The Science of Additive Manufacturing and What the Future ... · Additive Manufacturing Systems...

The Science of

Additive

Manufacturing and

What the Future Holds

Amy Elliott, PhD Research Staff Manufacturing Demonstration Facility

Oak Ridge National Laboratory

Oak Ridge, Tennessee

Key Takeaways

•About me

•The ten principles of additive manufacturing

•ORNL leading the way in areas of deposition rate and material science

•How additive manufacturing can be applied in companies

2 SPARK – Additive Manufacturing

Amy Elliott

BS – Mechanical Engineering (Tennessee Tech)

PhD – Mechanical Engineering (Virginia Tech)

Research: Additive Manufacturing

World’s First 3D Printing

Vending Machine


The Big Brain Theory – May 2013


Science Channel – Outrageous Acts

of Science: Season 4 – Present

Internet Movie Database Rating

(IMDb.com): 7.3/10

Total Episodes: 52

Average Viewership: 586,000

(http://tvbythenumbers.zap2it.com/)


1986: 3D Systems Stereolithography

Apparatus (Chuck Hull)


1995: Zcorp Indirect 3DP (MIT)


http://www.deskeng.com/virtual_desktop/?p=4722

https://c479107.ssl.cf2.rackcdn.com/files/12740/

area14mp/8k5997rw-1341844144.jpg

Bought by

3D Systems

in 2012

1989: Fused-Deposition Modeling –

Scott Crump, Stratasys


Types of Additive Manufacturing

ASTM International: Technical Committee F42 on Additive Manufacturing


Vat Photo- Polymerization

Material Jetting

Material Extrusion

Sheet Lamination

Powder Bed Fusion

Directed Energy Deposition

Binder Jetting

Principle 1: Complexity is Free


Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

Withinlab.com

Principle 2: Variety is Free



Goyaldiecast.com

Principle 3: No Assembly Required



Austechexpo.com.au

Replicatorinc.com

Principle 4: Zero Lead Time



Makepartfast.com

Principle 5: Zero Skill Manufacturing



Makepartfast.com

Principle 6: Less Waste



Principle 7: Infinite Shades of Materials



Key Principles of Additive Manufacturing


Replicatorinc.com

Complexity is Free Variety is Free

No Assembly Required

Less Waste

Infinite Shades of Materials Zero Constraints

Four more: Zero Lead Time, Compact and Affordable, Low-skill, Precise Replication

Manufacturing Demonstration Facility


Manufacturing Demonstration Facility: a multidisciplinary DOE-funded facility dedicated to enabling demonstration of next-generation materials and manufacturing technologies for advancing the US industrial economy

www.ornl.gov/manufacturing

Working with ORNL’s MDF

• Identify opportunities aligned with ORNL’s MDF technology thrust areas

• Discuss ideas with the MDF director

• Jointly pursue funding to support collaborative activity


Ever-Growing Partnerships:

Integrating the AM Supply Chain


• Site-specific material addition

• Application of advanced coating materials for corrosion and wear-resistance

• Repair of dies, turbines, etc.

• Metal matrix composites and sintered materials including:

• Stainless steel + bronze

• Tungsten + titanium • Ceramics + sand • Large build volumes

(10 x 10 x 16in) • Fast build times (30

sec/layer)

• Open-air environment • MIG welding arm with

6 DOF and 2 rotational degrees

• Print size not restricted

• Uses low-cost welding torches and wire

• CAD-to-path functionality

• Unheated powder bed

• Wide range of material choices (316L, 17-4PH, H13, Al, Ti, 718, 625)

• Precision melting of metal powders

• Up to 630 x 400 x 500mm build volume

Additive Manufacturing Systems

• Simultaneous additive and subtractive process for manufacturing complex geometries

• Solid-state process allows embedding of optical fibers and sensors

Ultrasonic Additive Manufacturing (1)

Laser Metal Deposition (1)

Selective Laser Melting (3)

Metal Binder Jetting (2)

Large-Scale Welding (1)

Electron Beam Melting (4)

• Developing in-situ characterization, feedback, and control

• Heated powder bed • Expanding range of

materials (Ti64, CoCr, 625, 718)

• Precision melting of powder materials


• Capable of depositing 300mL/minute

• Can control material properties and speed on the fly

• Cross-linking between layers

• 2-part resin

Additive Manufacturing Systems Cont’d

23 SPARK – Additive Manufacturing 23 SPARK – Additive Manufacturing

• Reducing buy-to-fly ratio of aerospace components

• Using 4kW laser and two 10kW lasers to melt Ti64 wire

• Inert system with argon-filled tent

• Prints ~10cubic inches/hr

• First rapid-quench HIP in America

• 180mm diameter • Can reach

pressures of 25,000psi

• Cooling rates of 3000C/min when cooled from 3000C

• Can HIP and heat treatment in same cycle

• Deposits up to 1000lbs. of pellet feedstock material per hour

• Build volume up to 20’ long x 6’ wide x 8’ tall

• Printed >37 different polymers and composites

• Dual material capabilities

• Under development • Will have 46’ x 23’ x

10’ build volume • Target deposition

rate of 1000 lbs./hr. • Will be 10x larger

and faster than previous commercial systems

• ~0.005” – 0.007” resolution

• Up to 914 x 610 x 914mm build volume

• 0.5 – 1.5 in3/hr. • Ultem and ABS

Large-Scale Laser Metal (1)

Hot Isostatic Press (1)

Large-Scale Polymer Deposition (3)

Ingersoll Large-Scale Polymer Deposition

Thermoset Dual Material Extrusion (1) Fortus MC

Big Area Additive Manufacturing (BAAM)

• Large scale deposition system

• Unbounded build envelope

• High deposition rates (~20 lbs/h)

• Direct build components

• Tools, dies, molds

• Carbon fiber material reduces warping out of oven


BAAM Printed Car with Local Motors

and Cincinnati Incorporated



• Throughput • Feedstock Cost

Vecna.com

Printed Car with Local Motors


3D Printed Shelby Cobra



AMIE Demonstration

Additive Manufacturing Integrated Energy (AMIE)

Digitally Manufactured Molds

Successfully Withstand Autoclave

ORNL’s digitally manufactured, high temperature thermoplastic molds withstood industrial autoclave cycles for the first time ever!


November 2015: Industry partners came to MDF to collaborate on this tooling

development effort Six new materials were successfully tested on the BAAM-CI during these trials

March 2016: Results from preliminary thermal characterization conducted at the

University of Tennessee Knoxville were very promising. Over three weeks, four tools

were fabricated using the two selected high temperature materials. Tools were 100%

digitally manufactured. No touch labor was involved. Each tool was printed in 1

hour and machined in 4 hours. Usual lead time is 14 weeks April 2016:The four tools were taken to an industry partner’s facility for testing from

April 5th – April 8th.

The tools withstood two autoclave cure cycles.

This was the 1st successful trial of 100% digitally manufactured tools in

autoclave cure cycles.

Carbon Fiber Technology Facility


A national asset to assist industry in lowering carbon fiber cost,

scaling technology, and developing products and markets

Scalable Process for Producing Low-

Cost Carbon Fiber

The Carbon Fiber Technology Facility at ORNL has developed a method for producing industrial-grade structural carbon fiber and flame-retardant fibers from commercially available acrylic precursor materials.


Exceeds DOE target

mechanical performance for

automotive applications

>50% cost reduction over

traditional production methods

From low-cost, commercially

available multipurpose

use commodity fiber

Exhibits properties equal to or exceeding

conventional carbon fibers

Increase in capacity

greater than 3x over traditional

conversion process

equipment

Power reduction up to

60% per unit vs. traditional

conversion techniques

Scalable Process for Producing Low-

Cost Carbon Fiber Cont’d


Vehicle Lightweighting

Reduce vehicle weight by using

carbon fiber throughout body and

chassis

Wind Energy

Build turbine components and

longer blade designs for applications in

wind energy

Gas Storage

High-strength, lightweight pressure

vessels for storage of gas

Recreational Equipment

Next-level performance for

sporting goods and recreational equipment

Enabling Next-Generation Robotics

• Titanium made using E-beam AM (operating pressure 3000 psi)

• Integrated pump, fluid passages, and pistons with mesh for weight reduction


Curved

fluid

passages

Pistons

integrated into

structure

Integrated

motor

and pump

Project AME

Additively Manufactured Excavator


Oak Ridge National Laboratory, in collaboration with

numerous partners in industry, government, and

academia, have produced the first fully

functional excavator using additively

manufactured components. Known as

Project AME, this working demonstration

showcases a wide range of industrial

applications for 3D printing.

Enabling AM of Aerospace Brackets

Collaboration with Industry

• Bleed Air Leak Detect (BALD) Brackets

• Buy to fly ratio of 33:1

• AM can reduce to 1.5:1

• ARCAM parts HIPed (900 ºC, 15ksi, 2 hours)

• Decrease cost by over 50%


Property Minimum Value Maximum Value

Ultimate Tensile Strength, (ksi, MPa) 132 910 152 1,048

Elongation, % 12 22

Over 60 tensile specimens tested within a matrix of processing conditions

Enabling AM of Aerospace Brackets Cont’d


Enabling AM of Turbine Blades

Science to Application

• Optimized internal cooling structures are desired for maximum efficiency

• AM can produce geometries not possible with conventional

• processes

• Decrease

• manufacturing

• costs while

• maximizing

• performance


Turbine blade

Reconstructed image

using neutron tomography

Profilometry map illustrating distortion

Laser AM creates

large residual

stress leading to

distortion

laser AM of

turbine blade


Enabling AM of Turbine Blades Cont’d


Headquartered in Cincinnati, OH

•Largest number of AM

machines worldwide

•18-yrs experience in

laser deposition

•Works with every

major aerospace

company in US

Critical to widespread adoption of technology

Understanding link between

residual stress and additive

manufacturing

Utilizing neutron science to impact industry

Case Study: Throughput and

Operator Burden


Figure 1: Arcam battery box

Figure 2: ExOne battery box

Figure 3: Renishaw battery box

Electron Beam Binder Jetting

25 hours 32 hours 160+ hours 1 Part

4 Parts ~100 hours 200+ ~35 hours

Laser

Mapping of Crystalline Structures


Highly textured Polycrystal Letter contour has some texture

R. R. Dehoff,, M. M. Kirka,, W. J. Sames,, H.Bilheux, A. S. Tremsin, L. E. Lowe, and S. S.Babu,,. "Site specific control of crystallographic

grain orientation through electron beam additive manufacturing." Materials Science and Technology 2015

AM Adoption and the Point of No Return...

Phase 1: Redesign

Individual Parts for AM

• Example: Optimized

Brackets

Phase 2: Redesign

Assemblies for AM

• Example: Rolls Royce

Trent Engine Blades

Phase 3: Redesign entire systems

• The point of no return – tooling,

process, and design revolves

around certain technologies

Reversible | Irreversible


Key Takeaways

•Additive enables • Optimized design and functionality

• Elimination or cost-savings in tooling

•Most important areas for research • Fundamental throughput limits and their impact on

cost

• Material properties need to be fully characterized and correlated with process parameters


Discussion


Amy Elliott

[email protected]

(865) 946-1577

The Science of Additive Manufacturing and What the Future ... · Additive Manufacturing Systems...

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