Brian A. Czapor 300 College Park Dayton, OH 45469-000 [email protected]
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Transcript of Brian A. Czapor 300 College Park Dayton, OH 45469-000 [email protected]
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Brian A. Czapor300 College Park
Dayton, OH [email protected]
Additive Manufacturing of Multi-Scale Composites
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Agenda
Introduction to Fused Deposition ManufacturingOhio Third Frontier (OTF) – Advanced Materials for Additive Manufacturing MaturationNational Additive Manufacturing Innovation Institute (NAMII) – Maturation of FDM Component Manufacturing
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Built on FDM Technology
Build Platform
FUSED DEPOSITION MODELLING
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Background – AM Technology
Process Model Build Remove Supportsand Use
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Material(click blue box to view more)
Characteristic
Versatile material
Static dissipative
Biocompatible (ISO-10993)
Translucent
High Impact Strength
High Tensile Strength
Biocompatible (ISO-10993)
FST Certification, High Mechanical
Thermal and Chemical Resistance
*Not a thermoplastic, alternate usage
Fortus Thermoplastics
Family
Polycarbonate
PPSF/PPU
ULTEM 9085
PC-ISO
PC-ABS
ABSi
ABS-M30i
ABS-M30
Soluble Supports*
ABS-ESD7
Fortus Solutions
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FDM Material Properties
PPSF
ABS
PCPC-ISO
Hea
t Def
lect
ion
[˚F]
Tensile Strength [KSI] @ AMB5 6 7 8 9 10
150
200
250
300
350
400
ULTEM 9085
PPSF
ABS
PC
PC-ISO
Flex
ural
Mod
ulus
[KS
I]8 10 12 14 16
300
310
320
330
340
350ULTEM
9085
Flexural Strength [KSI]
Flexible
Stiff
360
18
Strength vs Heat Deflection Flex Modulus vs Flex Strength
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MODIFIED NYLON FDM FILAMENT HAS 6.5X MODULUS INCREASE AND 2.5X STRENGTH INCREASE
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Ohio Third Frontier ProgramAdvanced Materials for Additive Manufacturing Maturation
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OTF - ADDITIVE MANUFACTURING
GE Aviation Engine Configurations
Lockheed/Northrop F -35Honda Acura NSX
Polymer powder CNF/CNT
Advanced Materials for Additive Manufacturing
Maturation
Leading Ohio’s Innovation
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Fused Deposition ModelingStratasys, Inc.
A KEY STRATEGIC ALLIANCE
UDRI and Stratasys have formed a partnership designed to accelerate development and transition of new FDM materials for aerospace and automotive applications.
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Supply Chain Developed for the OTF-IPP
AM - FDMStratasys
Scale-up CompoundPolyOne
FabricatorRP+M
Requirements / OEMGE Aviation
HondaLockheed
Prototype CompoundUDRI
Air ForceNASA Glenn
PolymerOhioEWI
Technology & Networking
Nominal 500 pound lots
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Program Status and Schedule
Ultem 1000 selected for aerospace applicationsCommercial chopped carbon fiber and CNF/CNT’s used for reinforcementsProperty goals for first 500 pound scale-up batch: tensile test, 25 ksi strength, 2 msi modulus.FDM feedstock recently manufactured using ULTEM 1000 and CF that meets dimensional requirements. Feedstock development is ongoing.
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National Additive Manufacturing Innovation Institute (NAMII)
Maturation of FDM Component Manufacturing
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Distribution A: Cleared for Public Release # 88ABW-2012-5792
GE AviationLockheed MartinThe Boeing Company
Maturation of FDM Component Manufacturing
Accelerating Innovation & Increasing U.S. Manufacturing Competitiveness
Northrop Grumman
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Distribution A: Cleared for Public Release # 88ABW-2012-5792
Objectives • Enable OEMs to productionize FDM Hardware• Raise Manufacturing Readiness Level (MRL) of
FDMTM technology for aerospace and defense applications from level 4 to level 7
• Build a platform for long-range technical and economic developments for Additive Manufacturing technology
Project Scope• Task 1: Design Allowables• Task 2: Certification Procedures• Task 3: Design Guide• Task 4: Validation• Task 5: Final Report
NAMII Project Scope
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Task 1 – Design Allowables
Phase I(FDM Parameter Investigation)
Phase II (B-Basis Allowables Testing)
Process Parameter Exploration• Influence on strength DOE’s• Influence on manufacturing yield DOE’s• Influence on manufacturing rate & cost DOE’s• Sub-element scoping
Down-Select DOE Parameters
Comprehensive Materials Database• Strengths (tensile / compression / shear)• Moduli (tensile / compression / shear)• Bearing Strength• Tension Creep• Fatigue• Thermal (expansion / specific heat / diffusivity)• Poisson's Ratio• Density
Phase III (Supplementary Testing)
Supplementary Testing• Test hardware representative sub-elements• Bolt holes, connections, thick wall, thin wall, tooling etc.• Chemical resistance
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FDM Design Considerations
Create 3D Model Print PartGreen Flag
Structural Defects
Raster +45/-45°
Repeating…
Slice 1 Slice 2 Slice 3
Raster 0°
Repeating…
Slice 1 Slice 2 Slice 3
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Distribution A: Cleared for Public Release # 88ABW-2012-5792
DOE Sustainability Goals• Reduced lifecycle energy cost of the FDMTM process compared to parts manufactured using the alternate
conventional manufacturing process• Energy efficiency of FDMTM manufacturing as compared to parts manufactured using the alternate
conventional manufacturing process• Environmental sustainability impacts of FDMTM manufacturing
Industry Energy Savings• Reductions in material use compared to existing conventional manufacturing process.• Energy savings from material substitution, including reduction in fuel burn as a result of light-weighting
structures.• Process energy of FDMTM manufacturing a part as compared to the conventional manufacturing process.• Reduction in water use as a result of using FDMTM manufacturing as compared to the conventional
manufacturing process.• Plant energy savings due to process overhaul resulting from utilization of FDMTM manufacturing compared to
the conventional manufacturing process.
Sustainability Overview
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Distribution A: Cleared for Public Release # 88ABW-2012-5792
Secondary Education• Module presented during summer camps held at the University of Dayton: focus on introducing high school students
to careers in engineering.
Community College• Design Guide data & non-proprietary processes share with Sinclair Community College, Dayton, Ohio, which operates
the National Center for Manufacturing Education (NCME) for workforce training in advanced manufacturing.
Undergraduate Education• University of Dayton undergraduate students will be employed to work on testing and design guide development
phases; Inclusion of material in required seminar series for undergraduate mechanical and chemical engineering students.
Graduate Education• Design guidelines to be incorporated into new graduate course on AM at University of Dayton which will cover
analysis, design, and processing of structures using Additive Manufacturing.
Workforce• Contribution to the creation of an engineering pipeline that is prepared to meet the demands of designing
for Additive Manufacturing technologies.
Workforce and Educational Outreach
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Outcome of NAMII Program
Members of NAMII have the rights to use the IP to generate economic developmentUDRI can use the IP to help design components for industry clientsRP+M can produce the components in Ohio
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Future Development Opportunities
TOOLING FOR COMPOSITES *(courtesy of Stratasys)
FDM Composite Applications
Patterns Lay Up / Cure Tools Consumable Cores Digitally Coordinated Tool Families
Trim
Too
l
Fem
ale
Tool
ing
Pat
tern
Mol
d
Mal
e La
yup
Tool
Mas
ter P
atte
rn
Nev
ada
Com
posi
te C
TE M
atch
ed T
ool
LMT
Tool
ing
Pre
preg
with
FD
M C
onsu
mab
le C
ore
Desired Part CAD Designed Tooling
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Sheet Metal ToolingDemonstrated Application
• Demonstrated Applications– Hydro Forming– Rubber Pad Forming
• Demonstrated Tooling– Female, Blow Down Tools– Male Tools– Punch Tools– Pressure Intensifiers– Matched Male & Female Tools– Back Filled Tools
• Demonstrated Conditions:– Range of alloys and thickness tested– Demonstrated forming pressures up to 10KSI– Variety of tools >100 cycles, some > 500 cycles– Large jointed tools have been tested
Hydro Form Rubber Pad
MaleBlow Down Blow Down
Pressure Intensifiers
Punch
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Questions?
Distribution A: Cleared for Public Release # 88ABW-2012-5792