CSIRO Metallic Additive Manufacturing High Performance ... · MANUFACTURING FLAGSHIP CSIRO Metallic...
Transcript of CSIRO Metallic Additive Manufacturing High Performance ... · MANUFACTURING FLAGSHIP CSIRO Metallic...
MANUFACTURING FLAGSHIP
CSIRO Metallic Additive Manufacturing High Performance Metal Program
Chad Henry | Metallic Additive Manufacturing
Sept 2014
Comprehensive Overview and Findings on 3D Printing for Construction CMIC 2014
Lab 22 - The Australian 3D Printing Centre for Innovation and Production
(d)
• CSIRO has an open house policy to Industry and for R&D
• De-risk to aid in Industry Adoption and Growth • Access our capital equipment • Access our trained operators
• Trial and Learn Metallic AM
• Access us for assistance on Developing Business Cases and Positive ROI’s • Access us for assistance on design (or re-designing) to take advantage of 3DP
Design Freedoms • Access us for assistance on material science solutions • Learn first-hand
• Technologies (next slides)
• Powder Beds – E-Beam and Laser • Powder Spray – 3D Deposition, Cold Spray, and Laser Cladding • Sand Printing – For Metallic Castings
Arcam Model A1 - Electron Beam Melting (EBM) - Powder Bed - Vacuum - Elevated Temp - Low Distortion - Excellent Properties - Model A1 - 200mm x 200mm x 180mm - Materials - Ti and Ti Alloys - CoCr - Nickel Alloys (Inconel) - Steel Alloys - Others??? - CSRIO Level 3 Training
E-Beam AM Equipment
Concept Laser M2 cusing • Laser fusion powder bed • 250 x 250 x 280 (mm) chamber build volume • 400W beam power • Very good part roughness Ra 9-12mm, Rz 35-
40mm (Ti-64) • <55cm3/h build rate (Ti-64) • Inert gas environment • Standard LaserCUSING materials include:
Stainless steel 1.4404 / CL 20ES Aluminium alloy AlSi12 / CL 30AL Aluminium alloy AlSi10Mg / CL 31AL Titanium alloy Ti6Al4V / CL 40TI Titanium alloy Ti6Al4V ELI / CL 41TI ELI Hot-forming steel 1.2709 / CL 50WS Rust-free hot-forming steel CL 91RW Nickel-based alloy Inconel 718 / CL 100NB Cobalt/chrome alloy remanium star CL
• Moderate residual stress • Prototyping, design, customising, light-
weighting
Optomec LENS MR-7 • IPG Fibre Laser “blown powder” • 300 x 300 x 300 (mm) chamber build volume • 500W beam power • Two powder feeder (layered composition profiles) • Part roughness Ra 20-50mm (Rz 150-300mm) • 22cm3/h build rate (Ti-64) (much higher build rates for
other LENS variants • High purity inert gas (O2 ≤ 10 ppm) • High residual stress • Optomec materials: *Non-standard Materials used in R&D
• Repair, prototyping, design, customising, light-weighting, alloy design, composite materials
Titanium Nickel Tool Steel
CP Ti, Ti 6-4, Ti 6-2-4-2
Ti 6-2-4-6*, Ti 48-2-2*,
Ti 22AI-23Nb*
IN625,IN718,IN690*, Hastelloy
X*, Waspalloy, MarM247*,
Rene 142*
H13, S7, A-2*
Stainless Steel Refractories Composites
13-8, 17-4, 304, 316, 410,420,
15-5PH*, AM355*, 309*, 416* W*, Mo*, N* TiC*, WC, CrC*
Cobalt Aluminum Copper
Stellite 21 4047 GRCop-84*, Cu-Ni*
Plasma Giken PCS-1000
Cold Spray Technologies
CGT Kinetiks 4000
Voxeljet
Manufacturing with Lasers & Asset Maintenance
High power laser facilities 4 kW fibre delivery diode laser Various beam shapes and sizes Closed loop temperature control Multi-axis robot Twin hopper powder delivery PTA system Provision for in-situ alloy deposition and/or
hardfacing
Services • R&D and procedure development for wear
resistant surface build up • Extensive knowledge in understanding in-service
wear modes • Expertise in low cost alloy selection and
development for crack-free deposition • Multi-physics modelling to predict cracking and
service life • Power generation, petrochemical, coal and
mineral processing, food processing
Fit-for-service assessment • Wide range of wear testing facilities for QA
(unique!) • All tests simulate field conditions for laboratory
evaluation
Courtesy Dr. Rob Sharman, GKN Aerospace
Must Understand ... One Size Does Not Fit All
Material
Build Volume
Rate
Design and Unitization
Unique Shapes/Details (free)
Surface Finish
Inspection
Laser vs.
E-Beam vs.
Solid State
Powder Bed vs.
Powder Spray vs.
Wire Fed
Product Requirements Manufacturing Processes
Production
Prototyping (form, fit, function)
Tooling
Rapid Design
Shop Aids
All for ...
Ti
Ni
Al
Metallic Additive Manufacturing Roadmap
Database for Production
•Ti 6Al 4V
Low Cost Feedstock
Distortion Control Management
In Situ Inspection Methods
Microstructure Manipulation
Additional Material Data
•Titanium, Steel or ?
Novel Titanium Materials
Wire Powder
(Bed or Spray)
Properties and Databases for Production
Ex Situ Powder Bed
Powder Manipulation
In Situ Modelling & Management
In Chamber Inspection Methods
Microstructure Manipulation
Novel Metallic Alloys
Additional Materials
Decrease final Component Cost
Increase the Application Space
Meltless Additive Manufacturing
Cold Spray
Additive Manufacturing Repair Coatings
Near Net Shape
Ti Pipe Seamless Continuous
Ti Bike Frame
Ti Coupler
Composite Dies
Defects Repair
Corrosion Resistant
Electroplating Replacement
Design Modification
Wear Resistant
Biofowling
Composite Coatings
Bulk
Billet
Forging Pre forms
Reclamation
Materials
Metals & Alloys: Ti, Ni, Fe, Cu, Al, Sn Ceramics + Metals: Al + TiB2 Polymers
CSIRO Additive Manufacturing ... The 2+1 Strategy
Modelling and Simulation
Feedstock and Powder
New Material Development
Distortion Management
Novel Sources
Physical Modification
The AX - Powder Flow
Industry Engagement
AM Network
Build, Consult, SIEF
Derived from Casting and
Welding
Derived from Cold Spray,
TiRO, and Alloys Processing
3D Printing for the Construction Industry My Findings (Based on Digging Around on the Web)
Companies 3D Printing for Construction
- Contour Crafting (upcoming slides)
- Suzhou Yingchuang Science and Trade Development Co (upcoming slide)
- Shanghai WinSun Decoration Design Engineering
- DUS Architects
- WikiHouse
My Findings (Based on Digging Around on the Web)
Materials
- From Waste (Plastic, Construction, Industrial, Glass)
- Sand, Gravel, Dirt (with Water and Binder)
D-Shape (Sandstone)
- Printed Hollow (for Reinforcement, Insulation, Plumbing, etc)
- Printing Construction Hardware (Fasteners, Connectors, etc)
Arup (3DP Metallic Nodes for Lightweight Material Construction)
3D Printing for the Construction Industry
My Findings (Based on Digging Around on the Web)
Printers
- Material and Deposition Technologies – hard part
G.tecz
- Frames and Movement Programming – easy part
BetAbram
3D Printing for the Construction Industry
Contour Crafting http://www.contourcrafting.org/
Contour Crafting http://www.contourcrafting.org/
Suzhou Yingchuang Science and Trade Development Co
http://constructionglobal.com/video/33/3D-Printer-Constructs-10-Buildings-in-One-Day-from-Recycled-Materials
Titanium Technologies and Lab 22 Achievements • Since Sept of 2012, Lab 22 has 3D printed over 700 pieces in titanium from over 150 files
for 52 entities in 130 total Arcam EBM builds. That is an average of 1.5 builds per week. Of these, 54% have been for industry, 21% have been for R&D, and 25% have been for marketing, media, and education. In 2012 we hosted 134 visitors, in 2013 it was 216, and at the end of the first quarter of 2014 it was over 100 (total >450).
• MPs - Adam Bandt, Julie Bishop, Anna Burke, Greg Combet
• EVP of the Lockheed Martin F-35 Joint Strike Fighter Program, Tom Burbage
• Lab 22 Chosen to be a Preferred Service Provider for Arcam EBM
• AM Fish Anchors Implemented (upcoming slide)
• AM Bicycle with Flying Machine (upcoming slide)
• AM Mining Drill Bit Holders
• AM Bugs (upcoming slide)
• AM Orthotic Horse Shoes
• AM Design Optimisation via student projects (upcoming slide)
• AM of Aero Engine Demonstration with SIEF (upcoming slide)
• AM Network (upcoming slide)
Rapid Design Iteration
Manufacture all of the design candidates at once in a single build.
Inexpensive physical testing was employed to make decisions.
Making the Business Case with Flying Machine
Three Conditions Together Made the Product Marketable Design Change for Every Customer Possible
Off-The-Shelf Tubing
The Novelty http://www.flyingmachine.com.au/2014/01/3d-printed-titanium-bike-of-the-future/ http://www.youtube.com/watch?v=_gOd3w69kh4
Topology and Design Optimisation
Same Performance ... Less Weight
Iteration 1 Iteration 6 Iteration 9 Iteration 13
Iteration 16 Iteration 20 Iteration 25 Iteration 29
SIEF Aero-engine AM Project with Monash University
I like big bugs ...
Sciaky DM Process (and CSIRO Modeling and Simulation)
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Sciaky DM Process and CSIRO Modeling and Simulation
Electron Beam Freeform Fabrication (EBFFF) is an additive manufacturing (AM) process that works efficiently with a variety of weldable alloys.
Residual stress and shape distortion are inherent features of AM, particularly at high deposition rates, as a result of the large thermal gradients.
Fabricated parts are stress-relief heat treated both during and after deposition to help relieve stresses, which adds to cycle time and the overall cost.
CSIRO has established and implemented modelling techniques to predict distortion and stresses during and after deposition by EBFFF as a first step towards developing an active distortion management system.
The model can be employed in a predictive mode to investigate the effects of various tool paths and process parameters on the (post-manufacturing) part distortion and residual stress.
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FEA Model of a T-shaped part - Substrate plate: 600 mm long, 12.5 mm thick, 100 mm wide - Deposit: 51 mm tall, 11.8 mm wide, single bead - Process parameters:
• Speed: 12.7 mm/s • EB power: 4.3 kW for preheat and 8.6 kW for deposit • 18 layers per side; each layer is 2.83 mm high • Substrate and wire have initial temperature of 30°C
Model of the part
12
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T-shaped part built by EBFFF
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Neutron Diffraction Used to Improve Results
200 MPa
- 135.2 MPa
- 94 MPa
235 MPa
Prediction
Residual Stress by ND (ANSTO)
The predictive tool has been recently refined further by using an updated material model.
The predicted stress distribution is in excellent agreement with residual stress measurements by neutron diffraction at ANSTO.
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Significance of the Predictive Tool
Cost saving ‒ The predictive tool can perform virtual EBFFF. We can run a series of
Design of Experiments (DoE) without having to consume materials and cost
‒ The tool can predict the expected distortion when deposition is made on a pre-bent plate or when insulated clamps are used
‒ Combinatorial effects such as the effect of combining a substrate preheat with half the building speed and insulated clamps can be predicted.
Provides insight into the evolution of thermal and stress distribution during and post build
Identifies critical moments when defects such as cracks and/or excessive distortion may occur
The application of the predictive tool can be extended to large deposition (wire or blown powder) and other AM processes
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Future Today
50% of the cost in operation is labour 20% is depreciation (i.e. Cost of the unit)
If the equipment cost comes down and labour gets more productive Powder becomes the mostly costly component of AM
$ $
Operational Cost Considerations of Additive Manufacturing – Why work on materials?
Where is “Cheap” Titanium Powder???
Armstrong Process – Cristal
FFC Process – Metalysis
TiRO
Alloys
CSIR
New Zealand
Hydride DeHydride
ADMA
China
Powder, Particles and Aggregate
Size
Size Range
Flow
Density
Alter Either or Both: - Improve the Inexpensive Powder - Alter the AM Equipment Operating Parameters
CSIRO Powder Manipulation
50
25
>1000 600 – 1000
400 – 600
250 – 400
150 – 250
100 – 150
75 – 100
45 – 75
25 – 45
< 25
E-Beam AM
Laser AM, Cold Spray
Weight pct
Particle Size in mm
Before
After
Powder hopper 25 kg of Ti each
Rake regulator
Powder table
Build tank
Rake
Optical Camera
Heat shield
Universal Powder Bed External laboratory bench-top unit to allow for studies of how low cost input material actually behaves without being encumbered by a full AM system.
Cold Spray Technology
CSIRO has developed a new solid-state additive manufacturing process using Cold Spray Technology to produce bulk 3D forms and coatings from powder feed stock that is both metallic and non-metallic.
Process and applications
• During cold spray, powder particles (typically 10 to 50 µm) are accelerated to high velocities (200 to 1200 m.s-1) by a supersonic compressed gas jet at temperatures well below their melting point. As the particles impact the surface they undergo large plastic deformations, consolidating to produce localised forge bonding, at spray rates up to several 100 g/min.
• The deposition efficiency is also very high, above 95% in most
cases.
• The technology is more efficient, cost effective and environmentally friendly and can be applied to the aerospace, biomedical, oil and gas, power generation, motor sport, petrochemical and electronics industries.
• Our 3D simulation outcomes has proved to be highly cost effective for optimization of the cold spray parameters.
Research at CSIRO
Preforms, Billet and Pipe
Coatings on polymer and metal
3D manufacturing of bulk billet and preforms
Repair and modification techniques for lightweight aerospace alloys
Improved biocompatible coatings for medical implants
Thick metallic coatings for thermally sensitive substrates
Ballistic protection composite coating for defence and space application
Anti-fouling coatings for marine application
Advantages of Cold Spray
Solid-state deposition - no melting therefore no solidification defects
No vacuum required for oxygen
sensitive materials such as Ti Environmentally friendly process Cost effective - capital and
operation
Cold Sprayed CP Ti
Conventional CP Ti
Cold Spray for Pre-forms
Continuous Billet Production
CSIRO has the capability to produce 45 kg/hr of product via cold spray
MISSION – Coordinate additive manufacturing for Australia.
The Additive Manufacturing Network is ... - Public with participation from academia, industry, and government welcome. - To be self governed once established. - Well poised to be a self supporting national asset.
GOAL – Market globally Australian additive manufacturing capability, for both technology R&D and production for profit in industry. - Publish who has what equipment and corresponding capabilities. - Create confidence in global customers investigating Australian potential. - Collaborate efficiently for new Australian business, creating greater total revenues in which to participate. - Connect those with a need to those with a solution.
The Additive Manufacturing Network The hub for all things additive.
Per the mission statement: co·or·di·nate (verb) - The act of harmoniously combining and interacting items to function effectively.
GOAL – Facilitate communication within Australia on additive manufacturing. - Use a network infrastructure, including focused working groups, to conduct regular face-to-face and web meetings. - Understand others’ roadmaps and strategies. - Coordinate and be efficient on resolving issues. - Achieve a comprehensive and non-redundant R&D project portfolio within the country. - Accelerate the deployment of technologies to industry.
Status - A survey of industry was taken and interest existed. - Kickoff Meeting - Inaugural Committee of 10. - Now Partnered with (i.e. handed over to) AMTIL.
For further information, please contact: Chad Henry CSIRO Additive Manufacturing Operations Manager Titanium Technologies Stream Leader Gate 7 Normanby Road, Clayton 3168 VIC Australia +61 3 9545 7844 (office) [email protected]
Thank you CSIRO Manufacturing Flagship High Performance Metal Industry ore to more Chad Henry Metallic Additive Manufacturing +61 (03) 9545 7844 [email protected]
FUTURE MANUFACTURING FLAGSHIP