This document discusses prospects and challenges of additive manufacturing (AM) and process automation in the aerospace industry. It outlines how AM allows for complex geometries and topology optimization to reduce weight. Automation of inspection and non-destructive testing is also discussed to increase flexibility and efficiency. The use of AM, composites, and automation is explored for opportunities to decrease costs and improve performance in aerospace manufacturing. Challenges around materials, post-processing, and verifying AM and composite parts are also addressed.

1. Oportunidades y retos de la Fabricación Aditiva y la
Automatización de Procesos en el sector Aeroespacial
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Fernando A. Lasagni
Head of Materials & Processes
Juan Pedro Vela
Carlos Pérez
General Manager
Head of Automation & Robotics
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)

2. Motivation
Some of the Major issues within
aircraft industry:
Application examples
metals
Additive Manufacturing
Manufacturing
composites
- Near net shape processing
RTM
- Out off autoclave curing (composites)
Infusion tech
Assembly
- Simulation tools
Augmented reality
Virtual reality
Inspection
ALM requires of advanced NDT
- Versatile full field NDT methods for
3D CFRP parts
complex geometries
- Automation
Decrease inspection time
- Automatic detection and evaluation
Software tools and novel
- Continuous Monitoring (maintenance)
inspection strategies
Structural Health Monitoring
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

3. Summary of presentation
Metallic Manufacturing
- Today & Next Generation (ALM)
- Materials and Post Treatments
- Advanced inspection methods
- Application case: Project ALM
Polymer base Composites fabrication
- Automation of NDT
- Dimensional analysis
- Structural Health Monitoring
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

4. Metallic Manufacturing today
Shaping into Components
Forging
Ring Rolling
Metal Removal (Machining)
Near Net Shape Processes
Casting
Powder Metallurgy
Conventional Sheet Forming
Superplastic Forming and Diffusion Bonding
Manufacturing
technology driven
design
Constraints in shape: Additive Layer Manufacturing
Design driven technology
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

5. Additive Layer Manufacturing - Fundamentals
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas I/F Brackets
CASA-ESPACIO
CATEC
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

6. ALM – Topology Optimization
ALM: Perfect application for topology optimization. Topology
optimization has to be ‘interpreted’ and sacrifices in the design
have to be made for conventional manufacturability
FEA of optimized
ALM part
>60% weight
reduction!
A320 nacelle hinge bracket
FEA of original part at
max. stress cases
Source: © Altair Engineering, EADS Innovation Works: Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

7. Materials
Commercial Available Metallic Materials (e.g. Renishaw)
Ultimate Tensile [MPa]
SLM
“conventional”
1,130
Stress Relief
1200°F / 3 hours
vacuum
1,170
S.T. 900-955°C
Aged 540°C
EADS Innovation Works: Scalmalloy®RP (AlMgSc)
6061: Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (e.g. particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

8. Post treatments
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part,
laser scanning strategy, etc.)
e.g. heat treatments
Part roughness must by adjusted to application req. (as manufactured = 10-20 Ra)
Electrochemical processes
Laser assisted (e.g. laser beam
machining)
Grinding/polishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

9. Inspection of Free Form geometries
NDT inspections: 100% full volume
Advanced NDI methods!
Available during product
development stages
© GKN Aerospace
Optimized A320 bracket
© EADS Innovation Works
ALM:
inner
porosity,
dimensional
distortion
(internal stresses), etc.
must be analyzed
CFRP fixtures: e.g. radii
inspections requires of
complex
and
time
consuming UT inspections.
Computed
Optimized A380
bracket / © EADS
Innovation Works
Dic 2013
CFRP Load Introduction Rib
© Airbone Aerospace
Inspiring Day: Industria y Fábrica del Futuro
Tomography:
reliable method for product
development and complex
inspections
Fernando Lasagni / flasagni@catec.aero

10. Inspection of Free Form geometries
X-Ray Computed Tomography
3D-Reconstruction
Materials characterization
NDT
Metrology
Detector
Specimen
X-Ray Tube
Rotating
stage
Inner features
2D Cross-sections
Object surface
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

11. Inspection of Free Form geometries
X-Ray Computed Tomography – Application examples
3D Characterization
Porosity ~5%
~2%
<0.5%
Actual to Nominal Comparison / Inner features!
CASA-ESPACIO/CATEC
3D View
ALM part for
clampband / ARIANE5
Variance distribution
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Cross
section
Fernando Lasagni / flasagni@catec.aero

12. ALM in Space
Application Example:
FLPP Systems 2.2
Additive Layer Manufacturing – ALM
FLPP/CT/M&S/ALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology, materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox. 19.000€/Kg)
“Decrease manufacturing costs”
Design leading technology (ALM)
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

13. ALM in Space
Identification
of
potential
target
applications in Launcher Vehicles and ALM
Technology assessment
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Definition of development
and verification plan
Mechanical characterization and
advanced NDT
ARIANE 5 Launcher Structural Stages with EADS CASAESPACIO participation
Phase 3 (in progress)
Phase 4 (in progress)
Execution of technology
development and verification
plan
Dic 2013
Preliminary Breadboard
definition and topological
optimization
Inspiring Day: Industria y Fábrica del Futuro
Phase 5
(not started)
Manufacturing
& Verification
Fernando Lasagni / flasagni@catec.aero

14. Composites - Manufacturing today
Research and innovation priorities (H2020)
(1) Innovative processing: Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital, virtual and resource-efficient factories
(4) Collaborative and mobile enterprises, (5) Human centric manufacturing and (6) Costumer focused mnf.
Automation
Raw Material:
Pre-preg
Vacuum Bag
SHM
NDT +
automation
Repairs +
Automation
Autoclave
Curing
NDT +
automation
Out Of
Autoclave
Repairs +
Automation
Finishing
New
possibilities?
Dic 2013
SHM
Joining and
Assembly
Inspiring Day: Industria y Fábrica del Futuro
NDT +
automation
Fernando Lasagni / flasagni@catec.aero

15. Automated inspections
Target: Increase flexibility
- Automated flexible process
- Object and NDT system
manipultation
Multi Robot inspection (ultrasonics)
- Non-contact inspections
Source: TECNATOM S.A.
- Data acquisition and
Non-contact Laser UT
processing
- Quantitative analysis and evaluation
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Source: TECNATOM S.A.
Fernando Lasagni / flasagni@catec.aero

16. Dimensional analysis
Contactless 3D reconstruction
CCD cameras
Location
Positioning
Acquisition
Control
Path optimization
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

17. Interior Inspections
Project
Reduced work space
Detection of indications, objects and
leakages
: subcontractor
Source: OC Robotics
(www.ocrobotics.com)
Dic 2013
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

18. Composites - Monitoring
Structural Health monitoring of
aerostructures during:
Manufacturing
In service
Scheduled maintenance
Application example: FBG
Real time signal
bonded
Dic 2013
Data processing strategies
embedded
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

19. Composites – Aging
Effect of environmental factors on composite life
e.g. temperature, humidity, oxygen
30 cycles, inert
500 cycles, oxidative
Sample level
300 cycles,
inert+
“T” CFRP profile
Temperature +
Vibration + load
Dic 2013
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour?
Inspiring Day: Industria y Fábrica del Futuro
Fernando Lasagni / flasagni@catec.aero

20. Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Fernando A. Lasagni
Head of Materials & Processes
Juan Pedro Vela
Carlos Pérez
General Manager
Head of Automation & Robotics
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)