TechRepublic | GE No.1 3D

Imagination at work.

GE Aviation – Additive Road to Production

Two Primary Observations:

1. When designing for additive, every element of the design process needs to be thought about differently.

2. Qualification of additive is no different than qualification of any new cast or forged alloy.

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Imagination at work.

GE’s Additive Pedigree

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GE Aviation Metal Additive Toolkit

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Metal Heat Source S

pee

d Pre

cis S

ize

Comments

Pow

der B

ed DMLM

Direct Metal Laser Melting

Powder Bed Laser LEAP Fuel Nozzle

EBM Electron Beam Melting

Powder Bed

Electron Beam

Alternate Process for Castings

Dep

ositi

on

LPF Laser Powder Forming

Powder Deposition Laser Large Prototypes

EBFF Electron Beam Free Form

Wire Electron Beam Large Prototypes

Hot Wire

Wire TIG/ Laser Large Prototypes

Con

solid

atio

n MIM Metal Injection Molding

Binder Injection Consolidation Small Part, High Volume

Binder Jet Binder Jet Consolidation

L

L

TIG/L

EB

EB

H M L

1 | GE Global Research Lab • Began work in early 1990’s

2 | Create New Materials

3 | Additive Design Expertise 4 | Accelerate Industrialization with Acquisitions

5 | Strategic Industry Partnerships

GE Additive Manufacturing Pedigree

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“GE has been developing additive technologies since the early 1990s.. the first signs that additive was about to take off appeared about five years ago. It was not so much a Eureka moment, but rather a natural reaction to helping our industrial businesses address a more competitive manufacturing landscape.”- Christine Furstoss, GE Manufacturing Technology Director

Est. 1994 Est. 2004

Imagination at work.

GE’s DMLM Fuel Nozzle

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History of DMLM Maturation

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1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Method and apparatus for producing parts by selective sintering

WO88/02677 US4863538 EOS M250 – First Commercial DMLS

First Fully Dense Material Milestone

EOS M160 – First Prototype DMLS

New Machine OEMs • SLM Solutions • Concept Laser • Phenix • Renishaw

GE: Prototype Testing

GE/Morris: First Metal Parts

First Commercialized & Regulated DMLS Part

GE: Acquisition of Morris

GE: Powder Laser Weld Repair Filed 2/89: US5038014

GE: LEAP 1-Piece Nozzle FETT

GE: LEAP 1-Piece Nozzle 1st Flight

GE: Laser Clad Blades in Repair & New Make

Photo Courtesy: EOS

Photo Courtesy: EOS

Preferred power for narrowbody

651 M I L L I O N f l i g h t h o u r s

CFM56 … • 25,000 engines

delivered • 28+ years

in service

• 34,000+ departures per day

2,400 3,400

'13E '20F

Shop visits

LEAP … • 2016

service-entry

• Selected by Airbus, Boeing, COMAC

• 7,500 orders, through Sept. 2014

*Compared to today’s generation CFM56. Claims based on GE estimates

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15 L O W ER fuel consumption*

%

Low-NOx Combustor Evolution

Single Annular Combustor (SAC)

• Rich burning (tech insertion) • 10% margin to CAEP/8 NOx

CFM56 DAC

GEnx

CFM56 SAC

Double Annular Combustor (DAC)

• Lean burning • 20% margin to CAEP/8 NOx

Twin Annular Premixing Swirler I (TAPS I)

• Lean burning • 40% margin to CAEP/8 NOx

Twin Annular Premixing Swirler II (TAPS-II) • Lean burning • >40% margin to CAEP/8 NOx

LEAP

NOx

Why Additive?

Better, lighter, cheaper parts and systems • Performance improvement (Precise features, less stack, eliminate leakage)

• More complex functions (Complex and internal fluid/air passages)

• Longer life, more durable (Organic designs, design for stress/life)

• Lighter (Use only value added material, eliminate the rest)

• Cheaper (Multiple pieces built as one, less resources to produce)

• Faster (Tooling elimination, net shape, reduced machining)

• Capital equipment reductions

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GE Additive – Fuel Nozzle

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Global Research Center

20 pieces replaced with 1 piece

GE Aviation – Design Engineering

Develop Materials and Processes

Parameters & Prototypes

GE Aviation – Development Center

GE Aviation – Lean Lab

GE Aviation – Auburn, AL

Design Freedom

Photo Courtesy: EOS

GE Additive Fuel Nozzle Design Freedom…

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1 | Design For Manufacturing

2 | Aero Design

3 | Fluid Dynamics 4 | Thermal Design

5 | Mechanical Design

CAD Design

Additive Design vs. Traditional: • 20 pieces replaced with 1 • 25% lighter • 30% lower cost • 5X more durable

The Additive Transformation

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From: 20 components manufactured and assembled GE Proprietary Information

Photo Courtesy: EOS

1 2 3 4 5 6 7

8 9

10 11 12 13 14

15 16 17 18 19 20

1 piece additively manufactured

Imagination at work.

Qualification

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GE Material Technology Maturation

Materials & Process Content • Microstructural evaluation & heat treatment • Process optimization/producibility • Mechanical property and design curves • Environmental evaluation (fluids, corrodants, temperature/time, etc.) • Effects of thermal processes (fabrication, brazing, welding, etc.)

Deliverables Material understanding Processing & robustness Specifications Physical/Mechanical Props Environmental evaluation Component suitability

Concept

Feasibility

Development

Maturation

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New Material Process

• Standard specification control system of property testing and generation

• Property Data determined from alloy & application requirements

• Thermal process conditions may be are determined from entire operating and manufacturing range

• Feature validation test plan determined from component-specific requirements

• Lifing methodology is performed consistent with existing GE lifing standards.

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Fully Dense, Small Grain, Isotropic Material

Stress Relief – Required to eliminate residual thermal stresses left during build process Hot Isostatic Press – High temperature, high pressure thermal cycle to eliminate sub-surface porosity Solution – Completes conversion of material to near wrought, isotropic structure

As-built (Top View) As-built (Side View) Heat Treated (All directions)

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Explicit Controls on Critical DMLM Parameters

Preheat Temp Interpass Temp Contour Pass Parameters Laser Dwell Time Line Spacing or Boundary Overlap HIP Cycle Parameters Heat Treat/Solution Atmosphere Braze HT Parameters Solution Temperature Surface Conditioning

Powder Source Powder Size Powder Composition Powder Reuse Procedures Layer Thickness Recoater Arm Material / Design Laser Parameter Changes Spot Size Laser Power Laser Travel Speed Build Atmosphere

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Today’s Inspection/Quality Touch Points

• Build Trials & Qualification per Machine • 100% Dimensional & CT Scan • Up to 2 Cut-ups per Build via Quality Plan • 100% Tensile Bar Test • Grain Size, Porosity, Surface Finish Samples • 100% Fuel Flow (All Circuits) • 100% Air Flow (All Circuits) • 100% Proof Pressure

Photo Courtesy: EOS

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Qualification Road Map

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Identify • Additive opportunities based on value • Durability, Fuel burn, emissions, weight, cost, etc…

Mature • Materials • Process: thin wall, surface finish, inspection, etc…

Design • To additive practices • Taking full advantage of design freedom

Qualify • Establish requirements • Demonstrate requirements are met

Validate • To performance level requirements • Using advanced analytics and testing

Certify • Component level qualification • Engine Level qualification

No New Cert Regulations Required For Additive

Imagination at work.

Greg Morris

Thank You!