Additive Manufacturing at Swagelok Changing a Cultureadditivemanufacturingseries.com/wp-content/uploads/2018/06/Bianco... · Power (Nuclear & Fossil Fuel) Fittings Valves Regulators

SmartManufacturingSeries.com

Additive Manufacturing at Swagelok – Changing a Culture

Robert Bianco, PhD, FASM

Senior Materials Scientist, Innovation & Technology

Outline

Company Overview – Manufacturing Culture

Additive Manufacturing Program

Application Examples

Path Forward – Challenges

Future Opportunities


WHO WE ARE

• Fred Lennon establishes Crawford Fitting Company in 1947.

• The Swagelok Tube Fitting is introduced

Swagelok Tube Fitting

WHO WE ARE • Global distribution and service is

established in 1954

• Products are expanded to include Cajon®, Nupro®, Sno-Trik®, and Whitey®

• Unification of 5 company resources as one Swagelok in 1998

• Today our products, services and global operations account $2 billion (USD) annual sales

Truly understand our customers’

needs and act on them.

Apply our collective talents with

understanding and passion to

improve each day.

OUR MISSION

OUR VISION

EXPANDING TO MAKE

THE WORLD SMALLER

1 Swagelok

6 Continents

70 Countries

220 Sales and

Service Centers

20 Manufacturing

Facilities

5 Tech

Centers

Brazil

China

India

Japan

USA (Ohio)

EXPANDING TO MAKE

THE WORLD SMALLER

Equaling

9400 associates worldwide

3900 sales and service associates

5500 corporate associates

MARKETS SERVED

Oil and Gas

Semiconductor

Chemical & Refinery

Transportation

Food Beverage & Dairy

Shipbuilding

Biopharmaceutical

Pulp & Paper

Power (Nuclear & Fossil Fuel)

Fittings

Valves

Regulators

Quick-Connects

Tubing & Tools

Filters

Hoses

Sample Cylinders

Welding Systems

Measurement Devices

Process Instrumentation

Medium & High Pressure

MPC Modular Systems

Pre-Engineered

Subsystems

Leak Detectors,

Lubricants & Sealants

Swagelok Custom Solutions

AN EVER-EVOLVING PORTFOLIO

• Extensive use of subtractive manufacturing for over 70 years

MANUFACTURING CULTURE

CN

CNC Machine Milling Machine

~85% of Swagelok products are made using subtractive manufacturing

Multi-Spindle Lathe

Additive Manufacturing Overview

11

Differs from conventional manufacturing processes Conventional Processes Additive Manufacturing

(7 categories of additive) Formative

Castings, Forgings…

Fabrication

Welding, Assembly…

Subtractive

Milling, Drilling…

Category Material

1 Vat Photo-Polymerization (SLA) Polymers

2 Material Extrusion (FDM) Polymers

3 Material Jetting Hybrid

4 Binder Jetting Hybrid

5 Powder Bed Fusion (PBF) Metals & Polymer

6 Directed Energy Deposition (DED) Metals

7 Sheet Lamination (UAM) Metals

Focus on PBF and DED but exploring or utilizing all 7 types

Option 1


12


Additive Manufacturing

Team

Value Creation

Strategy Outcomes

On-Demand/ Custom Solutions

High-Performance Materials

Novel Methods

Advanced, Unique Designs

Manufacturing Support

New Product Offerings

Vision: To create an additive manufacturing competency that designs and manufactures unique fluid systems that can’t be manufactured using traditional methods


Manufacturing Support – Fixtures, Holders


Test Fixture - Reduce lead time

Test Alignment Fixture - Improve accuracy

Inspection Tray - Reduce process time

Custom Jaws - Reduce process time

Manufacturing Support – Fixtures, Holders


Inspection Fixtures - Improve efficiency

Part Handling Trays - Reduce scrap

Custom Tool Trays - Improve efficiency - Ergonomic



Chucker Loader Clip - Prototype

Gantry claws - Prototype

Double Drop Gripper Fingers - Prototype

Wizmo Gripper Fingers - Prototype

16


Additive Manufacturing

Team

Value Creation

Strategy Outcomes

On-Demand/ Custom Solutions

High-Performance Materials

Novel Methods

Advanced, Unique Designs


New Product Offerings

Vision: To create an additive manufacturing competency that designs and manufactures unique fluid systems that can’t be manufactured using traditional methods


New Product Offering

• Thermal management of valves is often required to maintain process temperature/integrity

• Intimate contact of steam lines with valve body is difficult to achieve

• Cold spots in valve can result in freezing

• Current solutions void warranties

17 SmartManufacturingSeries.com

Background of problem

Steam Traced Ball Valve

18

• Integrated valve body design with internal steam or cooling fluid flow cavities to heat/cool valve

• Enabled by 3D printing – other features easy to add

• Applicable to any number of Swagelok valves or regulators


Alternate solution

Simulation – Thermal Response


Fluid Temperature Drops

Through a Cold Valve

Thermal Model Developed

Solution Validated

Prototype Builds

• Prototypes/test articles printed in 316L stainless steel at two separate vendors

20

Laser Powder Bed Fusion

Process (L-PBF)


Industrial Ball Valve Center Body

Material Performance – 316L SS

21

AM 316L ≥ CF-3M


316L Stainless Steel As-Built +

Stress Relieved

Accomplishments - STBV

• Test articles built at two different vendors

• US patent application submitted - utility

• Completed in-house and started site beta testing

• Defined path to regulatory compliance and certification


Instrumentation Panel

Challenges at Swagelok

• Quality Assurance

• Material Property Consistency

• Process Control

• Inspection

• Creating Value

• Unique Designs

• High-Performance Solutions

• Overcoming Embedded Manufacturing Culture

• Education – Community of Practice Series

• Associate Engagement


Quality Management System

Creating specification document hierarchy

Working with standards committees to align with industry: ASME, ASTM, SAE AMS, AWS


Swagelok AM Documentation

SMS-AM-XXXXX

316L Material Specification

Powder Procurement Specification

Powder Bed Laser Fusion

Process Control Document

Powder Removal Process

Digital File Control / File

Standardization

Thermal Processing

Stress Relief

Hot Isostatic Press (HIP)

Heat Treatment

Post Processing

Extrude Hone

Electropolishing

Bead/Grit Blast

Peening

Cleaning Inspection

Part Quality

Digital X-ray

3D Computed Tomography

Ultrasonic Inspection

Dimensional Inspection

Structured Blue Light Inspection

CMM

Supply Chain Development

25

Part Build HIP & Heat Treat

Quality & Inspection Finishing Lab & Customer Tests

Build Parameters Powder Quality Design Allowables


Rapid New Product Offerings

26

Revised

Model Prototype

Test

Idea Initial

Model

Simulations

To deliver qualified, new

products and on-demand

solutions with rapid

development cycles


Additive Manufacturing Future


Metal powder bed systems – examples SLM Solutions (powder bed)

EOS M 400-4

Build volume: 400 x 400 x 400 mm

Build rate: 100 cm3/hr

Laser system: 4 fiber lasers (400W)

Materials: light metals, stainless / tool steel, superalloys

Footprint: 4 x 1.6 x 2.4 m

Price: ~$1.6M

SLM 500HL

Build volume: 500 x 280 x 365 mm

Build rate: 105 cm3/hr

Laser system: 2 – 4 fiber lasers (400W)

Materials: stainless / tool steel, superalloys

Footprint: 5.2 x 2.8 x 2.7 m

Price: $0.85M – $1.8M

EOS (powder bed)

Machine Costs

Build Speed (cm3/hr)

Summary

Company Overview – Manufacturing Culture


Application Examples

Path Forward – Challenges

Future Opportunities


Additive Manufacturing at Swagelok Changing a Cultureadditivemanufacturingseries.com/wp-content/uploads/2018/06/Bianco... · Power (Nuclear & Fossil Fuel) Fittings Valves Regulators

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