Sirris_am in aviation and aerospace_state of the art

Metal Additive Manufacturing
A game changer for the manufacturing industry?

09/04/2014 2
Overview of Metal AM technologies
Definition
 Additive Manufacturing AM
 3D Printing
 Layer by layer process
 No necessary tools required
 26-year history in plastics
 Nearly 20-year in metals
[Courtesy of Materialise]
© Sirris | www.sirris.be | info@sirris.be |

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 Direct, single-step processes for tool-less manufacturing
 Complete local melting of metal
 Wide variety of standard metal alloys possible
 More than 99.5% dense parts
 Almost unlimited freedom of shape
 Structures: complex, inner, delicate, bionic, topology-
optimized, lattice, graded
 Limits: size, inner geometries, support structures

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“… A once-shuttered warehouse is now a state-of-the art lab where new
workers are mastering the 3-D printing that has the potential to revolutionize
the way we make almost everything …“
“… We can’t wait” initiative …”
Barack Obama, President of the USA, February 2013

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« … in our lifetime, at least 50% of the engine will be made with
additive technologies… »
Robert McEwan, General Manager, GE Aviation (2011)

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Manufacturing readiness (metals)
 Origin: meant to create prototypes
 First commercial metal printer in 1995
 Current AM systems are not designed for
series production
 « Decentralization state of mind »
 Process speed, material costs and
process control have not been an issue for
prototyping.
 AM needs to show that it can manufacture
parts economically, in volume and with
constant quality for several applications 1
2
3
4
5
6
7
8
9
10 Full rate production
Low rate production
Pilot line capability demonstrated
Production in production env. demonstrated
Systems produced (near production env.)
Basic capabilities shown (near prod. env.)
Technology validated in laboratory env.
Manufacturing proof of concept developed
Manufacturing concept identified
Basic manufacturing implications identified
TRL

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1
2
3
4
5
6
7
8
9
10 Full rate production
Low rate production
Pilot line capability demonstrated
Production in production env. demonstrated
Systems produced (near production env.)
Basic capabilities shown (near prod. env.)
Technology validated in laboratory env.
Manufacturing proof of concept developed
Manufacturing concept identified
Basic manufacturing implications identified
TRL
Dental, medical
instrumentation,
implants, artistic, …
tooling, space,
drones, defense, …
aviation,
automobile, …

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x2 growth

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AM in the aircraft engine industry:
 Aero engines suppliers have been exploring metal AM technology since
2003
 For performance testing of AM products, engine suppliers require high
quantities of AM samples and therefore invest heavily in AM
 Key players have expanded manufacturing capacity recently by
procuring new equipment and acquiring suppliers
 For series production, manufacturing capacity needs to be further
extended

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AM in the aircraft engine industry - Potential:
 Potential volume for new turbine series could be up to several thousand
per year
 Key AM components are found multiple times in each engine (injection
nozzles – thousands of componants per year)
 New generation of turbines is expected to be launched within the next 3
years, so the manufacturing infrastructure needs to be established in time
 AM fuel nozzles offer great potential as they are lighter an enable a
reduction in fuel consumption and CO2 emissions

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AM benefits: Design optimization –new functions

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Powder bed technologies
 Laser Beam Melting (LBM)
 Selective Laser Melting
(SLM)
 LaserCusing
 Direct Metal Laser Sintering
(DMLS)
 Electron Beam Melting (EBM)
 Material jetting process
Powder deposition technologies
 Laser Engineered Net Shaping
(LENS)
 Direct Metal Depositioning (DMD)
 Laser Cladding
Metal AM
Others:
 Sheet lamination © Sirris | www.sirris.be | info@sirris.be |

Generalities: Metal Additive Manufacturing
09/04/2014 16© Sirris | www.sirris.be | info@sirris.be |
Direct
Fabrication
system
Laser
E-Beam
Print head
Nozzle
Post-
processing
Indirect
Binder
Debinding
+ sintering
Post-
processing

Generalities: Metal Additive Manufacturing
Hybrid
Fabrication
system
Laser + Milling
Milling + micro
forging
Post-
processing
Liquid metal
jet

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Current metal AM costs under series production conditions:
Parameters (LBM technology):
 Machine cost: 500k EUR
 Operating time: 8 years
 Machine utilization: 85%
 Build rate: LBM 10cm3/h
 Material: Stainless steel
 Powder price: 89€/kg
2%
26%
21%
44%
7%
metal AM costs
Energy
Direct costs
(material)
Labor
Manufacturing
Overhead

Technology comparison
LBM EBM Powder
deposition
Max size (mm) 630 x 400 x 500 dia. 350 x 380 900 x 1500 x 900
Layer thickness (µm) 30 – 60 50 130-600
Min wall thickness (mm) 0.2 0.6 0.6
Accuracy (mm) +/- 0.1 +/- 0.3 N.A.
Build rate (cm³/h) 5 - 20 80-100 2-30
Surface roughness (µm) 5 - 15 15 - 20 15-20
Geometry limitations Supports needed
everywhere (thermal,
anchorage)
Less supports but
powder is sintered
No powder bed.
Same limitations
as 5 axes milling
Materials Stainless steel, tool
steel, titanium,
aluminum, ceramics,
…
Only conductive
materials (Ti6Al4V,
CrCo, TiAl, Tool steel,
Cu alloy, )
Steel, Ti, Ni-base
alloys, composites,
ceramics
CENG 09/04/2014© Sirris | www.sirris.be | info@sirris.be |
19

Technology comparison
LBM EBM Powder deposition
Energy Source Laser Electron Beam Laser
Multi-material processing (Yes) No Yes
Productivity vs costs Poor Medium Good
Residual stresses High Low Medium
Part complexity High Medium Low
Typical applications Tooling (mould & die
inserts), Implants, all
types of meta
components incl.
prototypes
Implants, Near-net-
shape manufacturing,
turbine blades,
prototypes
Near-net-shape repair
of blisks/blades, vanes,
shafts, ducts, coatings,
…
Internal cavities Printable Printable but complex
to remove powder
Possible but limitations
Build job change Fast Medium Fast
Necessity of support
structures
High Low None
CENG 09/04/2014© Sirris | www.sirris.be | info@sirris.be |
20

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Manufacturers (LBM)
 Concept Laser (Germany)
 EOS (Germany)
 Phenix Systems (USA)
 Realizer (Germany)
 Renishaw (UK)
 SLM Solutions (Germany)
 Trumpf (Germany)
Manufacturers (EBM)
 Arcam (Sweden)
Others
 Ex ONE (USA)
 Matsuura Lumex (Japan)
 Hermle (Germany)
 Vader Systems (USA)

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9%
12%
3%
5%
8%
18%
1%
10%
34%
Market shares
MTT Technologies
Arcam
SLM Solutions
ReaLizer
Trumpf
Concept Laser
Renishaw
Phenix Systems
EOS

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Today
 Prototypes
 Pre-series parts
 Small batch
Production for a few very
selected parts
• First tooling applications
(particularly for plastics
injection moulding)
Tomorrow
 Series production of:
 Small batches
 Spare parts
 Assembling aids
 Fixtures and tools
Future
 Wide use for the production
 Individual parts
 Assembly groups
 Tooling

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Future trends for key parameters
 Build rates
 Machine prices
 Powder prices
 Labor costs
 Chamber volume
 Price per part
 Available materials
 Quality control integration

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Necessary adoption steps for wide use in production
 Challenges:
 Missing technical standards
 Reproducibility
 Costs
 Education with regard to AM design
 Material variety (carbon steel, copper, ceramics, ...)
 Necessary steps:
 Standardisation
 Quality control systems/ in-situ feedback control systems
 Gained productivity
 Widely spread teaching of AM principles
 Material and process development

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Conclusions
 The market for systems, service and materials for AM currently totals
1.7 billion EUR (2012) and is expected to quadruple over the next 10
years
 The ability to manufacture metal objects without virtually no
limitations on geometry and without tools offers the opportunity to create
new products that help boost product performance or manufacture batch
sizes consisting of just one item using special highly resistant alloys.
 With about 1% of the machine tool market, the share of AM is
relatively small. The supplier base for metal AM machines is dominated
by German suppliers. In addition, an infrastructure of engineering and
AM service providers has developed close to technological leaders in
aerospace, turbine development and motorsport production.

09/04/2014 28
Conclusions
 In certain areas, the technology has already achieved manufacturing
readiness (dental, design, hip implants), whereas in the aerospace and
turbine industry, process development and complex field testing are
ongoing. The potential of AM in these industries is extremely high, which
means that AM is on the agenda of every CTO.
 The costs of this technology are significantly higher than for
conventional production, so it can be only justified by special benefits in
the lifecycle or tooling costs. A detailed analysis of the current
manufacturing cost and evaluation of expected improvements reveals a
cost reduction potential of about 60% in the next 5 years and another
30% within the next 10 years. These reductions will significantly boost
the market for metal AM.

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