


Outline

1. KSB Group


3. Quality Assurance for Additive Manufacturing


Process chain for Laser Powder BedFusion (LPBF)

Managing the completeprocess chain is critical

Additive manufacturingprocess is „only“ one part ofthe complete process chain

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pre-process

in-process

post-process

componentdesign

CAD design, topology

stress analysis

life and CFD analysis

partpositioning

supportstructures

datapreparation

QM, certificates

cleaning, depowdering

heattreatment

cutting partsfrom plate

blasting, polishing, etc.

machining, etc.

AM process

machine setup

powderpreparation powder

required specs


KSB Quality Assurance Program

• Part testing is critical and is complemented by: Comprehensive internal quality

program that covers every step from powder to post-processing

In-house testing and expertise Participating in standards

development and being ready to comply

Certification by TÜV Süd for pressure boundary parts

Long-term stable operation with ongoing testing to assure performance and resolve any performance deviations quickly

KSB Quality Assurance

for AdditivelyManufactured

Parts

Part testing: A. Non-

destructive testsB. Coupons for

destructivetesting

Comprehensiveinternal quality

program

In-house analytical testinglab – ISO 17025

Standards:ISO, ASTM, ASME, API, CSA, etc.

Certification for pressure parts

by AM fromTÜV Süd

Long-term stable operation


KSB first to achievecertification for pressure boundaryparts, 1.4404 (316L)

Certification process by TÜV Süd:• Company• Material• Machine• Print location on the build

platform• Print orientation• Print parameters• Test coupons for destructive

verification• …https://www.tuvsud.com/en/press-and-media/2019/august/tuv-sud-issues-first-ever-certificate-for-additive-manufacturing-of-materials

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End-users are assured of AM part safety

Pressure equipment must comply with the requirements of QM

system in line with the EU Pressure Equipment

Directive 2014/68/EU

TÜV Süd provides testing, certification, auditing and advisory services, including ASME code services for nuclear www.tuvsud.com I AM @ KSB I August 2021 I

https://www.tuvsud.com/en/press-and-media/2019/august/tuv-sud-issues-first-ever-certificate-for-additive-manufacturing-of-materials

http://www.tuvsud.com/

Quality Assurance Material testingin KSB’s ISO 17025 certified lab

• Test coupons across entire build chamber Mechanical and

chemical tests to demonstrate uniformity, including densities> 99,8%

• Routine testing to maintain long-term statistics to ensure stable operation

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- 552 551 551 554

546 552 549 554 554

551 557 559 558 552

549 552 555 553 553

550 550 555 554 -Example: Test coupons across build chamberTensile strength Rm /MPa

condition RP0,2/MPa

Rm /MPa AS /% KV /J

KSB Noribeam® 316L additive >275 >515 >40 >60

DIN EN 10088-3 wrought >200 500-700 >30 >60

DIN EN 10213 cast - 440-640 >30 >60

ASTM A479 wrought >170 >485 >30 -

ASTM F3184 additive >205 >515 >30 -

0

100

200

300

400

500

600

Rpo,

2 /M

Pa

Yield strength Rp0,2solution annealed

0°

45°

90°

2016 2017 2018 20202019

Example: Long-term data


Materials qualityAlloy 625

• Material Data Sheet: Noribeam® Alloy 625

• ASTM F3056standard for SLM Alloy 625

Other alloys available or in development:• Noribeam® 316L • Noribeam® Alloy 718• Noribeam® 17-4PH• Noribeam® 1.4462 – Duplex• Noribeam® Alloy 59• And others ….

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condition RP0,2 /MPa Rm /MPa AS /% KV /J

KSB Noribeam® Alloy

625additive >450 >750 >30 >60

DIN EN 10095 wrought >345 >760 >25 -

ASTM A494 cast >275 >485 >25 -

ASTM F3056 additive >275 >485 >30 -

Noribeam® Alloy 625 microstructure

Noribeam® Alloy 625 samples and test coupons


Quality AssuranceApproval for SaleKSB sales approval of AM parts requires:

• Material data sheets (MDS)

• Inspection plans

• Legal review

• Insurance secured

Customers are assured of part quality


Customer benefit:AM consulting and manufacturingWhy KSB as your partner?• Expertise in complete process:

R&D, design, manufacturing and quality assurance

• Represented in international AM standardization groups

• First company certified for AM of pressure boundary parts, by TÜV Süd

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KSB AM consulting

and production

Standardization DIN / CEN / ISO TC 261

ASTM F42

ASME BPVC

API

Accredited test lab

ISO/IEC 17025

Work groups AM VDMA

DGM expert committee AM

Bavaria: Bay. Innovativ, ...

Testing of AM parts in industrial environment BASF, Framatome, …

Consultancy technology screening

design (DfAM)

process reliability

materials R&D development of

materials for AM

international research projects

Manufacturing own machines

– metal

– polymer (FDM)

external partners

Auditing of AM process and parts partner: TÜV Süd


Thank you for your interest!

Questions?

Christine [email protected]

Website: https://www.ksb.com/en-global/company/innovation/additive-manufacturing

© Copyright KSB SE & Co. KGaA 2021

mailto:[email protected]

https://www.ksb.com/en-global/company/innovation/additive-manufacturing

Technology that makes its mark

Energy ConversionEfficient and Reliable OperationKSB is the global market leader for pumps and valves for energy supply applications. • Fossil-fuelled power stations• Combined cycle power stations• Renewable energy plants• Nuclear power plants Class 1, 2, 3 and non-

classified pumps and valves according to all relevant standards

KSB products installed in over 270 NPPs globally


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The following slides are additional examples of business cases for additive manufacturing.


AM business case:Shorten development time for pump design optimization

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Challenge: • Nuclear power plant with

challenging requirements for operating range for the charging system pumps, requiring physical verification tests

Solution• Impellers and diffusers required

for hydraulic tests were LPBF printed in days and were tested in full size test system within a week

Benefits• Required results delivered in

weeks, rather than months


KSB RVMVertical multistage barrel pull-out pump

AM business case:KSB seal coverextended sizes

model classes for different shaftdiameters / seals

• all-over cooling / heating

• external fluid circulation possible

• complete emptying of cooling/heating chamber, noventilation system needed

• operating pressures up to 40 bar

• models for different mechanicalseals

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model classes – seal cover part on substrate plate with almost no supports

high pressure testsassemblyI AM @ KSB I August 2021 I

AM business case:New products in serial production

Leakage detector Eta SYT

Measures leakage of mechanical pump seal

Product designed for additive manufacturing

• Compact design, maximum integration of functions

• Production by AM is lowest cost option

• 100s / year

R&D, first design studies ReDesign for Hybrid AM

finished part and assemblyfinal design in serial production28 I AM @ KSB I August 2021 I

Leckage detectorEta SYT

Pump seal monitoring and diagnostics

Benefits:

• displaying the leakage rate

• information about sealingwear / damage, enablingpreventative maintenanceon pump seal

• easy to install


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AM business case:Obsolete component replacement


Challenge • Nuclear power plant in Eastern Europe • Plant needed to replace casings on 6 pumps, and did not want to replace the entire

pump• Plant was no longer able to source the needed components

Solution• Additive manufacturing of the molds (binder jet with sand), followed by standard

casting and finishing (Rapid Casting)• KSB established a detailed Quality Control Plan• Customer provided 3D files • KSB created files for printing the molds, including designing offsets for areas

to be machined• KSB used sand binder jetting machine to print the molds followed by casting,

machining and inspection

Benefit• Lower costs• Much faster, weeks rather than months

AM at KSBRapid Casting with Binder JetPrinting of molds and cores with ExOne

• Printing binder onto sand

• Much faster compared toconventional

• Almost no post-processing

• High flexibility for production of prototypes orlow volume series

Located at KSB Standard Alloys, and KSB foundries in Germany31 I AM @ KSB I August 2021 I

metal additive manufacturing ksb am consulting and

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