ALM Additive Layer Manufacturing Metals Technologies

Dr.-Ing. Rainer RAUH Vice President

Head of Global Innovation Network - Platform Structures

London, 19th & 20th Nov, 2013

EADS – CTO

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18/11/2013

Background

A350-900 XWB Material Breakdown (%) Including Landing Gear

Al/Al-Li (Ribs, Floor beams, Gear bays,..) 19%

Titanium

14%

Steel 7%

Misc.

7%

Composite 53%

Titanium  is  needed  as  “Partner”  for  Composites    

Wing

Fuselage

Belly Fairing

Empennage

Frames

Reminder: 14 % Titanium parts on the A350XWB

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Additive Manufacturing Processes

Direct Deposition Layer Deposition

The Principle: Deposition Process Types

The productivity on the final part will decide the right process

Direct Metal Laser Sintering (DMLS)

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Advantages • Excellent Geometric flexibility & detail of features • Net-shape parts (little or no surface finishing required) • Relatively good dimensional tolerance achievable (+/- 0.2mm) • Excellent static properties (Ti6Al4V UTS > 1000MPa) • Acceptable fatigue properties ( Cast < ALM < Wrought)

Limitations • Maximum part size is limited (typically 250 x 250 x 250mm) • Relatively slow process (0.05kg/hr) – but getting quicker • Residual stress requires post process heat treatment • Must be fused to build plate and support structure required • High cost of powder feedstock – economies of scale

Applications: • Small complex parts, preferably produced in batches • Expensive, hard to machine materials (e.g. Titanium Alloys) • Parts with high buy/fly ratio • Parts with internal features (e.g. cooling channels) • Low volume production or prototyping

EOS M280 DMLS System

Parts on build plate Finished parts

ALM Processes: Metals Technologies

Example Application – Wingsail Hinges

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CAD Model Titanium ALM Parts Fitted to Invictus Wing Sail

The Challenge • Produce a set of wing to flap hinges for Team Invictus wing-sail. • Complex thin-wall titanium alloy parts • Short timescales for delivery

The Principle: Deposition Process Types

Electron Beam Melting (EBM)

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Advantages • Excellent Geometric flexibility • Very Near Net Parts (minimal surface finishing) • Good  fatigue  properties  (  ALM  ≈  Wrought) • Very Low Residual Stress – no stress relief required • Parts not fixed to build plate – less post processing • Relatively fast process (0.2kg/hr) • Very energy efficient process

Limitations • Maximum part size is limited (typically 200 x 200 x 350mm) • Surface finish is relatively poor – requires some post processing • Powder cost relatively high (but cheaper than for laser based) • Hot Isostatic Pressing required to achieve best fatigue properties

Applications: • Very-near-net pre-forms for small parts • Small batch production • Larger parts where distortion in DMLS would be prohibitive • Currently used to manufacture certified medical hip implants

Arcam A2 EBM System

EBM parts as-built (left) and post-machining (right)

EBM Process Video

Weight and Costsaving

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• First ALM (Additive Layer Manufacturing) commercial application in GEO on ATLANTIC BIRD 7, launched on September the 27th 2011, operational since October 23rd (Eutelsat): Titanium mast node.

Titanium ALM Part now Flying in Space - Astrium

Electron Beam Melting® (Arcam process), Ti64 powder based

Large potential of application to other

parts efficient production !

The Principle: Deposition Process Types

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Proprietary Material – ScalmalloyRP

• ALM processed Aluminium Alloy with excellent mechanical properties

• Static & Fatigue properties are improved compared to 7050 plate material

• Lower density than traditional aerospace Aluminium alloys

• Significant weight benefit when compared to aerospace Aluminium alloys used in castings

ScalmalloyRP Leading Edge Rib Demonstrator Static Strength better than 7050 Plate and with higher ductility

ALM Processes: Metals Technologies, Aluminium

Wire Feed Deposition

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Advantages • Low cost feedstock (Welding filler wire) • High deposition rate (up to 10kg/hr) • Scalable to large parts with relatively thick geometry • Relatively good mechanical properties demonstrated • Near-net pre-forms can be produced with no tooling • Wide variety of possible power sources (Laser, EB, TIG, MIG, CMT) • Excellent  Fatigue  properties  (  ALM  ≈  Wrought)

Limitations • Very poor surface finish – surface machining essential • Residual thermal stress – requires stress relieving • Anisotropy possible depending upon deposition strategy

Applications: • Near-net pre-forms for large parts • Addition of local features to large preforms

Example large part being deposited at Cranfield

Cranfield University HiVE platform with 3m demonstrator

Weight and Costsaving

Design Opportunities: Highest Complexity

Design for ALM - Example

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18 November, 2013

• Minimise cross sectional area in slice – minimise internal stresses • Minimise local rate of change in cross-section through z-direction • Maintain continuity where possible – minimise risk of distortion mismatch

Top View

Design Opportunities: Complexity gives Weight Savings

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Process Speed • ALM processes are currently very slow – currently suited to low volume production • Speed must increase without a loss of precision!

Powder Cost • Powder market is currently limited – hence high cost/kg • Potential for improved powder production techniques & larger market to drive down costs

Titanium and Aluminimium parts: stabilize powder & process parameters Start qualification right powder/wire right process, right online process control Develop & adapt design and stress methods to get highest weight saving Develop the right supply closed supply chain

ALM on Metals: Next Steps

A  potential  future  for  More  Electrical  Aircraft…

The Future of More Electrical Aircraft

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