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This document and all information and expression contained herein are the property of Honeywell
International Inc., are loaned in confidence, and may not, in whole or in part, be used, duplicated, or
disclosed for any purpose without prior written permission of Honeywell International Inc. All rights
reserved.
Non-Destructive Evaluation Techniques for Additive
Manufacturing
Donald Godfrey – Engineering Fellow – Honeywell International
Mark Cola – President and CEO – Sigma Labs, Inc.
2Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
• $40.5B in sales*
• Approximately 132,000 employees, 1,300 sites, 70 countries
• Morristown, NJ global corporate headquarters
Honeywell’s Businesses
Performance Materials
& Technologies
Morristown, NJ
headquarters
Automation &
Control Solutions
Minneapolis, MN
headquarters
Aerospace
Phoenix, AZ and
Rolle, Switzerland
headquarters
$15.8B*
$14.5B
$10.2B
* 2014 sales : ex-4Q14 OEM Incentives
3Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
The Aerospace business unit develops and integrates technologies
that span air traffic modernization, flight and runway safety, engines,
cockpit and cabin electronics, connectivity, logistics and more that deliver
safe, efficient, productive and comfortable
transportation-related experiences.
Aerospace
Thousands of Honeywell Aerospace
products and services are found on
virtually every commercial, defense
and space aircraft and its
turbochargers are used by nearly
every automaker and truck
manufacturer around the world.
Possibilities. Made Easy.
4Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
AEROSPACE FACTS
• Headquartered in Phoenix, Ariz. and Rolle, Switzerland
• Approximately 42,000 employees
• Nearly 110 worldwide manufacturing and service sites
• Total Revenue of $15.8 billion in 2014*
STRENGTHS
• Global leader in the aviation industry
• Developing innovative safety products
• Driving modernization of global air traffic management
• Revolutionizing combat technology
• Committed to improving operational efficiencies
• Serving all major automotive OEMs worldwide
About Aerospace
SALES
* Ex-4Q14 OEM Incentives
($B)
5Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Phoenix Engines Site Overview
Key Facts:
• ~50 years of building propulsion systems
• > 80,000 auxiliary power units produced
• > 40,000 engines produced
Key Customers:
• Airbus
• Bell
• Boeing
• Bombardier
• Cessna
• Dassault
• General Atomics
• Gulfstream
• Sikorsky
• US Military Services
• Foreign Military
• Other Govt Agencies
Gear Line Facility
Assembly & Test Facility
Engines Campus
6Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Honeywell HTF7000 Engines
• Historical deliveries- >1000 HTF7000 Integrated Propulsion Systems
delivered and in service
- >2.2 million flight hours to date
- Four HTF7000 models in the family:
› HTF7000 for Bombardier CL300
› HTF7350 for Bombardier CL350
› HTF7250 for Gulfstream G280
› HTF7500 for Embraer Legacy 450/500
• HTF7K Integrated Propulsion System:- Turbofan engine
- Nacelle
- Thrust reverser
- ~7000 - 7500lbf Take-off thrust (nominal)
• Applications & Entry Into Service Dates- Bombardier CL300 – In service since 2004
- Gulfstream G280 – In service since 2012
- Bombardier CL350 – In service since June
2014
- Embraer Legacy 500 – In service since
September 2014
- Embraer Legacy 450
>1000 HTF7000 IPPS Delivered– 5 Applications – 2M Fleet Hours
Bombardier Challenger 300
Gulfstream G280
Challenger 300
Embraer Legacy 450/500
Challenger 350
7Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Additive Manufacturing Technology Center
Benefits of Additive Manufacturing
• Rapid prototyping – development lead-time reduction
• Design freedom – high complexity, low volume
• Target markets in Aerospace:- Commercial Aerospace, UAVs, electronic housings
- Engine components, hinges & brackets, housings
- Spacecraft components
Honeywell Phoenix Focus
• Material and process development
• Prototype fabrication
External Collaboration Underway
• Air Force – Materials Affordability Initiative
- High temperature Alloys
• DARPA – Integrated Computational Materials Engineering (ICME) related
• Universities
Developing World Class Additive Manufacturing Capability
8Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Aerospace Engine Platforms
Over 150,000 Turbine Engines Delivered to Customers
• Wide spectrum of Aero Turbine Products
© 2014 by Honeywell International Inc. All Rights Reserved.
9Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Additive Manufacturing at Honeywell
• Mission: To be an industry leader in deployment of AM
- Metals
- Polymers
• Honeywell Views Technology as Game-changer Type of Technology
- Allowing Honeywell to:
Reduce costs of some components
Optimized Design
Shorten supply chain
Shorten engineering development cycle time
Honeywell is Committed to Additive Manufacturing Growth© 2014 by Honeywell International Inc. All Rights Reserved.
10Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Past Honeywell Powder Bed Metal AM Efforts
Success with AM Drives Technology Integration
Initial development of
prototype parts with
Morris Technologies
DMLS 718 Tangential On
Board Injector on flight
test bed
DMLS 718 swirler on
Airbus flight test bed
Began building internal R&D
lab for AM and production
planning
2007 2008 2009 2010 2011 2012 2013 2014
© 2014 by Honeywell International Inc. All Rights Reserved.
11Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Honeywell Components Fabricated - Powder Bed AM
Various Part Complexities and Materials Produced© 2014 by Honeywell International Inc. All Rights Reserved.
12Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
PhoenixBrno
Bangalore
Shanghai
• Aerospace/AME leads the initiative
• Leveraging global Honeywell presence
Honeywell Global Footprint with AM Labs
Utilize Global AM Presence for Speed and Cost © 2014 by Honeywell International Inc. All Rights Reserved.
13Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Design for Additive Manufacturing
• AM design flexibility
- Reduced weight
- Increased efficiency
- Improvements in component life
Additive Manufacturing Is Changing The Design Culture
Original Design
Redesign with AM: 56%
weight reduction while
maintaining required strength
© 2014 by Honeywell International Inc. All Rights Reserved.
14Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Objective Evidence
Sigma Labs
Honeywell International
Working Together to Build an in-process NDE System for:
Objective Evidence of Compliance to Design Intent
© 2014 by Honeywell International Inc. All Rights Reserved.
15Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Process Monitoring - DARPA
• Ensuring quality during build important for Part Quality
- Metallurgical Properties: PrintRite3D® INSPECT™
Melt pool monitoring and defect recognition
- Geometric Properties: PrintRite3D® DEFORM™
Dimensional variations and resolution accuracy of at least 100μm
- Coating issues
• Utilizing a sensor array
- Camera monitoring
- Photodiodes and Pyrometers
- Power meters
Advancing In-Process Monitoring to Meet Quality Needs
Copyright © 2014 Sigma Labs, Inc.
© 2014 by Honeywell International Inc. All Rights Reserved.
16Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
PrintRite3D® DEFORM™
Initial Resolution Analysis
Honeywell / Sigma Labs Technology Development
17Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Design Intent
PrintRite3D®
DEFORM™
Goal: Objective Evidence of Compliance to Design Intent
PrintRite3D®
INSPECT™
18Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
PrintRite3D® DEFORM™
Real-time geometric property measurement software
• Layer-by-layer geometric property
measurements.
• Provides for comparison of ‘as-
built’ to original digital CAD model
‘should be’.
• In development with Honeywell
19Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Application of PrintRite3D® to DMLS®
Avoids x-ray CT and CMM through use of in-situ
geometric measurements
20Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Geometry
215 μm shoulder
21Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Extract circular hole geometry
22Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Extracted geometry details
Chamfered layers ignored
215 μm shoulder
11.57 mm dia. (nom)
11.14 mm dia. (nom)
23Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Diameter of least squares fit circles11.5
7 m
m d
ia.
(no
m)
Mean diameter:
11.61 mm (0.46 in.)
11.16 mm
(0.44 in)
11.1
4 m
m
(no
m)
24Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Current DEFORM™ feature resolution
At least
215 μm
25Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Diameter distribution
Mean 11.61
SD 0.06 mm
Mean 11.16 mm
SD 0.06 mm
11.1
4 m
m
(no
m)
11.5
7 m
m d
ia.
(no
m)
26Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Compare DEFORM™ to specification
Small diameter:
Spec: 11.14 mm ± 0.01 mm
DEFORM™: 11.16 mm ± 0.06 mm
Big diameter:
Spec 11.57 mm ± 0.09 mm
DEFORM™: 11.61 mm ± 0.06 mm
27Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
DEFORM™ vs. standard techniques
*CT artifacts precludes an accurate measure
Measures
(Inches)
Shoulder
Width
Top hole
ID
Top hole
shoulder ID Base width Base ID
Center nub
to top of
bracket
Top hole
centers
Engineering
Drawing1.998 0.43 0.4383 3.7
0.218—
0.226-- 1.00
OCMM 1.997 0.4386 0.4556 3.76 0.222 1.34 1.0
CT* 2.01 0.44 -- 3.78 0.22 -- 1.0
DEFORM TBD 0.44 0.46 TBD TBD TBD TBD
28Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Current DEFORM™ Capabilities
Initial geometry resolution:
at least 215 μm
Measurement error:
60 μm
Goal: Objective Evidence of Compliance to Design Intent
29Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Summary
• Honeywell incorporating AM on Global Scale
• Working to be world leader in technology development in the area of in-process NDE for AM
• Objective Evidence of Compliance to Design Intent is the ultimate goal
30Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
Special Credits For Team Members
Sigma Labs
David Clark
Alberto Castro
Honeywell International
Brian Baughman
© 2014 by Honeywell International Inc. All Rights Reserved.
www.honeywell.com
www.sigmalabsinc.com