AM Opportunities at UTAS - EWI · AM Opportunities at UTAS Robert Bianco, PhD Manager, Materials...
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AM Opportunities at UTAS Robert Bianco, PhD Manager, Materials R&D This document is approved for public release. This document or file does not contain export controlled technology or technical data. July16, 2015
Transcript of AM Opportunities at UTAS - EWI · AM Opportunities at UTAS Robert Bianco, PhD Manager, Materials...
AM Opportunities at UTAS
Robert Bianco, PhD
Manager, Materials R&D
This document is approved for public release. This document or file
does not contain export controlled technology or technical data.
July16, 2015
UTAS OPPORTUNITIES IN AM
UTC/UTAS Overview
UTAS Opportunities and Strategy
AM Methodology
Development Lab
Design for AM
Process Modeling
External Funding
Future Needs
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Outline
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4/15/2015
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UTC PROPULSION & AEROSPACE SYSTEMS UTC BUILDING & INDUSTRIAL SYSTEMS
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Sales: Type & Geography
45%
20%
35%
Military
Aerospace
& Space
Commercial
Aerospace
Commercial
& Industrial
42% 58%
TYPE
Original
Equipment
Manufacturing
Aftermarket
GEOGRAPHY
38%
27%
20%
15% 0%
Asia Pacific
Europe
United States
Other
2014 net sales $65.1 billion
UTC PERFORMANCE
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2/24/2015 4/15/2015
• 8 strategic business units
• ~42,000 employees
• ~150 locations
July 2012 – United Technologies formed
UTC Aerospace Systems
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UTC AEROSPACE SYSTEMS
Global program execution
Bombardier Global
7000/8000
Airbus A350XWB
Airbus A320neo
Gulfstream G650
Mitsubishi MRJ
Bombardier
CSeries
COMAC C919
Irkut MC-21
Embraer KC-390
Airbus A400M
Lockheed F-35
Sikorsky CH-53K
Embraer E2
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Delighting customers
Global, 24/7 service
Game-changing technologies
Committed to perfect delivery and quality
Right attitude
Power Generation &
Distribution Systems
Landing
Gear
Fuel
Systems
Pilot/Crew
Seats
Wheels &
Brakes
Cockpit
Controls
Escape Slides
Nacelles
Pylons
Cargo
Systems
Actuation
Systems
Fire & Overheat
Protection Systems
Exterior/Interior
Lighting
Ice Detection/
Prevention
Vehicle health
management
Engine Controls
& Components
Air Management
Systems
Sensors
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UTC AEROSPACE SYSTEMS (UTAS)
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8 SBUs & 87 product lines
Engine & Environmental Control Systems Environmental control systems
Bleed air systems
Cabin pressure systems
Ventilation systems
Inert gas generating systems
Electronic engine controls
Engine control systems
Engine and nozzle actuation Gearboxes
Fuel metering units
Fuel pumps
Aero gas turbine components
Airfoils and rotating components
Drive shafts and couplings
Electric Systems Generation Primary distribution Secondary distribution Emergency power, motors and drives
Sensors & Integrated Systems Air Data & SmartProbe® Systems
Engine sensors and sensing suites
Fuel level and management systems
Fire detection and protection systems
Guidance, navigation and control
Health management systems
Ice detection and protection systems
Inertial sensors and rate gyros
Mission data recorders
Potable water systems
Rescue hoist and cargo winches
Smartdisplay® EFB systems
Specialty heated products
Temperature sensors
Video surveillance systems
ISR & Space Systems Reconnaissance systems
Airborne laser warning
Ground systems
NASA space suit/life support systems
Environmental monitoring
and control, mechanical
systems, thermal control
systems
Aerostructures Nacelle systems
Flight control surfaces
APU tail cones
Acoustic materials, coatings & structures
Interiors Cargo handling systems
Evacuation systems
Propulsion systems
Specialty seating
Lighting systems
Actuation and Propeller Systems Primary and secondary flight controls
Helicopter rotor actuation
Nacelle actuation
Utility actuation
Propeller systems with composite blades
and electronic controls
Cockpit controls
Cabin equipment
Trimmable Horizontal Stabilizer Actuators (THSA)
Landing Systems Landing gear
Wheels
Brakes
Brake control systems
High temp composites
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ADDITIVE TECHNOLOGY ROADMAP
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Cross-functional team across SBUs
Impellers & Rotors Fuel Injectors Housings Brackets
Part Families
Heat Exchangers
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BUSINESS CASE
Lead time reduction
Part count reduction
Buy-to-fly reduction
Manufacturing cost reduction
Optimized design for performance/weight reduction
Material and energy usage reduction
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Perceived Benefits
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ADDITIVE MANUFACTURING
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Materials of interest
Nickel alloys
Titanium and aluminum alloys
Cobalt and iron alloys
Thermoplastics
Additive Manufacturing Technologies
Powder Bed Fusion
Laser Powder Bed
Electron Beam Melting
Powder Deposition
Laser
Cold Spray
Consolidation
Ultrasonic
Extrusion
FDM
Printing
Direct Write
Hybrid
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ADDITIVE MANUFACTURING
Materials lab capabilities upgraded and enhanced including new AM cell
3DSystems ProX 300, L-PBF machine and Fortus 450mc FDM machine
installed
Development Lab
Additive Manufacturing
Analytical Chemistry
Lobby
Mechanical Test
Microscopy
Thermal
Processing
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ADDITIVE PROCESS FLOW
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Part Builds HIP & Heat Treat
Quality & Inspection Finishing Rig & Engine Tests
Build Parameters Powder Quality Design Allowables
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ADDITIVE MANUFACTURING
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OEM parts
Fuel Injector Impellers/Rotors Part design and builds
Material characterization
Post processing and impact
on properties
Process control & variability
Non-destructive methods
Designing for additive
manufacturing
NDE and Measurement Techniques
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ADDITIVE MANUFACTURING
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Laser additive repair
Repair of damaged fuel nozzles
Integrated 3D scan, repair and
CNC machining
Characterization of mechanical
behavior and properties
Source: Rapid 2012, Donovan (UTC Aerospace Systems), Xue & Li, NRC Canada
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DESIGN FOR ADDITIVE
Topology optimization determines load path for minimum
material configuration
Rig testing confirms FEA analysis of strength margin
Up to a 50% weight savings possible
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Topology Optimization
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Design Space FEA Model Optimized Geometry
PHYSICS BASED MODELING
Developing physics based understanding of key process parameters
Defining impact and control of parameters to guide spatially varying geometry
Using validated models to run virtual DOEs for new part families
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EXTERNAL FUNDING
AFRL / America Makes selects UTC team for additive heat exchanger
Focus on fundamental understanding of process parameters, surface finish and HX
performance
Team: UTRC (prime); subcontractors - UTAS, P&W, UCONN, Stratonics, and 3DSIM
UTC wins AFRL Additive Heat Exchanger contract
UTAS: HX design tool, builds and validation
UTRC: Modeling, Performance testing
Melt pool monitoring
Thermal imaging
Residual stress and distortion
Key process CTQs; Scan strategies
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TECHNOLOGY NEEDS
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Near Term (CY16)
Advanced NDT of AM Built Parts
For Internal Defects
For Entrapped Powder
Strategic Material Property Databases
High-Strength Steels
Fine-Grained, High Temperature Alloys
High Deposition Rate AM Techniques Without Loss in Precision
and Tolerance Control
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TECHNOLOGY NEEDS
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Near Term (CY17 and beyond)
Process Modeling for Improved Quality
Process/Microstructure/Performance Relationship
Grain Size/Morphology Control
Process Monitoring for Consistent Builds
LPBF Process Certification
Strategic Material Property Databases
High-Strength Al Alloys
High-Strength Ti Alloys
Sustainable Supply Chain
Nadcap Accreditation
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QUESTIONS
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UTAS POINTS OF CONTACT
Agnes Klucha
Program Manager, Research & Technology Partnerships
Office: (860) 654-9453
Email: [email protected]
Robert Bianco
Manager, Materials R&D
Office: (860) 654-1161
Email: [email protected]
Innovation and Technology
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