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ALM Additive Layer Manufacturing Metals Technologies
Dr.-Ing. Rainer RAUH Vice President
Head of Global Innovation Network - Platform Structures
London, 19th & 20th Nov, 2013
EADS – CTO
Page 2
18/11/2013
Background
A350-900 XWB Material Breakdown (%) Including Landing Gear
Al/Al-Li (Ribs, Floor beams, Gear bays,..) 19%
Titanium
14%
Steel 7%
Misc.
7%
Composite 53%
Titanium is needed as “Partner” for Composites
Wing
Fuselage
Belly Fairing
Empennage
Frames
Reminder: 14 % Titanium parts on the A350XWB
Page 3
Additive Manufacturing Processes
Direct Deposition Layer Deposition
The Principle: Deposition Process Types
The productivity on the final part will decide the right process
Direct Metal Laser Sintering (DMLS)
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Advantages • Excellent Geometric flexibility & detail of features • Net-shape parts (little or no surface finishing required) • Relatively good dimensional tolerance achievable (+/- 0.2mm) • Excellent static properties (Ti6Al4V UTS > 1000MPa) • Acceptable fatigue properties ( Cast < ALM < Wrought)
Limitations • Maximum part size is limited (typically 250 x 250 x 250mm) • Relatively slow process (0.05kg/hr) – but getting quicker • Residual stress requires post process heat treatment • Must be fused to build plate and support structure required • High cost of powder feedstock – economies of scale
Applications: • Small complex parts, preferably produced in batches • Expensive, hard to machine materials (e.g. Titanium Alloys) • Parts with high buy/fly ratio • Parts with internal features (e.g. cooling channels) • Low volume production or prototyping
EOS M280 DMLS System
Parts on build plate Finished parts
ALM Processes: Metals Technologies
Example Application – Wingsail Hinges
Page 5
CAD Model Titanium ALM Parts Fitted to Invictus Wing Sail
The Challenge • Produce a set of wing to flap hinges for Team Invictus wing-sail. • Complex thin-wall titanium alloy parts • Short timescales for delivery
The Principle: Deposition Process Types
Electron Beam Melting (EBM)
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Advantages • Excellent Geometric flexibility • Very Near Net Parts (minimal surface finishing) • Good fatigue properties ( ALM ≈ Wrought) • Very Low Residual Stress – no stress relief required • Parts not fixed to build plate – less post processing • Relatively fast process (0.2kg/hr) • Very energy efficient process
Limitations • Maximum part size is limited (typically 200 x 200 x 350mm) • Surface finish is relatively poor – requires some post processing • Powder cost relatively high (but cheaper than for laser based) • Hot Isostatic Pressing required to achieve best fatigue properties
Applications: • Very-near-net pre-forms for small parts • Small batch production • Larger parts where distortion in DMLS would be prohibitive • Currently used to manufacture certified medical hip implants
Arcam A2 EBM System
EBM parts as-built (left) and post-machining (right)
EBM Process Video
Weight and Costsaving
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• First ALM (Additive Layer Manufacturing) commercial application in GEO on ATLANTIC BIRD 7, launched on September the 27th 2011, operational since October 23rd (Eutelsat): Titanium mast node.
Titanium ALM Part now Flying in Space - Astrium
Electron Beam Melting® (Arcam process), Ti64 powder based
Large potential of application to other
parts efficient production !
The Principle: Deposition Process Types
Page 8
Proprietary Material – ScalmalloyRP
• ALM processed Aluminium Alloy with excellent mechanical properties
• Static & Fatigue properties are improved compared to 7050 plate material
• Lower density than traditional aerospace Aluminium alloys
• Significant weight benefit when compared to aerospace Aluminium alloys used in castings
ScalmalloyRP Leading Edge Rib Demonstrator Static Strength better than 7050 Plate and with higher ductility
ALM Processes: Metals Technologies, Aluminium
Wire Feed Deposition
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Advantages • Low cost feedstock (Welding filler wire) • High deposition rate (up to 10kg/hr) • Scalable to large parts with relatively thick geometry • Relatively good mechanical properties demonstrated • Near-net pre-forms can be produced with no tooling • Wide variety of possible power sources (Laser, EB, TIG, MIG, CMT) • Excellent Fatigue properties ( ALM ≈ Wrought)
Limitations • Very poor surface finish – surface machining essential • Residual thermal stress – requires stress relieving • Anisotropy possible depending upon deposition strategy
Applications: • Near-net pre-forms for large parts • Addition of local features to large preforms
Example large part being deposited at Cranfield
Cranfield University HiVE platform with 3m demonstrator
Weight and Costsaving
Design for ALM - Example
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18 November, 2013
• Minimise cross sectional area in slice – minimise internal stresses • Minimise local rate of change in cross-section through z-direction • Maintain continuity where possible – minimise risk of distortion mismatch
Top View
Design Opportunities: Complexity gives Weight Savings
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Process Speed • ALM processes are currently very slow – currently suited to low volume production • Speed must increase without a loss of precision!
Powder Cost • Powder market is currently limited – hence high cost/kg • Potential for improved powder production techniques & larger market to drive down costs
Titanium and Aluminimium parts: stabilize powder & process parameters Start qualification right powder/wire right process, right online process control Develop & adapt design and stress methods to get highest weight saving Develop the right supply closed supply chain
ALM on Metals: Next Steps
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