Additive Manufacturing for Aerospace Applications – Lessons Learned

6,051 views

Published on

Additive manufacturing technologies allows to get rid of pre-existing manufacturing restrictions that previously have limited a designer’s ability to make the product they had in mind. With these processes, products can be highly customized to the user thus, potentially increasing their applications. As additive manufacturing technologies evolve, and more new materials become available the field of product design has the potential to greatly change.

In order to fully exploit the capabilities of these technologies the application of the term “design freedom” for weight reduction as well as functional optimizations takes up a key role. FEM tools such as Altair Inspire provide the possibility to design parts, purely based on boundary conditions taking full advantage of the possibilities provided by additive manufacturing.

The presentation will show the application of such a numerically supported part design covering the complete process chain from idea to a “ready to fly” product. The potential of weight savings and lead time reduction as well as future needs in order to close existing gaps in the design process are addressed.

Published in: Engineering, Technology, Business

Additive Manufacturing for Aerospace Applications – Lessons Learned

  1. 1. Additive Manufacturing - Lessons Learned European Altair Technology Conference 2014 Andreas Nick, APWorks GmbH 25.06.2014 Acknowledgements: Airbus Group Innovations TX2 Airbus Cabin Innovation & Design (ECIU1)
  2. 2. APWorks – feel the power of AIRBUS Group technologies APWorks GmbH - Advanced Process Solutions Page 2 02.07.2014 In light of the increasing amount of new, complex technologies and manufacturing process solutions available within AIRBUS Group, APWorks GmbH was founded to leverage this knowledge, offering it to the outside world. As a 100% AIRBUS Group subsidiary, the company maintains close working relationships with the AIRBUS Group research and technology arm, AIRBUS Group Innovation, as well as the corporation’s divisions Airbus, Airbus Helicopters, and Airbus Defense & Space. Located near Munich, Germany, at the Ludwig Bölkow Campus, which pools high technology initiatives together, APWorks is situated in close proximity to AIRBUS Group divisions and other high tech companies such as IABG and Siemens.
  3. 3. The Future by Airbus – The Airbus Concept Plane APWorks GmbH - Advanced Process Solutions Page 3 02.07.2014
  4. 4. 5 Core Technology Themes APWorks GmbH - Advanced Process Solutions Page 4 02.07.2014 ATMOSPHERE • Natural Lighting • Bioluminescence/Surface Lighting • Nano System Technology • Aerosol Dispenser ADVANCED MATERIALS • Healthy Fabric & Interior Membranes • Recyclability & Hygiene • Morphing / Self-healing • Transparent / Electro-chromatic / Interactive Surfaces INTELLIGENT DATA CONTROL • Neuronal Network / Quantum Comp • Sensors & Actuator (health monitoring) • Energy Harvesting • Holographics / NextGen HMI / Augmented Reality BIONIC PRINCIPLES • Intelligent structures (“strength were needed”) • Structural Integrated Functions • Living organism: adaptive • Artificial Intelligence SUSTAINABLE ARCHITECTURE
  5. 5. Core Enabler for a Future Cabin Architecture BIONICS Intelligent weight optimized bird bone structures providing strength where needed NEURAL NETWORK Neural networks sense & allow an optimum adaption of the cabin along energy harvesting and regeneration CABIN MEMBRANE Biopolymers harmonize external and internal environment for optimized cabin atmosphere APWorks GmbH - Advanced Process Solutions Page 5 02.07.2014
  6. 6. Optimization of single parts APWorks GmbH - Advanced Process Solutions Page 6 02.07.2014 New design principles in combination with new manufacturing technologies get mature today!
  7. 7. Enabling a Future Cabin Architecture APWorks GmbH - Advanced Process Solutions Page 7 02.07.2014 Build structures as nature would do it DNA building blocks Human Skelton (rivitless) CNT building blocks Large rivitless airframe
  8. 8. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 8 02.07.2014 COST Titanium Price Material Waste with traditional Manufacturing 90% waste 90% waste 90% waste Titanium Plate TIME QUALITY BENEFITS & CAPABILITIES Weight Savings Unique Geometric Capability New Materials Material Price increasingly expensive 0.89kg 0.35kg Material Waste with AM Additive Manufacturing guarantees high flexibility in design as modifying a part in retrospective only requires changing the virtual CAD data.PROGRAMME RISK MITIGATION Data Release DFM Complete Dies / Patern Complete First Production Article Up to 95 weeks for large / complex parts Opportunity for design changes or risk mitigation~12 weeks Forging / Investment Casting AM
  9. 9. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 9 02.07.2014 APWorks controls each phase of the AM value chain with customized services generating superior results: • Concept Development & Consulting • Prototyping & Job Shopping • Powder Sales • Demonstration Center APWORKS OFFER high performance Al- alloy low performance Al- alloy End of Part‘s Life AM Design Quality Assurance Process & Post processes
  10. 10. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 10 02.07.2014 APWORKS OFFER: AM VALUE CHAIN During the design phase, a 3D part concept is developed. Detailed design, engineering and simulation knowhow is needed to optimize and fine-tune the part’s design for structure, flow, cooling and RF efficiency. Depending on the material/part being considered, the most appropriate additive process is selected. Finally, different printing rules are applied in terms of orientation, support, powder removal and nesting, when preparing the part for printing. Stage 1 AM Design Part Concept Detailed Design, Optimization Process Selection Build Design & Preparation
  11. 11. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 11 02.07.2014 APWorks has invested in state-of-the-art systems to secure highest quality powder production and supports the development of new materials / alloys. With extensive in-house facilities and a developing supply chain, APWorks is able to offer a wide range of AM processes. With extensive experience and the facilities to perform surface treatment, APWorks ensures long term performance of AM parts. Heat treatment is an important factor in determining the performance of an AM part, and APWorks has extensive facilities and experience to ensure that the quality you require can be achieved. The influence of finishing processes on the optimum part design is often forgotten during the design phase. By managing design and post-processing phases we can achieve the most efficient solution. Most parts have some areas where machining processes are required in order to achieve precise tolerances. By managing the design and manufacturing steps, APWorks ensures that this is catered for. APWORKS OFFER: AM VALUE CHAIN Stage 2 Process & Postprosses Material Production & Qualification Heat & Preassure Treatment Machining of Interfaces Part Removal from Plate Surface Treatment AM Process
  12. 12. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 12 02.07.2014 Stage 3 Quality assurance Destructive testing Non-destructive testing Finished part Validation testing Metrology APWorks testing facility is also used for component validation testing, and depending upon customer requirements a test rig can usually be developed to support part qualification. Dimensional validation is an important step in the manufacturing process, and is possible even for complex parts using laser scanning and micro CT methods. APWorks has an extensive testing facility, enabling AM specimens to be tested in order to validate the material quality from the process, providing confidence to the customer. APWorks also has the latest micro-CT technology available to enable detailed non-destructive examination of even the most complex parts. By controlling the entire value chain, APWorks ensures the delivery of high quality final parts. Even after delivery of the finished part, after-sales services are available. APWORKS OFFER: AM VALUE CHAIN
  13. 13. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 13 02.07.2014 Repair Recycle End of life Repair processes are being developed to help extend product life in case of damage, and minimize environmental impact. Recycling is an important factor in today’s world, and we are developing the means to recycle end-of-life products back into qualified powder for re-use. APWORKS OFFER: AM VALUE CHAIN
  14. 14. Topology Optimization APWorks GmbH - Advanced Process Solutions Page 14 02.07.2014 Define Design Space and Boundary Conditions Boundary Conditions Loads Design SpaceOriginal Part
  15. 15. Topology Optimization APWorks GmbH - Advanced Process Solutions Page 15 02.07.2014 FEM Optimization Results Safety Factor = 2 Safety Factor = 3
  16. 16. Topology Optimization APWorks GmbH - Advanced Process Solutions Page 16 02.07.2014 Design Interpretation Key influences • Design for additive manufacturing  Minimize support structures  Minimize residual stresses  Minimize machine time • Minimize weight • Minimize surface area
  17. 17. Topology Optimization APWorks GmbH - Advanced Process Solutions Page 17 02.07.2014 Result Weight reduction > 45% Material – Al7XX sheet – Manufacturing Laser cutting and bending Weight – 81g Material – AlSi10Mg Manufacturing – ALM Weight – 43g
  18. 18. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 18 02.07.2014 TOPOLOGY OPTIMIZATION PROCESS Material – 15-5PH Steel Manufacturing – Casting + Welding Weight – 1.57kg Material – Titanium 6/4 Manufacturing – ALM Design - Symmetric Weight – 0.747kg G250 Main Exit Door Hinge 45% reduction in required time through use of MMP
  19. 19. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 19 02.07.2014 TOPOLOGY OPTIMIZATION PROCESS 164 mm 65 mm A350 FCRC Bracket Connection Material – TiAl6V4 Manufacturing – Machining Weight – 0.37kg Material – TiAl6V4 Manufacturing – ALM Weight – 0.21kg
  20. 20. Additive Manufacturing APWorks GmbH - Advanced Process Solutions Page 20 02.07.2014 TOPOLOGY OPTIMIZATION PROCESS Material – HC101 Steel Manufacturing – Casting Weight – 0.97kg Material – Titanium 6/4 Manufacturing – ALM Weight – 0.36kg A320 Nacelle Hinge
  21. 21. APWorks GmbH - Advanced Process Solutions Page 21 02.07.2014 Further Information Andreas Nick Andreas.Nick@apworks.de +49-89-60724502 www.apworks.de

×