1

NSRP Robotic Arc DED AM ndashAdvanced Capabilities Workshop

Robotic DED Test-beds for Collaboration

1Approved for Public Release Distribution is Unlimited

Dennis Harwig EWISenior Tech Leader

bull Much of the content presented was developed in the National Shipbuilding Research Program ndash Advanced Shipbuilding Enterprise (NSRP-ASE) Research Announcement (RA) Project 2019-375-004

Acknowledgement

2Approved for Public Release Distribution is Unlimited

NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding

Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS

Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities

Reducing barriers to implement DED AM

Project Period June 2019 ndash July 2021

3Approved for Public Release Distribution is Unlimited

DED Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

eDEDCapability

DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity

4Approved for Public Release Distribution is Unlimited

bull Much of the content presented was developed in the National Shipbuilding Research Program ndash Advanced Shipbuilding Enterprise (NSRP-ASE) Research Announcement (RA) Project 2019-375-004

Acknowledgement

2Approved for Public Release Distribution is Unlimited

NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding

Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS

Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities

Reducing barriers to implement DED AM

Project Period June 2019 ndash July 2021

3Approved for Public Release Distribution is Unlimited

DED Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

eDEDCapability

DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity

4Approved for Public Release Distribution is Unlimited

NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding

Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS

Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities

Reducing barriers to implement DED AM

Project Period June 2019 ndash July 2021

3Approved for Public Release Distribution is Unlimited

DED Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

eDEDCapability

DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity

4Approved for Public Release Distribution is Unlimited

DED Deposition Rate vs Resolution

Courtesy Boeing

Decreased Resolution

Incr

ease

d D

epos

ition

Rat

eDEDCapability

DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity

4Approved for Public Release Distribution is Unlimited

Courtesy Autodesk

Autodesk PowerMill Additive ndash DED Build Categories

5Approved for Public Release Distribution is Unlimited

bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)

bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control

bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry

bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System

Robotic DED Training amp Build Test-beds

Shared EWIOSU Systems (MP) Multi-process torch changer

6Approved for Public Release Distribution is Unlimited

Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA

CloosMotion GMA-P amp T-GMA

Navus ABB Gantry(Multi-process DED)

OTC-Daihen GMA-PGMA

OTC-DaihenSyncroFeed

Fanuc - Lincoln GMA-PGMATW-GMA

Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)

7Approved for Public Release Distribution is Unlimited

Genesis Fanuc Robotic Arc DED Systembull Dual-arm system

bull Primary welding deposition armbull Fronius TPS 5000CMT

bull CMT GMA-P GMAbull Change waveform conditions based on build features

bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)

bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection

bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or

double-sided build platform structures

8Approved for Public Release Distribution is Unlimited

bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty

bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy

deposition) with wire and powder bull Singledual hot wire amp powder feed

SBI Plasma Arc DED

9Approved for Public Release Distribution is Unlimited

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)

bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control

bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry

bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System

Robotic DED Training amp Build Test-beds

Shared EWIOSU Systems (MP) Multi-process torch changer

6Approved for Public Release Distribution is Unlimited

Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA

CloosMotion GMA-P amp T-GMA

Navus ABB Gantry(Multi-process DED)

OTC-Daihen GMA-PGMA

OTC-DaihenSyncroFeed

Fanuc - Lincoln GMA-PGMATW-GMA

Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)

7Approved for Public Release Distribution is Unlimited

Genesis Fanuc Robotic Arc DED Systembull Dual-arm system

bull Primary welding deposition armbull Fronius TPS 5000CMT

bull CMT GMA-P GMAbull Change waveform conditions based on build features

bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)

bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection

bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or

double-sided build platform structures

8Approved for Public Release Distribution is Unlimited

bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty

bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy

deposition) with wire and powder bull Singledual hot wire amp powder feed

SBI Plasma Arc DED

9Approved for Public Release Distribution is Unlimited

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA

CloosMotion GMA-P amp T-GMA

Navus ABB Gantry(Multi-process DED)

OTC-Daihen GMA-PGMA

OTC-DaihenSyncroFeed

Fanuc - Lincoln GMA-PGMATW-GMA

Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)

7Approved for Public Release Distribution is Unlimited

Genesis Fanuc Robotic Arc DED Systembull Dual-arm system

bull Primary welding deposition armbull Fronius TPS 5000CMT

bull CMT GMA-P GMAbull Change waveform conditions based on build features

bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)

bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection

bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or

double-sided build platform structures

8Approved for Public Release Distribution is Unlimited

bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty

bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy

deposition) with wire and powder bull Singledual hot wire amp powder feed

SBI Plasma Arc DED

9Approved for Public Release Distribution is Unlimited

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Genesis Fanuc Robotic Arc DED Systembull Dual-arm system

bull Primary welding deposition armbull Fronius TPS 5000CMT

bull CMT GMA-P GMAbull Change waveform conditions based on build features

bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)

bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection

bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or

double-sided build platform structures

8Approved for Public Release Distribution is Unlimited

bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty

bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy

deposition) with wire and powder bull Singledual hot wire amp powder feed

SBI Plasma Arc DED

9Approved for Public Release Distribution is Unlimited

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty

bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy

deposition) with wire and powder bull Singledual hot wire amp powder feed

SBI Plasma Arc DED

9Approved for Public Release Distribution is Unlimited

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter

bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner

bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds

10Approved for Public Release Distribution is Unlimited

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed

bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds

bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate

bull Adapt waveform conditions based on build conditions to max productivity and control properties

bull Current Ma2JIC focusbull Adv High Strength Steels

11Approved for Public Release Distribution is Unlimited

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)

12Approved for Public Release Distribution is Unlimited

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process

bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle

bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of

quality control and part certification technologies

bull Unique resource for prototyping metal DED AM structures and components

System available for large-scale DED application development

Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020

13Approved for Public Release Distribution is Unlimited

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Welding Processesbull Welding systems

bull Fronius TPS 500i CMT system

bull Fronius WF 60i RobactaDrive CMT Torch

bull Fronius CU 1100i Water Cooler

bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water

Coolerbull STT Power Wave module

Large-scale Multi-process Robotic Gantry DED System

bull Binzel Torch Maintenance Stationbull Services Both Torch Types

bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot

Base

14Approved for Public Release Distribution is Unlimited

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Metalworking processesbull PushCorp 5-HP spindle

bull AFD340 Active Compliance Device

bull BT30 Tool Changing Stationbull Grinding burring brushing

bull Miller Coolmate 3 Water Cooler

bull ATI Tool Changer

Large-scale Multi-process Robotic Gantry DED System

15Approved for Public Release Distribution is Unlimited

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Monitoring Sensorsbull Synchronized weld parameter data

acquisition bull Melt Tools camera

bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal

Imaging Camerabull Non-contact measurement of surface

temperature from -4degF to 4442degFbull Inter-pass Temperature control

bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and

documentation during DED AMbull Used with both welding systems

bull Mount for Binzel Torchbull Mount for Fronius Torch

Large-scale Multi-process Robotic Gantry DED System

16Approved for Public Release Distribution is Unlimited

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis

bull Large-scale single-sided buildsbull Large scale double-sided builds

bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing

bull DED Welding Cladding Machining

Pre-Engineered Large-scale Robotic Gantry DED Systems

17Approved for Public Release Distribution is Unlimited

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)

bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)

bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI

bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze

bull Demonstrated single-sided integrated build platform standard qualification builds

bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems

New Capabilities - Summarybull Developed basic PowerMill Robotic DED training

seminarbull Developed advanced PowerMill robotic DED training

programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing

complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-

scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support

processes (thermal mgmt auto-maintenance quality monitoring amp control etc)

18Approved for Public Release Distribution is Unlimited

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)

bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals

bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling

Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance

bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station

bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management

bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET

19Approved for Public Release Distribution is Unlimited

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

bull Develop advanced large-scale builds and prototypes for candidate shipyard applications

bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes

bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements

bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition

bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan

Ongoing Development Needs

Accelerate shipyard implementationand impact

20Approved for Public Release Distribution is Unlimited

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions

Questions

21

• NSRP Robotic Arc DED AM ndash Advanced Capabilities WorkshopRobotic DED Test-beds for Collaboration
• Acknowledgement
• NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
• DED Deposition Rate vs Resolution
• Autodesk PowerMill Additive ndash DED Build Categories
• Robotic DED Training amp Build Test-beds
• Robotic Arc DED Systems
• Genesis Fanuc Robotic Arc DED System
• SBI Plasma Arc DED
• EWIOSU OTC Robotic DED Systems
• EWIOSU Cloos Robotic Multi-process DED System
• Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
• Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Large-scale Multi-process Robotic Gantry DED System
• Pre-Engineered Large-scale Robotic Gantry DED Systems
• New Capabilities - Summary
• Ongoing Development Needs - Lights-out Technology
• Ongoing Development Needs
• Questions