Download Materials Selection for Additive Manufacturing

Materials Selection for Additive
Manufacturing
K. Rogers,
Technology Leader, Additive Manufacturing
GE Center for Additive Technology Advancement
August 10, 2016
Imagination at work
Key additive manufacturing facilities
GE Healthcare AM COE,
Milwaukee, WI
(PBFAM metals & polymers,
direct write)
GE Corporate Center for
Additive Technology
Advancement, Pittsburgh, PA
(DMLM, EBM, polymers, sand
binder jetting, laser cladding)
GE Power AM COE,
Baden, Switzerland
(DMLM, polymers)
GE Global Research,
Niskayuna, NY
(DMLM, laser cladding,
polymers, ceramics, AM
design)
GE Oil & Gas,
Talamona, Italy
(DMLM production)
GE Aviation Additive
Technology Center,
Cincinnati, OH
(DMLM, EBM, polymers,
AM design)
GE Power Advanced
Manufacturing Works,
Greenville, SC
(DMLM, polymers, AM design)
GE Aviation, Auburn, AL
(LEAP fuel nozzle production
DMLM)
GE Aviation, Avio Aero,
Turin, Italy
(EBM)
GE Oil & Gas,
Florence, Italy
(DMLM, polymers)
2
AM Technologies at GE
Micro-scale features
Macro-scale features
Large-scale features
• Direct ceramic deposition
• Direct written sensors
• DMLM & Electron beam
• Commercial polymer AM
• Spray technologies
• Laser & EB cladding
• Sand casting mold and core
Functional metal, ceramics & polymer parts
Commercial polymer & metal machines
Large low volume functional metal parts
Custom built machines
Foundry of the future enabler
Ceramics
printing
U/S probes
Direct write
CBM Sensors
• Ultrasound probes
• Integrated circuitry
• Direct-written CBM sensors
15 µm
• Turbomachinery applications
• Test hardware
• Limited production since 2014
200 µm
• Repair & feature addition;
reduced buy-to-fly
• LRIP casting; NPI acceleration
• In use
500 µm
Center for Additive Technology Advancement
Mission Statement
This will be the flagship center for GE additive manufacturing where we will be on the
forefront of implementing industrial applications for the benefit of all GE businesses.
This site will be a hub of innovation and promote training and development in both
design and applications for this breakthrough technology
Project Details
Pittsburgh, PA
• First multi-modal US site
• ~50 employees
• 125,000 sq ft
• $39M Corporate investment
• April 2016 Opening
GRC
CATA
3 Technology readiness level
1
Invent
Business
Develop
7
10
Implement
• Part & process design tools
• Develop, prototype, scale & mature
• Large scale output
• Next generation equipment
• Should-be cost development
• Proven technology
• Material development
• Low rate initial production
• Standard routers & quality plans
Applying additive technology
Production
Tooling
Both metal & polymer
tooling applications
LEAP fuel nozzle
Flex tips
Identify
Develop
Design prototypes
Repairs & Services
NPI applications
Low rate initial production
Complex geometries
Lighter weight parts/ efficiency
Crankshaft repair
Industrialize
Globalize
Product offering
differentiation
Unique concepts that leverage nontraditional solutions for customers
Industrialization
Machine change-over reduction
In process monitoring
5
Additive supply chain
GE Supply Chain... Delivering REAL Production Parts
250K+
parts by
2020…
and growing!
T25 Housing
Flex Tip
Materials Selection
(Traditional)
Materials Selection (traditional)*
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with a large 40000+ alloys to select a few materials that look
promising
3. Selection of Candidate Materials
– Analyze candidate materials in terms of tradeoffs of product performance, cost,
fabricability, and availability
» Best material for the application
4. Development of Design Data
– Determine the key materials properties for the selected material and process to obtain
statistically reliable measurements
– ASTM / AMS specifications
*George E. Dieter, Engineering Design A Materials and Processing Approach, McGraw-Hill, 1983
9
CTE
Hardness
Electrochemical
Potential
K1SCC
K1C
Creep rate
Modulus
Transition T
Impact
Ductility
Fatigue
Shear Strength
Comp. YS
YS
UTS
Yielding
Bucking
Creep
Brittle Fracture
LCF
HCF
Contact Fatigue
Fretting
Corrosion
SCC
Galvanic
Corrosion
Hydrogen
Embrittlement
Wear
Thermal
Fatigue
Corrosion
Fatigue
Relations between failure modes and mechanical properties, Smith & Boardman, “Metals Handbook 9 th ed., vol 1, ASM international, Metals Park, OH 1980 10
Materials Selection: Interrelationship of design,
materials and processing
Design
service conditions
function
Cost
Product
Reliability
Materials
Properties
availability
cost
Processing
Equipment Selection
influence on properties
cost
11
TRADITIONAL MATERIALS SELECTION EXAMPLE
Example: Paperclip
1. Materials Requirements
1.
Elasticity
Too much opening force
MODULUS
Too little clamping force
2.
Strength
YIELD STRESS
Permanent bend
3.
Wire diameter, clip design, etc.
12
Materials Selection
(Additive)
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Materials Selection (Additive)
Can you print me a valve controller body out of a soft
magnetic material like 430 Ferritic Stainless or Nickel
Iron alloy?
We have several MIM & conventional machining
quotes and need some next month
14
Yes, But…...
Magnetic properties?
• Never heard of 403 stainless in DMLM additive…
weldable but prone to cracking – Possible?
• 50% Nickel–Iron alloys? Does anyone make
powder?
• Binderjet?
15
Yes, But…
Magnetic properties?
• Never heard of 403 stainless in DMLM additive…
weldable but prone to cracking – Possible?
• 50% Nickel–Iron alloys? Does anyone make
powder?
• Binderjet?
M300 Maraging steel, magnetic
permeability in test
16
Can you print me a bedplate out of grey iron?
IMAGE: GE Reports
17
Yes, But…...
Lets do some math
• 30000 Lb casting
• @ 10 lbs per hour for WAAM (www.waammat.com)
= 3000 hours or 2.9 parts per year!
18
How many do you need this decade?
IMAGE: GE Reports
19
People can have the
Model T in any color, as
long as it’s black”
-Henry Ford
Title or Job Number | XX Month 201X
20
LASER POWDER BED PROCESS I.E.. SLM / DMLM
You can have any alloy you want….
As long as it’s CoCrMo!
21
Andy Snow, GE Aviation October 2015
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Materials Selection Compared (metals)
Traditional Data Sources
Additive Data Sources
• ASM Metals Handbooks
• Senvol Database – 400 alloys
• SAE Handbooks
• Senvol Indexes - 2?
• Structural Alloys Handbook
• Manufacturer data sheets – 100?
• Grey and Ductile Iron Handbook
• Steel Castings Handbook
• Woldman’s Engineering Alloys
• Mil Standards
• Aerospace Materials Standards
COMING SOON:
ASTM standards
SME AMS standards
Limited data available
22
How to really do materials
& process selection
(Additive)
LASER POWDER BED PROCESS I.E.. SLM / DMLM
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Process Selection (Additive)
Production Vs
Prototype
Material Type
(Polymer, Metal, Ceramic)
• Part Size (<400mm)
• Production
rate/volume
• Tolerances
• Feature size
• Surface Finish
Preliminary
AM selection
• Part orientation
• Build Time
• Cost
High level materials
requirements
Final AM selection
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Additive Advantage
Topology optimization
Shorten NPI manufacturing time
Eliminate process steps
Reduce outsourcing
Design performance improvements
Product design freedoms
Reduce assembly costs
Design CNC machining fixtures on the additive part
Incorporate datum features into the part design
Reduce prototype lead times and costs
Reduce inventory
Build internal passages into almost any geometry
Change multiple part assemblies to be designed as one part
geometry
• Eliminate welds in an assembly
•
•
•
•
•
•
•
•
•
•
•
•
•
IMAGE: GE Reports
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
26
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Material Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with the 359 metal results to select a few materials that look
promising
27
Senvol database search 8 Aug 2016 5PM EDT http://senvol.com/5_material-search/
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
– Service/use conditions and use environment
2. Screening of Candidate Materials
– Compare needed properties with 359 metal results to select a few materials that look
promising
3. Selection of Candidate Materials
– Analyze candidate materials in terms of tradeoffs of product performance, cost, and
availability
» Best material for the application
28
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Use Casting Data as an approximation
Additive materials property data (CTE, YS, HCF) is “typically” between
cast and wrought data
• LCF, FCGR , toughness, creep, environmental effects unknown
29
LASER POWDER BED PROCESS I.E.. SLM / DMLM
Materials Selection (Additive)
Problem solving process
1. Analysis of the Materials Requirements
2. Screening of Candidate Materials
3. Selection of Candidate Materials
» Best material for the application
4. Development of Design Data
– Determine the key materials properties for the selected material and process to
obtain statistically reliable measurements
– Machine parameter optimization
– Support Structure & design optimization
 ASTM / AMS specifications
30
CATA Additive Materials - DMLM
Current
– CoCrMo
– Stainless steels - 316L, 15-5PH, 17-4PH
– Nickel Superalloys – IN718
– Haynes 188
– Maraging steel
Near Future
– Aluminum – A205
– Nickel Superalloys - Haynes 282
GE Proprietary Information
31
Summary & the additive future
• Feasibility of production AM established @ GE
• Game changing, high performance product
• Industrialization of supply base & GE
businesses via CATA
…..Exciting times to be in AM
Keys to success:
• Materials & process selection
• Design data development
“We are standing in front of a potential
revolution in manufacturing.”
Michael Idelchik
VP of Advanced Technologies, GRC