Additive Manufacturing at GE

Transcription

1 Additive Manufacturing at GE Greg Morris Imagination at work.

2 Who We Were Who We Are

3 Page 3 7/27/2014 Pre-GE Acquisition MTI & RQM Founded 1994 Introduced DMLM to NA in employees Services included: Engineering & Design Additive (Metals/Polymers) (25 additive machines) Post-Processes (Machining, Thermal Processing, Finishing) Collaborations/JV s i.e. MicroTek Finishing w/binc, etc. Customer Base: Aerospace, Medical, Consumer Goods, Energy

4 Page 4 7/27/2014 GE Acquisition of MTI & RQM (Nov 2012) Additive Development Center - GEA focus - Other GE - Select Externals Additive Lean Lab / Pilot Production - Low rate initial production

5 Manufacturing Technology Development Page 5 7/27/2014 DMLM (Today) Material Development Physics Models Early Process Dev GRC Material Development Machine Development Process Development Test Fixture/ Tooling Mfg Prototype Manufacturing Test Article Manufacturing Pre-Production Mfg Additive Development Center (ADC) Early Production Mfg Product VSE Production Process Dev Low Rate Manufacturing Additive Lean Lab (ALL) Final Production Site (Auburn, AL) High Rate Manufacturing Entitlement Cost Production TRL / MRL 0 TRL / MRL 3 TRL / MRL 6 TRL / MRL 9 ID New Technical Develop Mature Support Technologies Feasibility Technologies Technologies Production

6 How the Process Works...

7 Basic Process (DMLM) AM Process Thermal Processing Post Processing and Inspection 3D CAD Model Final Part Prep for Process

8 Additive Modalities

9 Types of Additive Photo Courtesy: Arcam Photo Courtesy: Stratasys Photo Courtesy: EOS Photo Courtesy: Stratasys Photo Courtesy: Stratasys Photo Courtesy: 3D Systems Rapid Prototyping? Additive Manufacturing? 3D Printing? Export Authorization, ECCN: 9E991, NLR

10 Polymers - SLA Photos Courtesy: 3D Systems Export Authorization, ECCN: 9E991, NLR

11 Polymers - SLS Photos Courtesy: EOS Photos Courtesy: Materialise Export Authorization, ECCN: 9E991, NLR

12 Polymers - FDM Export Authorization, ECCN: 9E991, NLR Photos Courtesy: Stratasys

13 Polymers - PolyJet Export Authorization, ECCN: 9E991, NLR Photo Courtesy: Stratasys

14 Metals Photo Courtesy: EOS Photo Courtesy: ORNL Photos Courtesy: Within Labs Export Authorization, ECCN: 9E991, NLR

15 Nano Additive Mfg. Photos Courtesy: Export Authorization, ECCN: 9E991, NLR

16 Other 3D Printing Export Authorization, ECCN: 9E991, NLR Photo Courtesy:

17 Additive at GE Aviation...

18 GE Aviation Additive: SLA: (2) 500 s, (2) Vipers (3) ProJet 3500 ARCAM: (8) A2(xx) FDM: (1) Fortus 900 Phenix: (1) PolyJet: (1) Connex 500 C-L: (1) M2 EOS: (11) M270 s (4) M280 s SLM: (2) 250HL Photos Courtesy: 3D Systems, Stratasys, EOS, SLM

19 GE Aviation Additive Support: CAD Modifications Multi axis milling Multi axis Turning Extrude Hone Airflow test stand CMM/Laser Scan 5-axis EDM Hole Drill Wire EDM

20 Production Prep: Inspection Thermal Processing: (1) Vacuum Stress, (1) HIP DMLM: (7) M270 s Powder Size Analysis

21 Design Matters...

22 Design to the Process Critical

23 Instrument Probe

24 Instrument Probe Successful builds (no crashes) Less cost to produce Higher test life More accurate probes Lower number of probes required Better data collection Shorter fabrication time Copyright GE 2014 Proprietary General Information Electric Company, U.S.A.

25 Design For Additive Topology & Shape Optimization Crowdsourcing Design Challenge Public challenge to find new design strategies for additive manufacturing Makers Guild 150 entries in less than 30 days Top designs will be manufactured and tested by GE Corporate initiative to gain exposure and expertise in the world of 3D printing Learn about: Build orientation Shape capability Support structure Original design Example entry

26 Design Challenge and the Potential of Additive Tapped into 750k+ online community Over 700 entries received Many submissions over 80% weight reduction Traditional Design

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28 Parts Grown and Tested Winning Design 7/27/2014

29 Materials are the Reason Why

30 Material Properties Drive Applications Super Alloys (2005) Many similar to wrought strengths Some materials characterized Large opportunity for novel alloy development Inco 718 Inco 625 SS 316L W Ti64 MS-1 Cu AlSi10 Mg Ti T6 CoCr Hast X 17-4 PH SS 15-5 TiAl Export Authorization, ECCN: 9E991, NLR

31 Material Properties Drive Applications Horizontal Vertical DMLM Solution Heat Treatment Melt Pool Directionality Vertical Grain Growth Similar to Wrought Isotropic / Homogeneous Wrought Typical Equiaxed Grain Structure ASTM ASTM ASTM ASTM YS (ksi) "UTS (ksi)" DMLS - V DMLS - H Wrought Low Elongation (%) DMLS - V DMLS - H Wrought Low Wrought High "Hardness (HRC)" Wrought High Export Authorization, ECCN: 9E991, NLR

32 Material Properties Drive Applications 180 YS (ksi) "UTS (ksi) DMLS EBM Wrought ASTM ASTM 120 Horizontal Vertical 100 Elongation (%) "Hardness (HRC) Typical Alpha + Beta Widmanstatten Structure Similar to DMLS Alpha on Deposition Layer Finer than DMLS or EBM ASTM ASTM Export Authorization, ECCN: 9E991, NLR

33 After the Build the Role of Post Processes

34 Machining Thermal Processing Metallurgical Lab Surface Finishing Special Processes

35 Additive Metal Challenges

36 Build Learnings

37 Witness Line due to a power outage

38 EBM Cake Limit of Internals 7/27/2014

39 How GE Aviation is Using Additive Metals

40 Leveraging AM NPI Hardware 7 th set of HPT s in 6 years Substantial cost and lead time reduction Design refinement options Fuel Swirlers Land-based Gas Turbine Engines 90 parts in (3) months Met testing timetable Eventually will be castings

41 DMLM Design Advantage LEAP Fuel Nozzle Export Authorization, ECCN: 9E991, NLR

42 DMLM Fuel Nozzle Design History Begin TAPS Development CoCr DMLM Material Development LEAP 1 piece DMLM Nozzle DMLM supply chain acquisition DMLM for prototype testing GEnx certifies Traditional Mfg. 22 piece construc. LEAP FETT

43 LEAP 56 Next Generation Fuel Nozzles 19 Fuel Nozzles in each engine 40K full production 20 pieces to 1 5x durability improvement 25% weight reduction (compared to GEnx) Fuel Nozzle is a very efficient heat exchanger

44 Exploring Optimized Structures Optimized Result: 30% less weight Original Re-designed (conceptual) Combine parts to eliminate weight Performance gains Maintenance reduction Optimal structure designs

45 EXPERIENCE ON EBM - TiAl Advantages of the EBM process: low level of internal defects, no typical casting defects, therefore low scatter in material properties homogeneous microstructure very fine grain size, leading to good material properties, in particular fatigue properties, and no need for grain refinement no limitations in chemical composition no residual stresses due to high process temperature little waste material: powder can be recycled as the oxygen pick-up is very low 45

46 AM Integration Within GE Corporation

47 Additional Considerations

48 Accelerating Adoption Process Automation Predictive Analysis Tool Accepted Best Practice Surface Finish Diversified Materials Application Specific Machines Gradiated Materials Validation Tools Process Monitoring Higher Capacity Machines Process Variation Accepted Industry Standards Present Growing Acceptance with Continuous Innovation Export Authorization, ECCN: 9E991, NLR

49 Gaps and Challenges Rapid Qualification & Materials Database IP: Rights & Tracking NDT / Internal Flaw detection Supply Chain: General Development & Protection Available Materials Technician Skill Level Process Specific Surface Finish Distortion Build Volume Throughput Process Monitoring and Control

50 Supply Chain Shift? From To Export Authorization, ECCN: 9E991, NLR

51 More Local? Field Operation Substantial supply chain challenge in remote locations Spare / Repair parts on-site? Mobile Additive Center concept Export Authorization, ECCN: 9E991, NLR

52 Parts Inventory Local ability to grow parts? Controls inventory Balance inventory with needs/delivery Flexibility for design changes (no order minimum) Export Authorization, ECCN: 9E991, NLR

53 Broad Trends Challenging IP landscape Further consolidation (all areas) Increased adoption of technologies Accelerating innovation New business models Applications IP Alloys

54 What Phase Are We In? Creators & Pioneers Early Adopters Primary Majority Secondary Majority Holdouts Technology Maturation and Acceptance Curves Export Authorization, ECCN: 9E991, NLR

55 Additive s Potential:: Global Mfg. Output: ~$10.5 Trillion ~$2.2 Billion Professional Industrial Additive Market ~0.02% of total global Mfg. output What if was 1%?...=$100B!

56 Thank You! Imagination at work.