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Disruptive Technologies in Forming and Joining Glenn S. Daehn, [email protected]
Impulse Manufacturing Lab Center for Design and Manuf. Excellence iml.osu.edu cdme.osu.edu
And other Collaborators from OSU and LIFT
Detroit, 20 February 2019
Disrup'oniscoming
• Why
• What
• How– MetamorphicManufacturing– ImpulseManufacturing
• Who
Why?
Changeisinevitableduetoglobalforces:Climatechange
Howweusevehicles.
Carbonwilldrivedecisions,likely,soon
Gore’sInconvenient Truth
released - 2006Presenterborn
280 ppm (last ~500 years) far pre-history ~200 ppm in ice agesLast 1000 years
Energyflows(Sankeydiagram)
2/3 energy is used in production and transportation!
Megatrendsinauto
• Moresharing(Uber,LyJ,scooters,etc.)
• Moreautotomy(sharing)
• Fewercarsperfamily
• Worldwidemanufacturingovercapacity
• Electrifica'on
• Lessownership(isconsumerismdead?)
What?
AutomobilesmaylookmorelieaircraJ.Drivenbyu'lity,notstyle
Ultra-durable,basedonshearing-layerconcept.
Whatdothetrendsmeanformanufacturers?
• Farfewer,butfarbeOerautos.– Light– Autonomous– Electric– Durable
• Longerlivedcars(mostincorporatefleets)
• Stylingnearlyirrelevant,comfortwillbevalued.– Exteriorstylingathinganymore?Whowashesarental?
Wheredoesthisgo?
• Carsmightlooklike737’s/787’s• Operatefordecades;upgradedandrefurbishedasrequired
– BaOeries– Opera'ngSystem– Centralprocessor– SensorSuite– Interior– Tires– Propulsionsystem
Minimalbutfunc'onal;Edison2,VLC(verylightcar)Winner of 2010 $5M Progressive X-Prize for 100 MPGe mainstream vehicle. Demonstrating: Safety, Manufacturability, features and seating for 4. Frame and skin design similar to aircraft.
Energyabsorbingfrontend
CastorforgedBulkheads&frame
HighStrengthSteelCabin
Rolling chassis can have varied powertrains, sensors, interiors on standard connections
Whatmightthefuturelooklike?
• Smallerpartcount
• High-quality,high-strength,lightweightcomponents.
• High-strengthmul'-materialjoints
• Agile,digital,on-demandmanufacturing(goalofaddi've)
How?
Processeshigherqualityandagility.MetamorphicManufacturing
ImpulseManufacturingandJoining.
MetamorphicManufacturing
Shapingassuredcomponents,ondemand.
Project in collaboration with:LIFT Manufacturing USA instituteTMSAlan Taub (U of Michigan)
DigitalManufacturing:Hope&HypeFirst Wave – CNC Removal USAF Funding at (MIT) starting in 1949.
Second Wave – AM Additive NSF, etc., early 1980’s
ThirdWave:Metamorphic
Robot
ICME-Computer
Sensors-Computer-Wires
Work-Horseshoe
Heat-Lazers
Machine
Sensors
ToolInterchangableheads
2
Robotwork holdingtool change
SensorstemperatureshapemicrostructureWorkpiece
Interchangeable tools
Sensorstemperatureshapemicrostructure
Powered Toolservo-presspower hammer, etc.
ComputerICMEshape à strainprocess sequenceAI & machine learning
Thermallasersinductioninfraredflameor cool/quench
Proof:Plas=cineandMetal
Robot
TeamHoneyBadger,ofOhioStateUniversity.AlexKoenig,BhuviNirudhoddiandBrianThurstonSee:Robo'cBlacksmithing.comfordetails.
LIFTPrize–$25kofferedforasingleprogrammablesystemthatcanshape2of3targetparts.
Technical:What
Germananonymous,circa1606
High-ValueComponent
SimulationandICME
Machine
Heatingand
CoolingSensors
Position
Track with time: • Temperature • Strain tensor • Stress tensor Predict: • Microstructure • Damage • Anisotropy • Etc…
MetamorphicTMSreportreleaseMarch11,2019
ImpulseManufacturing
Largeforce,shortdura'onprocessing
AcknowledgementstoDr.AnupamVivekandmyteamatOSU’sImpulseManufacturingLab
hOp://iml.osu.edu
How:ImpulseManufacturing?Explosives Direct Impact Impact Presses
Laser Impulse
Capacitive Discharge Elecrohydraulic
Electromagnetic Vaporizing Foil
Fromstresstech.com
Water Confinement
OpticalPulse
t
Primary Ionization
Parasitic Ionization
ShockFronts
100 kAFlyer
Target
PDV Probe
Standoff
Whyimpulseandhighspeed?Enhanced Formability Conformal Joining Collision Welding
Embossing Cutting Precision Shape Control
Flanging/Hemming Shock Hardening Light & Agile Equipment
400µm%
Cu#
#
Ti#
500#µm#
Aluminum'foil'
Die''
Work'piece'
Clamping'force'
Die''
Fixture''
Fixture''
Whatistheidealdissimilarmetalinterface?
Transition metals share electrons…
Atomically clean, flat surfaces would bond.
Can conventional methods do this?
What kind of process can?
Impactwelding
• Je'ngcleanssurfaces
• Ultrahighpressuresforatomiccontact.
• Largeplas'cstrains
• Adiaba'chea'ng:deforma'on,fric'on,gas
• Localheterogeneity
• Veryrapidcooling
• Reflectedstresswaves(top) mechanism of Bahrani, Black and Corssland, Proc. Roy. Soc., (1967).
Solid-StateWelding(CivilizedExplosiveWelding)• ProcessàStructureàProper'esofanewweldingprocess
– Solid-State– Noheat– Nodistor'on– Noheataffectedzones– Parentmetalstrength– Joinsstrongalloys– Joinsdissimilaralloys– <20%energyoffusionwelding– SimpleEquipment– Singlesidedpossible
steel
Aluminum
ProcessingàStructureàProper'es
wavymelt
voids
VW
(5748m/s)(8◦) VW
(1893m/s)(24◦) VW
(937m/s)(28◦)
Vivek,Liu,HansenandDaehn,J.MaterProc.2014
wavy
melt voids
SmoothedPar'cleHydrocodeSimula'on800m/s,20°impactTionCu
Nassiri, Appl Phys Let (2017)– LS DYNA SPH
Cu
Ti
Cu
Ti
Advanced/DissimilarMetalWelding
Cu- Zr BMG Cu-17F W alloy AA6061-AZ91D CP Ti-1018 steel
AA6061-SS304 AA6061-Cu Ti 6242-Inconel 718 Cu-CP Ti
• Solid-State• No heat• No distortion • No heat affected zones• Parent metal strength• Joins strong alloys• Joins dissimilar alloys• <20% energy of fusion• Simple Equipment
AA5052 / DP980 AA5052 / 22MnB5 AA6111-T4 / DP980 AA6111-T4 / 22MnB5
ManualAl-FeFlangeWeld
CommercializingtheVFAMethod
20 impact welds~1.5 m long
• Automated foil feed• Automated part feed• Weld training • Cycle time: <3 sec•.Noise: <85 decibels
VFAWResearch&Prototypingsystem
• Takingtechnology“outsidethelab”
• Betasystemsbeingsetupatweldtrainingschoolandprototypeshops
VFAWHowthick?
A 1100
1018 Steel
A 3003
1018 Steel
A 50526mm
10 kJ discharge energy,~ 250 m/s impact speed
6mm
Who?
Fortunefavorsthebold.EmbracechangeHavepurpose.
Differentisprofitable!Market Capitalization: 2010 to now
Ford Tesla
Plot via Wolfram Alpha
FordGM
Summary:Disrup'oniscoming
• Why
• What(onevision)
• How– MetamorphicManufacturing– ImpulseManufacturing
• Who
• BeBold
Acknowledgements
Details: iml.osu.edu
