Advancing Aerospace Production with Arcam Electron Beam Melting Technology

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1 Advancing Aerospace Production with Arcam Electron Beam Melting Technology Donald Godfrey Advanced Manufacturing Engineering HONEYWELL-PROPRIETARY: This copyrighted work and all information are the property of Honeywell, contain trade secrets and may not, in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell. All Rights Reserved.

2 Honeywell s Businesses Automation & Control Solutions Minneapolis, MN headquarters Aerospace Phoenix, AZ and Rolle, Switzerland headquarters $14.5B $10.2B $15.8B* $40.5B in sales* Approximately 132,000 employees, 1,300 sites, 70 countries Morristown, NJ global corporate headquarters Performance Materials & Technologies Morristown, NJ headquarters * 2014 sales : ex-4q14 OEM Incentives

3 Phoenix Engines Site Overview Key Facts: ~50 years of building propulsion systems Engines Campus Key Customers: Airbus Bell Boeing Bombardier Cessna Dassault General Atomics Gulfstream Sikorsky US Military Services Foreign Military Other Govt Agencies Assembly & Test Facility Gear Line Facility

4 Additive Manufacturing Technology Center Benefits of Additive Manufacturing Rapid prototyping development lead-time reduction Design freedom high complexity, low volume Target markets in Aerospace: - Commercial Aerospace, UAVs, electronic housings - Engine components, hinges & brackets, housings - Spacecraft components Honeywell Phoenix Focus Material and process development Prototype fabrication Production of AM Components External Collaboration Underway Air Force Materials Affordability Initiative - High temperature Alloys DARPA Integrated Computational Materials Engineering (ICME) related University Partnerships Developing World Class Additive Manufacturing Capability

5 The Honeywell Additive Manufacturing Organization Applications: 1. Prototypes 2. Tooling 3. Gov Funded Research 4. Production Aerospace/AME leads the initiative Leveraging global Honeywell presence

6 Additive Manufacturing at Honeywell Mission: To be an industry leader in deployment of AM - Metals - Polymers Honeywell Views Technology as Game-changer Type of Technology - Allowing Honeywell to: Reduce costs of some components Optimized Design Shorten supply chain Shorten engineering development cycle time Honeywell is Committed to Additive Manufacturing Growth

7 Powder Bed Fusion Machines Laser Based EOS Concept Laser SLM

8 Powder Bed Fusion Machines EB Based Arcam A2X - Electron beam technology - Preheats each layer by scanning with EB Can reach up to 1100 C inside build chamber. Lowers residual stresses in build Filament Optics Heat Shield Electron Gun Powder Container Powder Distributor Build Table Courtesy Dr. Frank Medina, Arcam

9 Prototypes & Lead Time Reduction Past AM Efforts Initial development of prototype parts with Morris Technologies Laser PBF 718 swirler on Airbus flight test bed Laser PBF 718 Tangential On Board Injector on flight test bed Began building internal R&D lab for AM and production planning Success with AM Drives Technology Integration

10 Prototype Components Fabricated - Powder Bed AM Various Part Complexities and Materials Produced

11 EBM with IN Honeywell EBM Development - Large volume of IN718 Components - Develop IN718 build feasibility with Arcam experts Microstructure and Material properties - As-built condition - Benefit of Hot Isostatic Pressing (HIP) - Understand EBM vs. Laser Inconel 718 is an precipitation hardenable Ni-base superalloy that exhibits high strength at elevated temperatures. Applications of this alloy are found in gas turbine engines, aerospace, valves and fasteners, rocket motor components, and cryogenic storage tanks.

12 Case Study IN718 Transition Duct 11 Current part sheet metal fabrication with 8 piece total assembly Redesigned one-piece component for AM print

13 EBM Powder Bed Process Map Conceptualization and modeling Convert Model to AM compatible format (STL) Model manipulation and support generation Machine setup Heat Treatment, Machining, and Inspection Final application Post-processing of parts Part removal and cleaning Build the parts

14 Build Programming This is where we enter in the recipe: - Orientation, supports, machine parameters, set-up, etc

15 Building the Part 14 For 718, the surface of powder bed needs to reach ~1000 C - Necessary to prevent smoke events during build - Requires longer pre- and post-heating times than other standard EBM materials - Cooling times are also longer Build Time: 36hrs Cooling Time: 12hrs TOTAL: 48hrs

16 Removing the Part 15 Powder is loosely sintered in and around the part - Must be removed by blasting the part using the same powder from the build - Large builds can be heavy when removing from machine Part is welded to base plate - Must be removed by cutting similar to laser based processes

17 Removing Supports and Post-Processing 16 From this To This

18 Powder Feedstock 17 Used Arcam IN718 powder made by Plasma Atomized process - Typical size range from 45 to 105µm Courtesy Dr. Frank Medina, Arcam

19 Metallography 18 Build Direction (Z) No HIP HIP Courtesy Dr. Frank Medina, Arcam Strong Directionality Observed in Build Direction

20 Metallography 19 Top Bottom Courtesy Dr. Frank Medina, Arcam Similar Microstructure Throughout

21 Material Properties Tensile (Z and XY) UTS (ksi) % Elongation Z Heat Treat XY HIP/Heat Treat 0 Z Heat Treat HIP/Heat Treat XY Elevated Tensile Tests at 1200 F Courtesy Dr. Frank Medina, Arcam

22 Material Properties Low Cycle Fatigue 21

23 Summary 22 Demonstrated feasibility of IN718 builds using EBM - First use of EBM IN718 material in industrial trial - Successful case study of transition duct Directionality observed along build direction - Must be accounted for in design - Possibilities for new applications and materials Properties compare favorably to laser powder bed fusion

24 Future Work 23 Continue development with EBM IN718 - Testing improved build themes (faster processing) - Wider range of geometries Build upon existing material property data - Understand surface roughness effect Path to Production with EBM IN718 - Complete Internal Substantiation of EBM built components - Regulatory Certification process Strong Potential for EBM IN718 in Aerospace

25 2015 Honeywell International All Rights Reserved

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