Post on 01-Jul-2018
Additive Laser and Electron Beam Manufacturing
William E. Frazier, Ph.D.
Chief Scientist, Air Vehicle Engineering
NAVAIR
November 10, 2010
A Laser Workshop on “Laser Based Manufacturing”,
University of Virginia, VA 22904
Based upon a Navy DDM Workshop Held on 11-12
May 2010, Holiday Inn, Solomon Island, MD
PRESENTATION OVERVIEW
• Naval Aviations Challenge
• Vision for Direct Digital Manufacturing (DDM)
• Results of the May 2010 Navy DDM Workshop
• Needed DDM Systems Technology Development
• Summary and Conclusions
3
Aircraft Inventory MaturingSupply Chain has limited capability to
address needs of maturing A/C
• 3828 Aircraft
• 39 Type-Model-Series
• 19.18 yrs Avg A/C age
• 3074 Operating
Red Stripe (Grounding
Bulletin) due to part
unavailability directly
impacts Warfighter
Readiness
SUPPLY CHAIN LIMITATIONS
Maturing A/C need
replacement parts
for One-off or
Crash Damage
– As aircraft fatigue, parts that were never expected to break or fail do.
– The supply chain does not have the ability to repair or produce new parts.
– Aircraft are grounded while we spend precious time researching vendors who can repair or replace the part.
RED STRIPE EXAMPLES
UNEXPECTED REPAIRS IMPACT WARFIGHTER READINESS
Garry Newton, COMFRC, DDM Workshop 5/11/10
READINESSR
ep
air
s
Infant
Mortality
Sustainment
Sun Down/
Disposal
Time
Agile and Viable Source of
Manufacturing & Repair
Garry Newton, COMFRC, DDM Workshop 5/11/10
6
6
Notional Vision State
Solution: Insert into the operations of the Fleet Readiness Centers (FRC) a
new capability to have certified critical parts-on-demand (Conventional parts
manufacture and procurement ~ 6-12 months; DDM ~ 6-12 days)
DLA/NAVICP/PMABuild Package Database
Provide CAD file Process
& Design Spec
DDM Notional Rapid Manufacturing Life Cycle
Problem Statement: “The Navy’s inventory of aircraft is being pressed into service beyond their
design life. As a result, components fail that were never expected to be repaired or replaced. With
no replacements available in the supply system, long lead times develop for the repair or
manufacture…..” Garry Newton, Deputy Commander, Fleet Readiness Centers (FRC)
Broken Part
FRC for Rapid ManufactureUsing DDM Technology
Aircraft Ready for TaskingParts on Demand
Reverse Engineer
if necessary
Conventional Vice DDM Manufacturing
Titanium Parts Via Direct Digital Technology“Ship Electron not Parts”
Technology Needs
• Certification Methodology: A scientific and
technological approach to the rapid
certification of DDM metallic parts
• Materials Science:
Models for structure-processing-
property-performance
Effect of defects
Part life prediction (probalistic and
statistical)
• Rapid Reverse Engineering Methods
• Innovative Structural Designs using DDM
• Fusing of Technologies: Laser scanning,
database, design tool, and DDM
Technological Benefits
• Parts on Demand –
Reduced part acquisition time: 6-12 months
to potentially less than 24 hrs
• Reduced Cost –
Reduce buy-to-fly ratio from an industry
standard of 10 to 20:1 to approximately 1:1
Eliminates tooling and dies
Reduces transportation, packaging, &
storage costs
• Energy Savings - Potentially savings include
80% reduction in the energy content of part
90% reduction machining energy cost
95% + reduction the energy to produce tool
and dies - no longer required
15% reduced the logistic foot print
50% reduction in shipping energy
• Enhanced Aircraft Ready For Tasking
Richard Gilpin, NAVAIR 4.3, DDM Workshop 5/11/10
The Navy DDM Workshop
The overarching goal is to enhance Operational Readiness, and reduce Total Ownership Cost, and enable Parts-on-
Demand Manufacturing.
The workshop focused on Identifying the opportunities and the technical challenges the research approaches
associated with using DDM of metallic components. The intent is to use this information to help the Navy
formulate a robust R&D program.
Navy DDM Workshop Held on 11-12 May 2010,
Holiday Inn, Solomon Island, MD
Workshop ObjectivesInnovative Structural Design1. Reduce structural weight by 25% with no increase in acquisition cost..
2. Enable complex part fabrication with a 50% reduction in cost. (DDM processes with competitive properties and lower cost compared to how build today)
3. Reduce the design, engineering, build, test & qualification time cycle by 60%.
Maintenance and Repair1. Reduce time to acquire-out-of-production parts by 90%
2. Reduce total energy content by 60%
3. Reduce logistic foot print by 20%
Qualification and Certification Methodology1. Qualification of DDM fabrication processes
2. Eliminate the need to qualify each part individually
3. Reduce the time & cost of qualification by 90%
DDM Science and Technology1. Static and fatigue performance equivalent to wrought
2. Achieve Statistically Repeatable and Predictable Processes
3. Surface Finish / Minimize Assembly and Post Deposition Processing
Innovative Structural DesignNear Term
(1 – 5 yrs)
Mid Term
(5 -10 yrs)
Far Term
(10 yrs +)
Robust modeling & simulation tools.
Develop processes and techniques to improve the
mechanical properties of DDM parts in-situ
Bio-Mimicry: Develop structures based upon biological examples
Integrated structural and material
design optimization tool for DDM
Knowledge based design combined with
structural optimization
Material and process
standards and
specifications
A shared Database of Material Properties for DDM
accounting for anisotropy and fabrication system
New alloys specifically designed for DDM .
Maintenance and RepairNear Term
(1 – 5 yrs)
Mid Term
(5 -10 yrs)
Far Term
(10 yrs +)
Validated, structure-property-processing models for
predicting material performance
Improve surface finish and
dimensional accuracy
Non-Hip alternative to achieving full density
and wrought fatigue properties
Develop qualification-by-similarity approach to part
DDM part certification
Establish a robust test program in support
of a qualification-by-similarity
Conduct a top-level energy
content audit for various DDM
processes & materials
Versatile DDM systems. Performs multiple
processes / geometries and use wire or powder
Qualification and Certification Methodology
Near Term
(1 – 5 yrs)
Mid Term
(5 -10 yrs)
Far Term
(10 yrs +)
Complete generation of material property
databases for Ti, Al, and Ni base alloys
Advanced, in-process monitoring and controls
Machine-to-machine output must be compared,
variability understood, and controlled.
Industry standards for DDM processes
Industry specifications and standards for DDM
processes and DDM processed aerospace for alloys
Develop alternatives to conventional qualification methods. validated
models, probabilistic methods, and part similarities
DDM Science and Technology
Near Term
(1 – 5 yrs)
Mid Term
(5 -10 yrs)
Far Term
(10 yrs +)
Surface finish: process parameter effects
Physics based models that help us understand what causes defects
and correlate defect size/type to resulting properties
Develop hybrid DDM processes (e.g., electron
beam and laser)
Develop and integrate sensing
technology into the machine design
Develop a means of working the material during deposition e.g.,
vibration, friction stir processing, laser shock peening, etc.
Validated predictive structure-property-processing models
Alloys designed specifically for DDM
Closed-loop monitoring & control fabrication systems; integrates sensor
data into process control algorithms.
Recommended R&D Areas
1. Sciencea) Physics based models for microstructure, properties, and defectsb) Control of surface roughness (internal and external)c) Hybrid DDM processes (e.g., electron beam and laser)d) Develop in situ DDM processes to achieve full density and wrought fatigue propertiese) Technology Fusion: Integration of ”Vision State” component technologies
2. Process Controla) Develop and integrate in-process, sensing, monitoring, and control technologiesb) Industry specifications and standards for DDM processed aerospace alloys c) Machine-to-machine output must be compared, variability understood, and controlled
3. Qualificationa) Alternative to conventional qualification methods based upon validated models,
probabilistic methods, and part similaritiesb) Industry specifications and standards for DDM and processed aerospace for alloysc) DDM NDE techniques
4. Innovative Structural Designa) Integrate structural and material design tool for DDMb) Shared DDM database (material properties & anisotropy and fabrication system)c) Educate design community
16
Technology Areas:
1. Direct digital manufacturing technology – hybrid and/or dual beam system
2. Real-Time, Closed-Loop, Integrated Sensing and Control Technology
3. Accelerated part certification methodology
4. Fusion of DDM technologies including laser rastering, cloud map, CAD system, build package development, and fabrication.
S&T Challenges:
• Validating structure-process-property models
• Developing predictive models for thermally controlled microstructures
• Tailoring powder size, type, distribution
• Controlling or eliminating gas induced microporosity
• Thermally controlling shrinkage induced porosity
• Developing heuristic, predictive property models for part certification
• Controlling machine-to-machine variability
• Converting CAD information into DDM fabrication programming
PARTS-ON-DEMANDNEEDED SYSTEM TECHNOLOGY DEVELOPMENT
17
Molten Pool
Focused LaserBeam
Dual Beam and/ or Hybrid DDM for increased• Fatigue life• Surface finish• Deposition rate• Part structural integrity
HYBRID & DUAL BEAM TECHNOLOGY
0
20
40
60
80
100
120
140
0.50 1.00 1.50 2.00 2.50 3.00
Fati
gue
Str
en
gth
, ksi
Stress Concentration Factor, Kt
Elimination of Micro-porosity could improve fatigue strength by 5 to 10 ksi
Reduced Surface Roughness could improve fatigue strength by 20 to 40 ksi
Effect of Surface Roughness and Micro-porosityon the Fatigue Strength of Ti-6Al-4V: Kt Effects
107 Cycles
105 Cycles
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Approach• Multi-sensor thermal imaging
system• Real time NDI• Real-time algorithms for EB/LB
beam power control • Integrated material models
and process control
Purpose• Ensure complete fusion• Surface Quality• Eliminate Micro-porosity • Control Microstructure• Control thermal stresses
REAL-TIME, CLOSED-LOOP, INTEGRATED SENSING AND CONTROL TECHNOLOGY
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Purpose• Rapid method for qualifying
DDM parts• No increase in risk• Materials & process
qualification• Structural Qualification
Approach• Develop heuristic, predictive property models for
part certification• Utilize the AIR-4.3 engineering certification
community • Build upon extant processes where possible• Utilize the results of an ONR/NAVAIR SBIR project
focused on streamlining qualification of DDM parts.
MaterialsTechnology
Standardized
MaterialsTechnology Fully
Characterized
MaterialsTechnology
Demonstrated
Full Scale ManufacturingDemonstration
Full ScaleTest ArticlesTest Criteria
Full Scale Inspections
Full Scale Tests Post Test Inspections
Extant Qualification Process Summary
Materials
Structure
RAPID QUALIFICATION AND CERTIFICATION PROCESS
20
Approach• Use extant laser scanning
technology into digital cloud map• Minor software development• Convert Digital Model into Design:
Triangulated format - .STL file
Approach• Develop tailored software specific
to the selected DDM unit.
Purpose• Accurately capture a parts form
and shape in an electronic format.• Data must be in a format usable
by CAD systems.
TECHNOLOGY FUSION AND COMPONENT SYSTEM INTEROPERABILITY
Purpose• Convert CAD information into DDM
fabrication programming needed to control the DDM fabrication process.
Capture Part Form and Shape
CAD to DDM Build Package
The development and use of Direct Digital Manufacturing because it enables
– Enhanced operational availability
– Reduces total ownership cost (TOC)
– Reduces energy content
– Innovative structural design, and
– A more rapid response to the Warfighter.
Innovative in situ processes (e.g., hybrid laser and electron beam systems) and
an improved understanding of structure-property-processing relationships are
required in order to enhance fatigue properties reduce surface roughness.
The ability to achieve the vision state of parts-on-demand requires accurate and
predictable control of the DDM fabrication process
Part-by-part certification is costly and time consuming and is antithetical to
achieving the Navy’s vision; therefore, alternatives to conventional qualification
methods must be found.
Component technologies associated with DDM fabrication, reverse engineering,
qualification, and design must be made to work together seamlessly.
SUMMARY AND CONCLUSIONS