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SIF #2 Day 2: Additive manufacturing (3D printing) - Research Activities within RIT

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Angelica Lindwall, Christo Dordlofva and Magnus Neikter gives an introduction to additive manufacturing and the space industry, talks about their projects and the Sweden tour in additive manufacturing.

Projects:
- Radical Innovation within Space Applications
- Microstructural characterization of additive manufactured Ti-64
- Design and Qualification Methods for Additive Manufacturing in Space Applications

Published in: Engineering
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SIF #2 Day 2: Additive manufacturing (3D printing) - Research Activities within RIT

  1. 1. Additive Manufacturing – Research Activities within RIT Angelica Lindwall, Christo Dordlofva and Magnus Neikter 2016-05-10
  2. 2. Introduction Additive Manufacturing, or 3D-printing, has received much attention in media in recent years with the fast development of different processes, both for industrial and home use. The technology enables a new freedom for the designer/artist due to its possibility to manufacture complex shapes. Aerospace early identified the possibilities with the technology. Höganäs, Digital Metal GE Aviation Airbus Industries
  3. 3. Additive Manufacturing for Metals •  Layer by layer process to build products •  Two categories are suitable for aerospace applications: –  Powder Bed Fusion (PBF) –  Directed Energy Deposition (DED) using powder or wire material
  4. 4. Space Industry •  Characterized by: –  Complex systems and component designs with high technical requirements –  High development costs –  Low volumes (Europe launched six Ariane 5 rockets in 2015) •  Future challenges to keep up with the growing competition (e.g. SpaceX) are cost, cost, cost, weight, reliability, flexibility, … •  High demands and requirements implies great technical challenges à Driver for Innovation and Technology Development
  5. 5. RIT Projects •  Radical Innovations within Space Applications –  Angelica Lindwall •  Microstructural characterization of PBF and DED of Ti-64 –  Magnus Neikter •  Design and Qualification Methods for AM in Space Applications –  Christo Dordlofva AM = Additive Manufacturing
  6. 6. Sweden Tour
  7. 7. Universities Örebro university - Product approach: Design, inspection, qualification Mid university - Process development: Focus on medical implants Chalmers university - Powder and material development University West - Process development Lund university - Design
  8. 8. Companies Arcam - Manufactures Electron Beam Melting machines Höganäs/Digital metal - Produces powder/Operates and build precision ink-jets Siemens - Uses AM in production, have their own AM center Sandvik - Investigates the possibilities with AM, produces powder, AM center GKN Aerospace - Process development, uses AM in production
  9. 9. AM Clusters in Sweden •  Chalmers is part of an AM arena where the core partners are Swerea IVF and Swerea KIMAB. The arena include other partners such as University West. •  TTC (Tillverkningstekniskt Centrum) is part of Alfred Nobel Science Park in Karlskoga. Joint cooperation between Örebro University, Saab Dynamics, Bofors Test Center, Lasertech LSH AB. •  AM competence center applications at Vinnova: –  Chalmers with University West and Linköping University –  Örebro University –  KTH with Uppsala University “Swedish industry and academia need to cooperate for Sweden to become a world leader in AM”
  10. 10. Supply chain for AM in Sweden
  11. 11. Radical Innovation within Space Applications Angelica Lindwall RIT meeting Kiruna 2016-05-10
  12. 12. Design for Additive Manufacturing •  Complex structures •  Shorten lead time •  Open up possibilities •  New restrictions/limitations
  13. 13. •  RQ1: What influence does the implementation of Additive Manufacturing into a production system have on the Innovation Process in the Space Industry? •  RQ2: What challenges does the designer encounter when an organization within the Space Industry implements Additive Manufacturing? •  RQ3: What effect does Additive Manufacturing have on the innovativeness of designers in the Space Industry? (Designer= Design Engineers working within the design process) Research questions
  14. 14. Microstructural characterization of additive manufactured Ti-64 Magnus Neikter 10/5-2016
  15. 15. Introduction •  Make a microstructural investigation of different AM-methods •  Five different AM-methods •  Microstructure is determined by heating and cooling, for AM this is complex •  Leads to a complex thermal history –  Microstructure hard to predict •  Microstructure is important as it determines the mechanical properties
  16. 16. Alpha laths
  17. 17. Prior beta grains •  Columnar shape •  Grows toward heat source •  Grain boundary alpha
  18. 18. Alpha colonies and hardness •  Hardness differences between and within the samples •  Measure alpha colonies with EBSD
  19. 19. Design and Qualification Methods for Additive Manufacturing in Space Applications Christo Dordlofva RIT meeting Kiruna 2016-05-10
  20. 20. Why AM in Rocket Engines? •  Benefits include: –  Ideal for low volume products for high performance parts –  Lightweight materials and/or mass optimized designs –  Increased functionality using novel designs –  Cost reduction –  Supplier independency –  … •  Challenges include: –  Process limitations –  Process verification –  Part verification –  Material characterization –  Lack of standards –  Designer limitations –  …
  21. 21. Design for Additive Manufacturing GKN Aerospace GKN Aerospace
  22. 22. Design and Qualification Design and Qualification of AM in Space Applications Design Verification Requirements AM Industry
  23. 23. •  RQ1: What are the prerequisites, possibilities and limitations with additive manufacturing in the design of rocket engine components? •  RQ2: What are the qualification challenges for additively manufactured rocket engine components? •  RQ3: What are the important adaptions to an engineering design system for rocket engine components when implementing additive manufacturing? Research questions
  24. 24. GKN Aerospace Applications •  GKN Aerospace has over 40 years of experience in designing, developing and manufacturing parts for rocket engines •  Competence centers/Center of Excellence are: –  Turbines for turbopumps –  Nozzle extensions

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