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Industrialisation of Additive ManufacturingSiemens Corporate Technology | March 2016
Additive World Conference; March 23rd, Eindhoven; NetherlandsMartin Schäfer
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Additive Manufacturing @ CT RTC MAT COA-DE
• General remarks Siemens and AM• AM process chain and opportunities• Applications and Industrialisation
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Managing Board
Customer-oriented organizationSetup as of October 1, 2014
Global presence and go-to-market of our businessesAmericas Europe and Africa C.I.S.1 and Middle East Asia and Australia
Powerand Gas
WindPower andRenewables
EnergyManagement
BuildingTechnologies
Mobility DigitalFactory
ProcessIndustriesand Drives
Power GenerationServices
Corporate CoreCorporate Services
Healthcare(separatelymanaged withglobal supplychain)
FinancialServices
1 Commonwealth of Independent States.
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Our global presence –Partner to customers all over the world
A worldwide presence
lies at the heart of theSiemens brand – andthat goes for us as well.
That presence enablesus to quickly offertargeted solutions thatare tailored to regionalrequirements.
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Additive Manufacturing at Siemens
Prototyping Manufacturing
1989CT Start
~ 2007Laser Melting
2010Burner repairPower Generation
R&
DP
rodu
cts 2014
Spare partsDifferent Divisions
~ 2004Ceramic SLA
2002X-ray gridsHealthcare
1984Stereolithographie
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Different requirements
Consumer Industry
Different requirements
Source: makerbot.com Source: EOS
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“3D printing” versus Additive Manufacturing
Establishedmarket requirementsare driving theindustrialization ofAdditive Manufacturing
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Additive Manufacturing – Process Chain
Process chain Additive Manufacturing (AM)
Phase IDesign
Phase IIAM process
Phase IIIPostprocessing
Phase IVQuality assurance
Dataprepa-ration
Materialproduc-tion andsupply
AMprocess
Partsepa-ration
Heat &pressuretreat-ment
Machi-ning ofinter-faces
Surfacetreat-ment
Systemimple-men-tation
Test/Vali-dation:non-de-structive
Test/Vali-dation:destruc-tive
Cus-tomerfeed-back
Partconcept
AMprocessselection
Designoptimi-zation
Designformanu-facturing
Require-ments
Materialrecycling
Powderremoval
Machineconcept
Residualstress
Finishing(AFM, ...)
Nesting Behaviourat melting
Handling RF,thermal, …
Damagetolerance
FunctionRepro-dibility
CADBestsuited AMtechn.
Mech. Orientation CAD/CAM Grain size Scanstrategy
Removalfrom plate
Adjust-ment ofstructure
Grinding,turning, … REM Stiffness Ideas
generationAssemblyEngi-neering
Corrosion-protection
Processmonitoring
Function Supports(res. tress)
Parameter(power,…)
Sizedistribution Separation Coating CT Strength CIPData opti-
misationSimulationClosingof pores(HIP)
Joiningtechnology
EDM/ECM-pro-cessing …
Simulation Supports(thermal)
Compo-sition
Yieldstability
Powderremoval
Propertyimprovem.
Prep. forprocessing
Surfaceroughness Fatigue
Laser-Micro-processing…
Potential for unique features are based on the mastery of knowledge intensive process chain and theinteraction between manufacturing process, material condition and component properties
Source: European project MEGaFIT
Source: European project MEGaFIT
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Applications
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Additive Manufacturing forGas Turbine Applications:Opportunities and Challenges
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Power and Gas Division
Div
isio
nB
usin
ess
Uni
tsB
usin
ess
Fiel
ds
* Combined heat and power ** Integrated gasification combined cycle
� Turbocompressors for
- Oil & Gas
- Industrialapplications
� Compressorpackages incl.drives
� Compressorautomation
� Gas turbinesfrom 100 to400 MW
� Electricalgenerators from25 up to2,235 MVA
� Fuel gasifiers
� SystemIntegration
� Industrial gasTurbines from5 to 50 MW
� Aero derivativegas turbinesfrom 4 to64 MW
� Steam turbinesfrom 45 kW to1,900 MW
� Steam turbinesfor industrialapplications &powergeneration
� 50 HZ and60 HZ Gasturbine powerplant solutions
� CHP*
� IGCC**
� Repowering
� Integrated solarcombined cycle
� HRSG
Instrumentationand Electrical
(PG IE)Compressors
(PG CP)
Large GasTurbines,
Generators(PG GT)
DistributedGeneration
(PG DG)
Steam Turbines(PG SU)
EnergySolutions(PG ES)
� Controlsolutions
� Electricalsolutions
� Energymanagementsolutions
� Solutions fordistributed andhybrid powergeneration
Power and Gas (PG)
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AM at is PG DG and PS DG; Industrial Gas TurbineSelective Laser Melting (SLM)
Combustion chamberBurner
Swirler / Nozzles / Filter / Mixer
High Tech-Components with complex design and high potential to increase thebenefits of the customer (e.g. efficiency; life time)
a SGT750 from Finspong (PG DG/PS DG)
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SLM: RaBuTiR (3)
Main benefits:
• Faster repair
• Technology updates included
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Power and Gas Division
Div
isio
nB
usin
ess
Uni
tsB
usin
ess
Fiel
ds
* Combined heat and power ** Integrated gasification combined cycle
� Turbocompressors for
- Oil & Gas
- Industrialapplications
� Compressorpackages incl.drives
� Compressorautomation
� Gas turbinesfrom 100 to400 MW
� Electricalgenerators from25 up to2,235 MVA
� Fuel gasifiers
� SystemIntegration
� Industrial gasTurbines from5 to 50 MW
� Aero derivativegas turbinesfrom 4 to64 MW
� Steam turbinesfrom 45 kW to1,900 MW
� Steam turbinesfor industrialapplications &powergeneration
� 50 HZ and60 HZ Gasturbine powerplant solutions
� CHP*
� IGCC**
� Repowering
� Integrated solarcombined cycle
� HRSG
Instrumentationand Electrical
(PG IE)Compressors
(PG CP)
Large GasTurbines,
Generators(PG GT)
DistributedGeneration
(PG DG)
Steam Turbines(PG SU)
EnergySolutions(PG ES)
� Controlsolutions
� Electricalsolutions
� Energymanagementsolutions
� Solutions fordistributed andhybrid powergeneration
Power and Gas (PG)
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SLM Rapid Manufacturing and Rapid RepairAdditive manufacturing has arrived in customer engines
§ Long repair times§ Costs for repair
Driver Result
§ Significant lead timereduction
Rapid Repair
SLM burner repair
§ Long lead times§ Long time line for
implementation ofnew designs
Driver
SLM-Swirler
Result
§ Lead time reduction by sixmonths§ short term implementation of
re-designs
Rapid Manufacturing
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IndustrializationLine Integration
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Hannover Fair 2015Digitalization Forum
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Additive Manufacturingprocess overview
2D conversion
AdditiveManufacturing
Product
CAD / CAM design
Additive Manufacturing summarizes various production processes.
Production process MaterialPowder bed fusion
Vat photopolymerization
• Metal• Polymer• Ceramic
• Photopolymer
Directed energy deposition • Metal
Material extrusion • Polymer
Material jetting
Binder jetting
• Photopolymer• Wax• Metal• Polymer• Ceramic
1 based on ASTM F2792-08
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Our Portfolio for AM covers the entire Value Chain
Siemens competence
PL portfolio
CT expertise,plants: Application know-how
Scanlab
AS, MC, PL portfolio
Plants, energy, railways
Plants, energy, railways
PLMsoftware
Materials
OEMs
Production
"Print heads"
Automation& Drives
Products& services
Added value
Reproduced Optimized Completed
PROFINET
SINUMERIKwith SINAMICS S120
Sinumerik OP
SIMATIC ET200 SP
SCADA
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Additive Manufacturingis influencing high end and daily life applications
Energy, aerospace,automotive
Medical andhealth care
Daily life
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Siemens vision ofindustrialized Additive Manufacturing
Material Finishing
4. Line Integration
MOM*
KPI based Certificates
5.
Increased part accuracyOne seamless software platform synchronizing theentire PLM tool chain down to the machine runtime(e.g. optimized formats w/o “STL-triangles”)
1.
PP
CAE
CAM
CAD
1.Design &
Simulation
2.
AM machine
3.
5. Increased production efficiencyKPI based certificates for documented part quality ofproduced parts w/o inefficient workarounds(e.g. w/o computer tomography)
2. Increased process qualityReal time acquisition, analysis and control of therelevant process data on the machine level(= closed loop control)
3. Increased machine efficiency & flexibilityOpen CNC enables comprehensive machine dataanalytics for continuous improvement(e.g. condition monitoring)
4. Enhanced process streamFully automated horizontal work flow integratingpre- and post- processes in one production line(strong analogies with production machines)
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The Siemens portfolio along the entire value chainenables the industrialization of AM
PLM Software Automation Products
MaterialPROFINET
SINUMERIK with
SINAMICS S120
SINUMERIKOP
SIMATICET200 SP
HMI
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Production
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Siemens Bets Big on Metal 3D Printing with €21.4Million Facility
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Siemens Bets Big on Metal 3D Printing with €21.4Million Facility
Ø €21.4 Million FacilityØ Currently staffed with 20 employees such as operators and engineersØ Producing metal 3D printed components for Siemens’ own industrial gas
turbinesØ Both for prototyping, as well as for end-part production and repair.
Thorbjorn Fors, global business director for Distributed Generation at Siemens, said of the facility, “Withthis investment, we can develop new and improved components and repairs, for example burner tips toserve our industrial gas turbine SGT-800, significantly faster. Using this innovative approach, we willshorten repair times from months to weeks. It is an important step in our ability to respond to the needsof our customers.”
http://3dprintingindustry.com/2016/02/03/66016/?utm_source=3D+Printing+Industry+Update&utm_medium=email&utm_campaign=5ff97e5909-RSS_EMAIL_CAMPAIGN&utm_term=0_695d5c73dc-5ff97e5909-64470153http://www.mynewsdesk.com/se/siemens_ab/pressreleases/siemens-oeppnar-sveriges-foersta-3d-verkstad-foer-serietillverkning-av-metallkomponenter-i-finspaang-1307672
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Summary and Outlook
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Additive Manufacturingis a key technology to fulfill market requirements
Market requirements
Individualizedmass production
Increased energy andresource efficiency
Shorterinnovation cycles
1) ISO/TC 261 – Additive manufacturing
AdditiveManufacturing1
Highly complexstructures anddesigns
Designed-infunctionality
High endresilient materials
Levers
Spare partson demand
Rapid prototyping
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Summary
Additive Manufacturing …… facilitates optimizationpotentials.
… is on the path ofindustrialization.
… requires a holistic digitalizedapproach.
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Many thanks for your attention!
Martin SchäferSenior Key Expert “Additive Manufacturing”Corporate Technology / Germany /CT RTC MAT COA-DE
Siemensdamm 5013629 Berlin
Phone: +49 30 386 – 23087Fax: +49 30 386 – 25764Mobile: +49 173 9795263
E-mail:[email protected]
intranet.ct.siemens.com
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