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Quality and Additive Manufacturing…What You Need to Know and LearnShane Collins 4-14-17
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IntroductiontoAdditiveManufacturingUniqueaspectsofAdditiveManufacturingSignificantQualityConcerns
Quality Concerns for Additive ManufacturingAgenda
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Introduction to Additive Manufacturing
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• Foundedin2005forAdditiveManufacturingofmetalcomponents.
• AS9100certifiedsince2006.• ITARregistered.• NADCAPaccreditationinprocess
• LocatedinVenturaCountyinSouthernCalifornia.• AcquiredbyInsightEquityin2014.• Currentlymanufacturingstructuralflighthardwarefortwosatelliteproducerswithpowderbedfusion.
MB CalRAM Overview
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Space Systems Loral Antenna TowerHundreds of parts per satellite, but each part is unique
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Additive Manufacturing or 3D Printing
AMProcessCategories
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Material Jetting
• AM process in which droplets of build material are selectively deposited
– Wax or Photopolymers– Multiple nozzles – Single nozzles– Includes
• Objet• 3D Systems Projet• Stratasys Solidscape machines• Several Direct Write machines• XJET• Etc.
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Vat Photopolymerization Process
• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization.
– Stereolithography– DLP– Micro-SLA
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Material Extrusion
• AM process in which material is selectively dispensed through a nozzle or orifice.
– Based on Stratasys FDM machines
– DIY community
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Sheet Lamination
• An additive manufacturing process in which sheets of material are bonded to form an object.
– Paper (LOM)• Using glue
– Plastic• Using glue or heat
– Metal• Using welding or bolts• Ultrasonic AM…
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Binder Jetting
• AM process in which a liquid bonding agent is selectively deposited to join powder materials.
– Zcorp– Voxeljet– ProMetal/ExOne– …
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Directed Energy Deposition
• AM process in which focused thermal energy is used to fuse materials by melting as they are being deposited
DMGMori
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Powder Bed Fusion
• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed
– SLS®, SLM®, DMLS®, EBM®, BluePrinter, etc. – Polymers, Metals & Ceramics
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Conventional AM Prototype Uses
Rapid Prototyping• Wind Tunnel Models• Form-Fit-Function
Models• Experimental Rigs• Desktop Models
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Indirect AM for Production Applications
Surfacerepairusingdirectedenergydeposition.MIL-STD-3049
3Dprintedmoldsforsandcastingusingmaterialjetting.
3Dprintedinvestmentcastpatternsusingmaterialjettingandvatphotopolymerization
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Production AM Platform Categories
Polymers Metals
PolymerPBF
MaterialExtrusion
LaserPBF
ElectronPBF
DirectedEnergyDeposition
HybridDED/CNC
ProcessTechnology
ProductionMaterials
Applications
Polyamides
PAEKs
Ultem®
Polyamide12
17-4PH15-5PH316LToolSteelTi6-4Ti6-4ELITiCPIN718IN625HASXAlSi10MgCoCrMo
CoCrMoTi6-4Ti6-4ELITiCPIN718TiAl
Ti6-4Ti6-4ELITiCPTi6-2-4-213-817-4PH304316L4104204047IN625IN718ToolSteel
SameasDED?
DuctsBracketsFixturesUAVparts
BracketsCompositeTooling
NearNetShapeParts
PartPreforms
PartRepair/LargeParts
TBD
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ImplementationProgressofHighDensityNylon12SelectiveLaserSintering(SLS)
• Nylon12SLSwasfirstAdditiveManufacturing(AM)processimplemented;adoptionisinearlystagesandusecontinuestogrow
AsofOct2013Part#’s/Veh.
TotalParts/Veh.
6Part#’s7TotalParts
7Part#’s7TotalParts
3Part#’s3TotalParts
18Part#’s22TotalParts
24Part#’s31TotalParts
15Part#’s223TotalParts
ThousandsofAMPartsFlyingonNGASAirVehicles
Nylon12SLSDesign
AllowablesDatabase&Associated
Specifications
UCAS-D
Global Hawk
FireScout
Triton
Firebird
SpecialPrograms
NorthropGrummanOakRidgePresentation
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*About20,000partsmadebylasersinteringarealreadyflyinginmilitaryandcommercialaircraftmadebyBoeing,including32differentcomponentsforits787Dreamlinerplanes.
*Jerry Clark, Boeing
Laser Sintered Nylon Parts for F/A-18 began ~ 2001
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X-47B Air Mixer (2010)Ti 6-4
Boeing 777 LED Light Housing (2006)
17-4 SS
Early Examples of Metal Powder Bed Fusion for Production Applications
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Laser Sintering Material Extrusion
Stratasys Fortus
Cincinnati BAAM
EOS
3D Systems
AM Production Technology-Polymers
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Direct
Powder Bed Fusion
IndirectMetal Powder ConsolidationAnd Sand Cast Patterns
ExOne
Voxeljet
Directed Energy Depositon
Hybrid Systems
AM Production Technology-Metals
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Concept LaserEOS
3D Systems
SLM Solutions Renishaw
Realizer
Farsoon Additive Industries
Trumph
Arcam
A Sampling of Metal Powder Bed Fusion Machines
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When to Use Additive Manufacturing
ScheduleReduction
ExpensiveChips
LowVolume
TolerancebyFeature
HighComplexity
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Barriers to Additive Manufacturing3DCADIsAvailable
MaterialandProcessStandardsExists
DesignAllowableDatabaseExists
SupplyChainExistsfortheAMProcess
MaterialSubstitutionsAreAllowed
DesignChangeAuthorityExists
NDEIsAvailableforTechnology
AdditiveManufacturing
TraditionalManufacturing
NO
NO
NO
NO
NO
NO
NO
InterpretDrawingsor3DScanYES
NO
CreateInternalSpecificationsYES
NO
Non-StructuralPointSpecificationYES NO
YESTimetoDevelop
Vendors NO
AMPartPropertiesEquivalenttoWroughtYES NO
NO
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The Promise of Additive Manufacturing
LightweightStructures
CompetitiveAdvantage
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Unique Quality Aspects of Additive Manufacturing
PowderbedfusionMaterialextrusion
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Metal Powder Bed Fusion Combines
Welding PowderConsolidation
NumericalMachine
Control
PBF
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SDO Involved
Welding PowderConsolidation
NumericalMachine
Control
PBF
AWSASMEY14.46
ASTM
IEEE
ISOTC44
ISOTC261
MPIF
NEPA
SAEAMS-AM
NADCAP
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PBF Inputs Affecting Quality
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Quality Concerns both Internal and with Supply Chain
MachineSet-up
DataPreparation PBFProcess Machine
TurnaroundPost
Processing
• Digitalproductdefinition
• CADModification• Support
Generation• Machinecontrol
softwareconfigurationmanagement
• Pre-buildchecklist
• InstallPlatform• Fillingpowder
reservoir• Recycle
strategy• Machine
fitness
• Selectalloyspecificsettings
• Loadexposures• Warmupbuild
platform• Startbuilding
process• Document
buildingprocess
• Cleanprocesschamber
• Powdercontaminationcontrol
• Emptycollectorreservoir
• Cleanmachine
• StressRelief• Removeparts
fromplatform• HIP• Thermal
Processing• Coatings• Witnesscoupon
testing
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BeamOverlap
OMtopviewafterscan
Beampower,Hatchspace,Scanspeed,Layerthickness
• ThinsectionOMshowfulldensity• Mechanicalpropertiesmeetspecificationminimum• Createfixedbaselinemachinesettingsfor
ManufacturingPlan
Layer-wise Welding Produces Unique Microstructure
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PowderConsolidation
MicrostructureMechanicalProperties
PartAttributes
ExposureParameters
ScanStrategyandThermal
Treatments
ThinWalls,Overhangs,HollowAreas
PBF Parameters Determine Porosity and Part Buildability
SurfaceSlowbeam Fastbeam
New Layer
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NitrogenTemp Yield (ksi) ULT (ksi) Elong % R.A. % S/N
RT 129 165 28 35 RFH-ZRT 127 165 32 46 RRH-ZRT 125 165 31 44 LRH-ZRT 130 166 29 45 LFH-ZAve 127.8 165.3 30.0 42.5RT 138 179 25 34 LRVRT 135 179 26 29 RFVRT 134 181 26 30 LFVRT 134 178 29 32 RRVAvg 135.3 179.3 26.5 31.3
ArgonTemp Yield (ksi) ULT (ksi) Elong % R.A. % S/N
RT 125 166 29 41 1-ZRT 123 165 27 42 2-ZRT 122 165 29 41 3-ZRT 123 166 27 33 4-ZAve 123.3 165.5 28.0 39.3RT 130 174 28 28 5RT 130 174 28 25 6RT 130 175 27 30 7RT 129 173 29 28 8Avg 129.8 174.0 28.0 27.8
Affect of Purge Gas on 17-4 SS Properties
ObservetheanisotropicbehaviorbetweentensilebarsbuiltinX,YvsZdirection.
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Powder Affects Part Quality
Particlesizedistribution,powdermorphology,powderrheology
Recoater generatingceramicinclusionsinusedpowder
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PBF Feedstock Diagram
• Usedpowderisallowedtoberecycled.• Theproportionofvirginpowdertousedpowder
shouldberecordedonthecomponenttravelerwithcorrespondinglotnumbers.
• Componentpurchasermayspecifynumberoftimesusedpowdercanberecycled.
• Outofspecificationpowdershouldbescrappedandnopowderdopingallowed.
• Stratificationofvirginandusedpowderinthefeedbinnotrecommendedforproductionapplications.
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Internal Cavity Challenges with PBF
Smallholedefinitionandremainingsinteredparticles.
Down-facingsurfacesoninternalchannels.Internalsupportswouldnotberemovable.
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FeedstockAnalysisAndTestingLab
AdvancedSubtractiveMfg.
ComputerTomography
UltrasonicPowderRemoval
Powder Bed Fusion Supply Chain Management
AbrasiveFlowMachining
HotIsostaticPressing
HeatTreatment
MultipleOSPpresentparttrackingchallenges
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Challenges with Material Extrusion
Beadturnspronetohaveporosity.
Smallvariationindiameterofplasticfilamentcaninduceporositybetweenlayers.
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Digital Product Definition
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Significant Quality Concerns
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No Standard AM Callouts
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ASTM F42 Working to Develop Standards for AM
42
X-rayinspectionsperASTME1742– 2TsensitivityAMS2635– GradeA
P.O.21451 AlSi10Mg LOC.:80NO X TOP 25X
1000 µm
P.O.21451 AlSi10Mg LOC.:80NO Y TOP 25X
1000 µm
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ASTM F42 Working to Develop Standards for AM
43
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Questions
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Additive Manufacturing Health and Safety
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Health and Safety in AM for Aerospace and Defense
AMProcessCategories FeedstockTypes HealthandSafetyImpact
DirectedEnergyDeposition Metalwire,metalpowders Dust,fireandexplosion
MaterialExtrusion Polymerwire,gels,concrete Vapors
MaterialJetting Liquidpolymers Vapors
VatPhotopolymerization Liquidpolymers Vapors,skinirritation
BinderJetting Organicpowders,metalpowders,ceramicpowders,polumerpowders Dust,fireandexplosion
PowderBedFusion Metalpowders,polymerpowders Dust,fireandexplosion
SheetLamination Ceramicsheets,metalsheets General H&S
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Is 3D Printing Safe – A Study at Penn State University
PresentedatSolidFreeformFabricationbyTimSimpson
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Particle Counters and VOC Detection
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Particle Emissions from Material Extrusion 3D Printers
ChartsarefromMastersThesisbyWilliamMcDonnell
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Volatile Organic Compounds
ChartsarefromMastersThesisbyWilliamMcDonnell
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From 3D Printers to Metallic Part Production
Powder Bed Fusion
Directed Energy Depositon
Hybrid Systems
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TypicalAMAlloysTitanium
Ti 6Al-4VTi 6-2-4-2TiAl
AluminumAlSi10Mg
SteelNi-Fe17-4316L
NickelIN625IN718HasX
TypicalAMPolymers
PA-11PEIPEKKPEEK
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Health and Safety Affects of Powders
AirborneDustsSkin,eyeandrespiratoryirritants
ChemicalHazardsReactivemetalpairsandthermites
CombustibleDustsFirePrimaryandsecondaryreactions
ImperialRefinery;Savannah,GA,2008;fromwww.csb.gov
Theexplosiontriangle:Airbornedustconcentrationsalongwithanoxygenrichenvironmentandanignitionsource.
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Personal Protection for Handling Metal Powders
WhentoWear• Loadingpowderintomachine• Unloadingfinishedparts• Changinggasflowfilters• Sievingpowderoffline• Mixingpowders
Headandfaceshield
Respirator
Fireretardantfabric
Weldinggloves
Conductivefootwearwithsteeltoe
Fireretardantfabric
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Fire Codes for AM Powders
• NFPA484StandardforCombustibleMetals• Aluminum,TitaniumandMagnesiumconsidered
combustible
• NFPA68StandardonExplosionProtectionbyDeflagratingVenting
• Ceilingblowoutpanelshouldbeconsideredforaluminumandtitanium
• NFPA654StandardforthePreventionofFiresandDustExplosionsfromtheManufacturing,ProcessingandHandlingofCombustibleParticulateSolids
• Keepallareascleanandfreefromspills
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My Decade of Experience Working with Powder Bed Fusion
• Accidentshaveoccurredwhenworkinstructionswerenotfollowedcorrectly.• Changingfilters• Vacuuminsideofchamber• Disengagingmachinesafetyswitches
• Accidentshaveoccurredwhenancillaryequipmentwasnotmaintainedproperly.• Groundingstrapsonvacuums• Wearingofvacuumhosetips• Vacuumsnotcleanedoutregularlyandmixingpowders
• Sievingequipmentinstalledincorrectly• Noproperground• Noinertgasatmosphere
• Handlingofmetalpowderbedfusionfeedstocksusuallydonotproducedustclouds.
• Dustdoesbuilduponfloorsandtablesincloseproximitytomachinesoverafewdaysandrequireconsistentcleaning.
• Dependingonthetypeofmachine,filterchangescanbedangerous.• I’veneverbeeninorseenanyfiresmorethanasmolderingfilter.
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Other Safety Considerations for Metal Powders
AsphyxiationduetoshieldgasaccumulationinworkroomDrophazardforbuildplatesHandlacerationsfromsupportmaterialremovalFormationofhydrogengasduringwireEDMprocessforaluminumRemainingpowderinsupportsoraccumulatedscrappowderignitedbysandingorgrinding.
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Questions