Additive mfg consortium overview 2010

Additive Manufacturing ConsortiumAn Overview

Ian D. Harris, Ph.D.Technical Director, AMCTechnology Leader, Arc Welding

(614)[email protected]

About EWI

Most extensive joining expertise in the western hemisphereLocated in Columbus, Ohio in a 132,000 square foot facility$20 M in capital equipmentMix of industry and government clientsNot-for-profit 501(c)(3) organization with revenue ~$30 MM and 134 employees

EWI Mission

Advance our customers’ manufacturing competitiveness through innovation in joining and allied technologies

About EWI

EWI bridges the gap between fundamental research and production processes- EWI finds, develops, and deploys new technologies

and materials

FundamentalResearch

TechnologyDevelopment

TechnologyApplication

Universities, National Labs &

Inventors

Member Companies & Suppliers

Possibilities of Metal Additive Manufacturing

Produce net-shape components by successive metal build-upOffer potentially disruptive competitive advantagesMany U.S. companies and researchers exploring AMMany emerging AM technologies- Based on laser, electron beam, arc,

high-power ultrasonics, etc.- Using powder, wire, strip, sheetNickel-alloy pressure

vessel components

AM – Progressive Layers

Build in layers, Stress relieve/PWHT, Machine

AM Processes for Metals

EBW freeform fabrication - EB(FFF)Laser powder and wire for FFFLAM, LENS, DMLS, from companies such as Arcam, EOS, POM – powder and wire based laser and EB metals AM in confined envelope Arc processes – GTAW-HW, GMAW-P, PTA (wire and powder) based on commercially available equipment for FFFVHP UAM – very high power ultrasonic AM

Example Metals AM Processes

Concept Laser DCM®

EOS DMLS®

MTT SLM®

Phenix Systems

Optomec LENS®

MTS Aeromet LAM(No longer in

business).

Sciaky EBFFF

Arcam EBM®

Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

e

Example Applications

EB FFF and DMLS parts for aerospace components

Example Applications

Land vehicles- OEM- Repair

Power generation and nuclear

Arc-Based Additive ManufacturingDemonstration of low cost arc-based processes for Titanium AM- GMAW-P- RWF-GMAW- PAW (Cold Wire)- PTA (Powder)- GTAW (Hot Wire) GMAW-P

PAW (Cold Wire)GTAW (Hot Wire) RWF-GMAW

PTA (Powder)

Proprietary to Lockheed Martin Copyright 2009

Emerging Apps

Range of emerging applications … rapid prototyping, low volume tooling, direct parts manufacture, tailored materials, MMC, embedded fibers, smart materials, sensors, cladding, armor, thermal management

Embedded Ni Tape

0.003” Diameter NiTi Wire (400X)

Potential Competitive Advantages

Reduce material waste and energy usageLower cost (fewer operations, reduced inventory, simplified supply chain)Support lean/agile manufacturing (shorter lead time, less hard tooling, reduce batch size)Enable new product design features (internal features, tailored materials, reduced parts)Reduce time to launch new productsProduce replacement parts for legacy systemsSupport environmental sustainability

Realities of Metal Additive Manufacturing

Relatively few U.S. industrial applications beyond prototyping. Some perceptions:- Performance of AM components not sufficiently

characterized- ROI not sufficiently understood to support business

justification- Not sufficiently productive, cost effective, or capable of

producing part sizes and alloys needed

Multidisciplinary solutions are needed- No one company has the capacity to address all the

needs- Shared investment is needed to quickly close gaps

Additive Manufacturing…. Need for Collaboration

Pooling of Resources Developing from MRL 1–9 at each OEM is costly/time consumingNetwork of end users, OEMs, service bureaus and academia Need more coordinated effort…. generate a critical mass

Business Case Cost modeling, Need mature process costs

Technical Challenges Material property databaseProcess development/distortion control

Equipment OEMs Voice of the Customer… size capacity, build times, etc.

Controls/Requirements Design rules/guidelines for AM, F42 Committee

Low cost input materials Cost effective NDE Process control (real time)

Collaboration NeededWide Range of Processes Necessitates InvestigatingEach Process in Detail – this is very expensive and requires

collaboration

Initial Acceptance Values Based on LAM Process FormLower Bound for Tensile Properties, Typical forFatigue Crack Initiation

Stage 2 Evaluation of Several Processes Necessary toFully Validate Use of LAM Values for All Approvals ofProposed AMS 4999 Revision

Stage 2 Evaluation of 6 to 7 Processes Needed forCertainty of Generating MMPDS Allowables

AM in Europe

Most metal AM capital equipment is built in Europe by Arcam, EOS and othersLarge, informal, network of users for plastics and metalsLoughborough University, England hosts annual AM conference, all materials and marketsFraunhofer Institutes have a coordinated focus on AM in GermanyThere is a concern in the US with technology lag

AM Evaluation Stages

Evaluation Stages – AMS-4999 Revision- 1 Initial Screening- 2 Process/Source Approval- 3 Deposition Parameter Approval- 4 Approval on Non-Critical Flight Hardware- 5 Approval of Critical Flight Hardware

MMPDS data generationNon-flight Hardware Qualification stops at Stage 4

The Answer: AMC

The Additive Manufacturing Consortium (AMC) was founded to provide a U.S. AM forumNational consortium of industry, government, and research organizationsMission: Advance the manufacturing readiness of metal AM technologies to benefit consortium members

Time to deployment

Man

ufac

turin

g R

eadi

ness

University & Federal Labs

Manufacturers & Suppliers

Additive Manufacturing

Consortium

MRL 3-7Significant commercial impacts in 2-5 years

MRL 8-10Incremental improvements and implementationShort time horizon

MRL <3High-risk basic research and educationLong time horizon

Advancing Manufacturing Readiness

AMC StructureEncompass a wide spectrum of manufacturersInclude technology and material suppliersEngage a national technology network of research partners; “National Test-Bed Center” Creates a non-competitive environment for industry to share experience and best-practicesLeverages public and private funding sourcesDistinct from university-led centers which often focus on education and basic-research

Setting AMC PrioritiesDiscussions with stakeholders- Industry, universities, government

Review of past efforts- 2009 Roadmap for Additive Manufacturing- 2009 Air Force additive manufacturing workshop- 2009 EWI Ultrasonic Additive Manufacturing symposium

2010 AMC Meeting Ideation: “What should be the highest priority AMC activities?”- 3 breakout groups; 125 ideas contributed; 64 ideas had votes;

distilled into 15 themes

AMC members ultimately identify the priorities

AMC Business Priorities

Sustained consortium fundingEducation & supplier developmentBusiness analysisAdditive manufacturing solutions networkTechnology/IP assessmentsCollaborative leadership

AMC Technical Priorities

Property databaseQuality controlDistortion controlEquipment developmentFeedstock/input materialsDesign rulesStandardsProcess modeling/optimizationAM knowledgebase

Proposed 1st year goals & deliverablesObtain broad industry & government support Conduct state-of-the-art review of metal AM technologyEstablish a database for collecting metal AM property informationOrganize “National Test Bed Center” research partners networkIdentify technology priorities and create development plan

AMC Member StructureMember types- Full members: Major manufacturers / end-users- Supplier member: Equipment/material suppliers:- Associate member: SME component suppliers- Research partners: Universities/labs (by invitation only)- Government: Partnering agencies

Seeking members to identify 1st year priorities- All members and research partners attend AMC

meetings and receive research results- Full members and partnering agencies eligible to serve

on AMC Industrial Advisory Board

BenefitsMembers identify AMC prioritiesMembers receive results regularly; 2 year moratorium on public release Programs engage a broad range of technical resources Continuity allows long-term planning to advance AM manufacturing readinessCollaboration with industry and government facilitates acceptance and commercializationAMC provides program management to oversee projects and deliver results

BenefitsFunding leveraged with other members, government programs, and other EWI programs Full members and associate members receive a worldwide, non-exclusive license to use IP from member-funded programsSupplier members receive first opportunity to commercialize developmentsResearch partners have access to funding opportunitiesRegular update meetings allow members to interact with colleagues and review activities

AMC Differentiation

National center - through collaboration with other centers and programsAMS 4999 and MMPDS configured data and data sharing – National standards and data for aerospace and other designersConsortium uses equipment and human resources at existng centers – no need to replicate activity – this is happening nowFunding from government agencies as well as congressional requests – all data available to all AMC members

AMC Differentiation

Navy SBIR awarded – AMC member Applied Optimization/EWI effort – results available to AMC membersCoordinating needs in process, material, properties and modelingArmy, Navy and AF along with NASA –significant synergyDOE Green and sustainability aspectsNationally directed programsLinked into ASTM F42 activities

EWI’s RoleAbout EWI- Non-profit corporation - Largest material joining technology application

center in the Western Hemisphere- Mission to advance our customers’ manufacturing

competitiveness through innovation in joining and allied technology

- Broad range of technical capabilities and expertise- Experience in managing centers / consortia- Staff of full time program managers

AMC Role: Organize, operate, seek funding, program manage, contribute to technology development activities

Ultrasonic additive manufacturing

system

AMC - Current Member Status

Air Force (partner)NASA (partner)Army (partner)GE P&WR-RHoneywellLockheed MartinNorthrop GrummanGDLSMorris TechnologiesApplied OptimizationThe Ohio State University (partner)University of Kentucky (partner)University of Texas, Austin (partner)University of North Carolina (partner)

October 1, 2010 AMC membership year The First AMC Members Meeting is scheduled for Dec 7, 2010

Questions?

Ian [email protected]

Rene 142 Laser powder deposition