This document discusses the development of a topologically optimized hinge arm component through a combination of additive manufacturing and investment casting processes. It begins with an overview of Alcoa, describing its founding, global operations, and business groups. It then provides details on Alcoa's investment casting capabilities and facilities. The document presents a case study on redesigning an aircraft hinge arm component using topology optimization, additive manufacturing of patterns, and investment casting. The optimized design achieved a 47% weight reduction while meeting all stress and displacement constraints.
2. Alcoa Confidential
Welcome
Development of a topological optimised Hinge Arm through
combination of ALM- and Investment Casting processes
Rainer Sabisch
APP Director Global Application Engineering
3. Alcoa Confidential
About ALCOA
Founded in 1888, after inventing
process for making aluminum
Global innovation leader in
lightweight, high-performance
metals, products, solutions
59,000 employees across
30 countries
2014 sales: $24 billion
At-a-Glance Serving Several End Markets
Aerospace Automotive
Commercial
Transportation
Beverage Packaging
Building and Construction Industrial Gas Turbines
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4. Alcoa Confidential
Downstream
Engineered Products & Solutions
Midstream
Global Rolled Products
Strategy
Drive Share Gains through
Leadership in product and process
Innovation
Power & Propulsion
Fastening Systems & Rings
Building & Construction Systems
Forging & Extrusions
Wheel & Transportation
Bauxite mining
Alumina refining
Aluminum smelting
Aluminum recycling
Power generation
Move down the refining cost
curve
Move down the smelting cost
curve
Drive growth through product
innovation
Reduce cost through process
innovation
Packaging
Aerospace & Defense
Automotive
Consumer Electronics
Industrial
Operations
2014 Revenue: $6.0 Billion 2014 Revenue: $7.4 Billion 2014 Revenue: $10.3 Billion
Upstream
Global Primary Products
ALCOA’s three Business Groups
5. Alcoa Confidential
APP Structural Casting Location Map
2,331 employees
(as of 02/28/15)
Alcoa Power and Propulsion
Structural Casting Facilities
1. Whitehall, MI USA (Titanium)
2. Hampton, VA USA (Titanium &Superalloy)
3. La Porte, IN USA (Superalloy)
4. Georgetown, Ontario, Canada (Aluminum)
5. Laval, Quebec, Canada (Aluminum)
6. Evron, France (Aluminum)
7. Gennevilliers, France (Superalloy)
8. Bestwig, Germany (Titanium & Aluminum)
9. Nantong, China (Aluminum)
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6. Alcoa Confidential
General Capabilities – Castings
Superalloy Titanium Aluminum
Aerospace engine components
Aircraft structural components
Military components
Turbochargers
Aerospace engine components
Aircraft structural components
Military components
Aerospace engine components
Aircraft structural components
Military components
Turbochargers
Max length = L = 52 inch 1321 mm
Max width = W = 52 inch 1321 mm
Max height = H = 25 inch 635 mm
Pouring weight = P = 700 lb 318 Kg
HERO Premium & SOPHIA Casting
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Casting Processes
Casting processes
of metal-based materials
Permanent pattern
(devided mould)
Without pattern
Permanent mould
Lost pattern
(undevided mould)
Lost mould
Die casting
Chill casting
Continuous casting
Sand casting
Shell-mould casting
Evaporative
pattern casting
Investment casting
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Investment Casting Benefits
Optimized use of material
Max. design freedom (undercuts)
High level of precision
Low wall thicknesses
High mechanical properties
Excellent material consistence
Little weight
Tooled or tool free manufacture
(Rapid Prototyping)
10. Alcoa ConfidentialAlcoa Confidential
Overview ALM-Technology (Polymer)
SLS - Selective Laser Sintering (Powder)
Models preferred for Al-Castings
SLA – Stereolithography (Resin)
Models preferred for Ti Castings
Usability as Lost Pattern for the Investment Casting process
Alcoa Confidential
11. Alcoa ConfidentialAlcoa Confidential
Advantages / Limits of the RP-process
Reduced lead times
Reduced development cost
Flexibility
Identical mechanical properties as serial production
Max. design freedom (undercuts)
Part sizes up to 1500 x 1300 x 900mm
Qualified processes
Best prerequisite for topology optimisation
Alcoa Confidential
12. Alcoa ConfidentialAlcoa Confidential
What is Topology Optimization?
Alcoa Confidential
Body mass is distributed in an optimal way within a determined room
Topology optimization is applied during the design phase
Conditions of loads and connections are determined and these data are
used to generate a FE (finite elements) model
The result is a scraggy model which will finally be smoothed to form a
CAD-model
Targets:
Cost and weight savings of monolithic investment castings!
13. Alcoa ConfidentialAlcoa Confidential
Topology: Nature is the best inventor
Alcoa Confidential
The leaf is only 2 mm thick and 2 meters
in diameter, but it can carry a human
body of 50-60 kg weight.
Giant Water Lily
Source: Nachtigall, Blüchel:
Das große Buch der Bionik
22. Alcoa ConfidentialAlcoa Confidential
Case Study „Hinge Arm“
Alcoa Confidential
Displacement
Load Case Displ. Tz Displ. Txyz
Closed -0,754mm 1,763mm
Position 1 -0,770mm 1,734mm
Position 2 -0,780mm 1,713mm
Open Gravity -0,740mm 1,975mm
Iteration 2 – No Manufacturing
Constraints
Final Mass: 4,81 kg
Max Stress: 319 MPa