Additive Manufacturing at GE Greg Morris Imagination at work.
Who We Were Who We Are
Page 3 7/27/2014 Pre-GE Acquisition MTI & RQM Founded 1994 Introduced DMLM to NA in 2003 135 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
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
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
How the Process Works...
Basic Process (DMLM) AM Process Thermal Processing Post Processing and Inspection 3D CAD Model Final Part Prep for Process
Additive Modalities
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
Polymers - SLA Photos Courtesy: 3D Systems Export Authorization, ECCN: 9E991, NLR
Polymers - SLS Photos Courtesy: EOS Photos Courtesy: Materialise Export Authorization, ECCN: 9E991, NLR
Polymers - FDM Export Authorization, ECCN: 9E991, NLR Photos Courtesy: Stratasys
Polymers - PolyJet Export Authorization, ECCN: 9E991, NLR Photo Courtesy: Stratasys
Metals Photo Courtesy: EOS Photo Courtesy: ORNL Photos Courtesy: Within Labs Export Authorization, ECCN: 9E991, NLR
Nano Additive Mfg. Photos Courtesy: Export Authorization, ECCN: 9E991, NLR
Other 3D Printing Export Authorization, ECCN: 9E991, NLR Photo Courtesy:
Additive at GE Aviation...
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
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
Production Prep: Inspection Thermal Processing: (1) Vacuum Stress, (1) HIP DMLM: (7) M270 s Powder Size Analysis
Design Matters...
Design to the Process Critical
Instrument Probe - 2005
Instrument Probe - 2007 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.
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
Design Challenge and the Potential of Additive Tapped into 750k+ online community Over 700 entries received Many submissions over 80% weight reduction Traditional Design
Parts Grown and Tested Winning Design 7/27/2014
Materials are the Reason Why
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 6242 6061 T6 CoCr Hast X 17-4 PH SS 15-5 TiAl Export Authorization, ECCN: 9E991, NLR
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 200 180 160 140 120 100 80 60 40 42 38 34 30 26 22 18 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
Material Properties Drive Applications 180 YS (ksi) "UTS (ksi) DMLS EBM Wrought ASTM 160 140 ASTM 120 Horizontal Vertical 100 Elongation (%) "Hardness (HRC) 35 30 25 20 Typical Alpha + Beta Widmanstatten Structure Similar to DMLS Alpha on Deposition Layer Finer than DMLS or EBM ASTM ASTM 15 10 5 0 Export Authorization, ECCN: 9E991, NLR
After the Build the Role of Post Processes
Machining Thermal Processing Metallurgical Lab Surface Finishing Special Processes
Additive Metal Challenges
Build Learnings
Witness Line due to a power outage
EBM Cake Limit of Internals 7/27/2014
How GE Aviation is Using Additive Metals
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
DMLM Design Advantage LEAP Fuel Nozzle Export Authorization, ECCN: 9E991, NLR
DMLM Fuel Nozzle Design History Begin TAPS Development CoCr DMLM Material Development LEAP 1 piece DMLM Nozzle DMLM supply chain acquisition 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 DMLM for prototype testing GEnx certifies Traditional Mfg. 22 piece construc. LEAP FETT
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
Exploring Optimized Structures Optimized Result: 30% less weight Original Re-designed (conceptual) Combine parts to eliminate weight Performance gains Maintenance reduction Optimal structure designs
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
AM Integration Within GE Corporation
Additional Considerations
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 2014 2016 2018+ Growing Acceptance with Continuous Innovation Export Authorization, ECCN: 9E991, NLR
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
Supply Chain Shift? From To Export Authorization, ECCN: 9E991, NLR
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
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
Broad Trends Challenging IP landscape Further consolidation (all areas) Increased adoption of technologies Accelerating innovation New business models 160 140 120 100 80 60 40 20 0 2012 2013 2014 2015 2016 Applications IP Alloys
What Phase Are We In? Creators & Pioneers Early Adopters Primary Majority Secondary Majority Holdouts Technology Maturation and Acceptance Curves Export Authorization, ECCN: 9E991, NLR
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!
Thank You! Imagination at work.