Industrialisationof Additive Manufacturing World Conference... · Industrialisationof Additive...

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Unrestricted © Siemens AG 2016. All rights reserved Industrialisation of Additive Manufacturing Siemens Corporate Technology | March 2016 Additive World Conference; March 23rd, Eindhoven; Netherlands Martin Schäfer Unrestricted © Siemens AG 2016. All rights reserved Additive Manufacturing @ CT RTC MAT COA-DE • General remarks Siemens and AM • AM process chain and opportunities • Applications and Industrialisation

Transcript of Industrialisationof Additive Manufacturing World Conference... · Industrialisationof Additive...

Unrestricted © Siemens AG 2016. All rights reserved

Industrialisation of Additive ManufacturingSiemens Corporate Technology | March 2016

Additive World Conference; March 23rd, Eindhoven; NetherlandsMartin Schäfer

Unrestricted © Siemens AG 2016. All rights reserved

Additive Manufacturing @ CT RTC MAT COA-DE

• General remarks Siemens and AM• AM process chain and opportunities• Applications and Industrialisation

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Managing Board

Customer-oriented organizationSetup as of October 1, 2014

Global presence and go-to-market of our businessesAmericas Europe and Africa C.I.S.1 and Middle East Asia and Australia

Powerand Gas

WindPower andRenewables

EnergyManagement

BuildingTechnologies

Mobility DigitalFactory

ProcessIndustriesand Drives

Power GenerationServices

Corporate CoreCorporate Services

Healthcare(separatelymanaged withglobal supplychain)

FinancialServices

1 Commonwealth of Independent States.

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Our global presence –Partner to customers all over the world

A worldwide presence

lies at the heart of theSiemens brand – andthat goes for us as well.

That presence enablesus to quickly offertargeted solutions thatare tailored to regionalrequirements.

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Additive Manufacturing at Siemens

Prototyping Manufacturing

1989CT Start

~ 2007Laser Melting

2010Burner repairPower Generation

R&

DP

rodu

cts 2014

Spare partsDifferent Divisions

~ 2004Ceramic SLA

2002X-ray gridsHealthcare

1984Stereolithographie

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Different requirements

Consumer Industry

Different requirements

Source: makerbot.com Source: EOS

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“3D printing” versus Additive Manufacturing

Establishedmarket requirementsare driving theindustrialization ofAdditive Manufacturing

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Additive Manufacturing – Process Chain

Process chain Additive Manufacturing (AM)

Phase IDesign

Phase IIAM process

Phase IIIPostprocessing

Phase IVQuality assurance

Dataprepa-ration

Materialproduc-tion andsupply

AMprocess

Partsepa-ration

Heat &pressuretreat-ment

Machi-ning ofinter-faces

Surfacetreat-ment

Systemimple-men-tation

Test/Vali-dation:non-de-structive

Test/Vali-dation:destruc-tive

Cus-tomerfeed-back

Partconcept

AMprocessselection

Designoptimi-zation

Designformanu-facturing

Require-ments

Materialrecycling

Powderremoval

Machineconcept

Residualstress

Finishing(AFM, ...)

Nesting Behaviourat melting

Handling RF,thermal, …

Damagetolerance

FunctionRepro-dibility

CADBestsuited AMtechn.

Mech. Orientation CAD/CAM Grain size Scanstrategy

Removalfrom plate

Adjust-ment ofstructure

Grinding,turning, … REM Stiffness Ideas

generationAssemblyEngi-neering

Corrosion-protection

Processmonitoring

Function Supports(res. tress)

Parameter(power,…)

Sizedistribution Separation Coating CT Strength CIPData opti-

misationSimulationClosingof pores(HIP)

Joiningtechnology

EDM/ECM-pro-cessing …

Simulation Supports(thermal)

Compo-sition

Yieldstability

Powderremoval

Propertyimprovem.

Prep. forprocessing

Surfaceroughness Fatigue

Laser-Micro-processing…

Potential for unique features are based on the mastery of knowledge intensive process chain and theinteraction between manufacturing process, material condition and component properties

Source: European project MEGaFIT

Source: European project MEGaFIT

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Applications

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Additive Manufacturing forGas Turbine Applications:Opportunities and Challenges

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Power and Gas Division

Div

isio

nB

usin

ess

Uni

tsB

usin

ess

Fiel

ds

* Combined heat and power ** Integrated gasification combined cycle

� Turbocompressors for

- Oil & Gas

- Industrialapplications

� Compressorpackages incl.drives

� Compressorautomation

� Gas turbinesfrom 100 to400 MW

� Electricalgenerators from25 up to2,235 MVA

� Fuel gasifiers

� SystemIntegration

� Industrial gasTurbines from5 to 50 MW

� Aero derivativegas turbinesfrom 4 to64 MW

� Steam turbinesfrom 45 kW to1,900 MW

� Steam turbinesfor industrialapplications &powergeneration

� 50 HZ and60 HZ Gasturbine powerplant solutions

� CHP*

� IGCC**

� Repowering

� Integrated solarcombined cycle

� HRSG

Instrumentationand Electrical

(PG IE)Compressors

(PG CP)

Large GasTurbines,

Generators(PG GT)

DistributedGeneration

(PG DG)

Steam Turbines(PG SU)

EnergySolutions(PG ES)

� Controlsolutions

� Electricalsolutions

� Energymanagementsolutions

� Solutions fordistributed andhybrid powergeneration

Power and Gas (PG)

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AM at is PG DG and PS DG; Industrial Gas TurbineSelective Laser Melting (SLM)

Combustion chamberBurner

Swirler / Nozzles / Filter / Mixer

High Tech-Components with complex design and high potential to increase thebenefits of the customer (e.g. efficiency; life time)

a SGT750 from Finspong (PG DG/PS DG)

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SLM: RaBuTiR (3)

Main benefits:

• Faster repair

• Technology updates included

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Power and Gas Division

Div

isio

nB

usin

ess

Uni

tsB

usin

ess

Fiel

ds

* Combined heat and power ** Integrated gasification combined cycle

� Turbocompressors for

- Oil & Gas

- Industrialapplications

� Compressorpackages incl.drives

� Compressorautomation

� Gas turbinesfrom 100 to400 MW

� Electricalgenerators from25 up to2,235 MVA

� Fuel gasifiers

� SystemIntegration

� Industrial gasTurbines from5 to 50 MW

� Aero derivativegas turbinesfrom 4 to64 MW

� Steam turbinesfrom 45 kW to1,900 MW

� Steam turbinesfor industrialapplications &powergeneration

� 50 HZ and60 HZ Gasturbine powerplant solutions

� CHP*

� IGCC**

� Repowering

� Integrated solarcombined cycle

� HRSG

Instrumentationand Electrical

(PG IE)Compressors

(PG CP)

Large GasTurbines,

Generators(PG GT)

DistributedGeneration

(PG DG)

Steam Turbines(PG SU)

EnergySolutions(PG ES)

� Controlsolutions

� Electricalsolutions

� Energymanagementsolutions

� Solutions fordistributed andhybrid powergeneration

Power and Gas (PG)

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SLM Rapid Manufacturing and Rapid RepairAdditive manufacturing has arrived in customer engines

§ Long repair times§ Costs for repair

Driver Result

§ Significant lead timereduction

Rapid Repair

SLM burner repair

§ Long lead times§ Long time line for

implementation ofnew designs

Driver

SLM-Swirler

Result

§ Lead time reduction by sixmonths§ short term implementation of

re-designs

Rapid Manufacturing

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IndustrializationLine Integration

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Hannover Fair 2015Digitalization Forum

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Additive Manufacturingprocess overview

2D conversion

AdditiveManufacturing

Product

CAD / CAM design

Additive Manufacturing summarizes various production processes.

Production process MaterialPowder bed fusion

Vat photopolymerization

• Metal• Polymer• Ceramic

• Photopolymer

Directed energy deposition • Metal

Material extrusion • Polymer

Material jetting

Binder jetting

• Photopolymer• Wax• Metal• Polymer• Ceramic

1 based on ASTM F2792-08

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Our Portfolio for AM covers the entire Value Chain

Siemens competence

PL portfolio

CT expertise,plants: Application know-how

Scanlab

AS, MC, PL portfolio

Plants, energy, railways

Plants, energy, railways

PLMsoftware

Materials

OEMs

Production

"Print heads"

Automation& Drives

Products& services

Added value

Reproduced Optimized Completed

PROFINET

SINUMERIKwith SINAMICS S120

Sinumerik OP

SIMATIC ET200 SP

SCADA

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Additive Manufacturingis influencing high end and daily life applications

Energy, aerospace,automotive

Medical andhealth care

Daily life

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Siemens vision ofindustrialized Additive Manufacturing

Material Finishing

4. Line Integration

MOM*

KPI based Certificates

5.

Increased part accuracyOne seamless software platform synchronizing theentire PLM tool chain down to the machine runtime(e.g. optimized formats w/o “STL-triangles”)

1.

PP

CAE

CAM

CAD

1.Design &

Simulation

2.

AM machine

3.

5. Increased production efficiencyKPI based certificates for documented part quality ofproduced parts w/o inefficient workarounds(e.g. w/o computer tomography)

2. Increased process qualityReal time acquisition, analysis and control of therelevant process data on the machine level(= closed loop control)

3. Increased machine efficiency & flexibilityOpen CNC enables comprehensive machine dataanalytics for continuous improvement(e.g. condition monitoring)

4. Enhanced process streamFully automated horizontal work flow integratingpre- and post- processes in one production line(strong analogies with production machines)

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The Siemens portfolio along the entire value chainenables the industrialization of AM

PLM Software Automation Products

MaterialPROFINET

SINUMERIK with

SINAMICS S120

SINUMERIKOP

SIMATICET200 SP

HMI

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Production

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Siemens Bets Big on Metal 3D Printing with €21.4Million Facility

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Siemens Bets Big on Metal 3D Printing with €21.4Million Facility

Ø €21.4 Million FacilityØ Currently staffed with 20 employees such as operators and engineersØ Producing metal 3D printed components for Siemens’ own industrial gas

turbinesØ Both for prototyping, as well as for end-part production and repair.

Thorbjorn Fors, global business director for Distributed Generation at Siemens, said of the facility, “Withthis investment, we can develop new and improved components and repairs, for example burner tips toserve our industrial gas turbine SGT-800, significantly faster. Using this innovative approach, we willshorten repair times from months to weeks. It is an important step in our ability to respond to the needsof our customers.”

http://3dprintingindustry.com/2016/02/03/66016/?utm_source=3D+Printing+Industry+Update&utm_medium=email&utm_campaign=5ff97e5909-RSS_EMAIL_CAMPAIGN&utm_term=0_695d5c73dc-5ff97e5909-64470153http://www.mynewsdesk.com/se/siemens_ab/pressreleases/siemens-oeppnar-sveriges-foersta-3d-verkstad-foer-serietillverkning-av-metallkomponenter-i-finspaang-1307672

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Summary and Outlook

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Additive Manufacturingis a key technology to fulfill market requirements

Market requirements

Individualizedmass production

Increased energy andresource efficiency

Shorterinnovation cycles

1) ISO/TC 261 – Additive manufacturing

AdditiveManufacturing1

Highly complexstructures anddesigns

Designed-infunctionality

High endresilient materials

Levers

Spare partson demand

Rapid prototyping

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Summary

Additive Manufacturing …… facilitates optimizationpotentials.

… is on the path ofindustrialization.

… requires a holistic digitalizedapproach.

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Many thanks for your attention!

Martin SchäferSenior Key Expert “Additive Manufacturing”Corporate Technology / Germany /CT RTC MAT COA-DE

Siemensdamm 5013629 Berlin

Phone: +49 30 386 – 23087Fax: +49 30 386 – 25764Mobile: +49 173 9795263

E-mail:[email protected]

intranet.ct.siemens.com

Questions???