Inspiring Day "Industria y Fábrica del Futuro" (Fernando Lasagni - Catec)

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Inspiring Day es un foro de encuentro donde visualizar escenarios futuros, desarrollar negocio o identificar nuevas oportunidades de diversificación, a través de la investigación y el desarrollo tecnológico.

Este evento tuvo lugar en Sevilla, en Parque Aerópolis, el 12 de diciembre de 2013.

Más información en http://www.tecnalia.com/inspiringday/

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Inspiring Day "Industria y Fábrica del Futuro" (Fernando Lasagni - Catec)

  1. 1. Oportunidades y retos de la Fabricación Aditiva y la Automatización de Procesos en el sector Aeroespacial Prospects and Challenges of Additive Manufacturing and Process Automation in the Aerospace Industry Fernando A. Lasagni Head of Materials & Processes Juan Pedro Vela Carlos Pérez General Manager Head of Automation & Robotics Andalusian Foundation for Aerospace Development (FADA) Center for Advanced Aerospace Technologies (CATEC)
  2. 2. Motivation Some of the Major issues within aircraft industry: Application examples metals Additive Manufacturing Manufacturing composites - Near net shape processing RTM - Out off autoclave curing (composites) Infusion tech Assembly - Simulation tools Augmented reality Virtual reality Inspection ALM requires of advanced NDT - Versatile full field NDT methods for 3D CFRP parts complex geometries - Automation Decrease inspection time - Automatic detection and evaluation Software tools and novel - Continuous Monitoring (maintenance) inspection strategies Structural Health Monitoring Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  3. 3. Summary of presentation Metallic Manufacturing - Today & Next Generation (ALM) - Materials and Post Treatments - Advanced inspection methods - Application case: Project ALM Polymer base Composites fabrication - Automation of NDT - Dimensional analysis - Structural Health Monitoring Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  4. 4. Metallic Manufacturing today Shaping into Components Forging Ring Rolling Metal Removal (Machining) Near Net Shape Processes Casting Powder Metallurgy Conventional Sheet Forming Superplastic Forming and Diffusion Bonding Manufacturing technology driven design Constraints in shape: Additive Layer Manufacturing Design driven technology Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  5. 5. Additive Layer Manufacturing - Fundamentals Near Net shape manufacturing 3D complex geometries Topological optimization (same functions with optimized weight) Available commercial aerospace materials Lower product development costs Green technology Stainless Steel AISI316L Antennas I/F Brackets CASA-ESPACIO CATEC Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  6. 6. ALM – Topology Optimization ALM: Perfect application for topology optimization. Topology optimization has to be ‘interpreted’ and sacrifices in the design have to be made for conventional manufacturability FEA of optimized ALM part >60% weight reduction! A320 nacelle hinge bracket FEA of original part at max. stress cases Source: © Altair Engineering, EADS Innovation Works: Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  7. 7. Materials Commercial Available Metallic Materials (e.g. Renishaw) Ultimate Tensile [MPa] SLM “conventional” 1,130 Stress Relief 1200°F / 3 hours vacuum 1,170 S.T. 900-955°C Aged 540°C EADS Innovation Works: Scalmalloy®RP (AlMgSc) 6061: Morris Future developments - Aerospace alloys - Metal Matrix Composites (e.g. particle reinforcements) - Nano Reinforced Materials (Metallic and Polymer base materials) Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  8. 8. Post treatments Parts manufactured by ALM presents accumulated internal stresses due to fast solidification of the melt during fabrication (also influence by shape part, laser scanning strategy, etc.) e.g. heat treatments Part roughness must by adjusted to application req. (as manufactured = 10-20 Ra) Electrochemical processes Laser assisted (e.g. laser beam machining) Grinding/polishing Fatigue life improvement and roughness improvement Shot Peening Laser Peening Electron Beam hardening Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  9. 9. Inspection of Free Form geometries NDT inspections: 100% full volume Advanced NDI methods! Available during product development stages © GKN Aerospace Optimized A320 bracket © EADS Innovation Works ALM: inner porosity, dimensional distortion (internal stresses), etc. must be analyzed CFRP fixtures: e.g. radii inspections requires of complex and time consuming UT inspections. Computed Optimized A380 bracket / © EADS Innovation Works Dic 2013 CFRP Load Introduction Rib © Airbone Aerospace Inspiring Day: Industria y Fábrica del Futuro Tomography: reliable method for product development and complex inspections Fernando Lasagni / flasagni@catec.aero
  10. 10. Inspection of Free Form geometries X-Ray Computed Tomography 3D-Reconstruction Materials characterization NDT Metrology Detector Specimen X-Ray Tube Rotating stage Inner features 2D Cross-sections Object surface Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  11. 11. Inspection of Free Form geometries X-Ray Computed Tomography – Application examples 3D Characterization Porosity ~5% ~2% <0.5% Actual to Nominal Comparison / Inner features! CASA-ESPACIO/CATEC 3D View ALM part for clampband / ARIANE5 Variance distribution Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Cross section Fernando Lasagni / flasagni@catec.aero
  12. 12. ALM in Space Application Example: FLPP Systems 2.2 Additive Layer Manufacturing – ALM FLPP/CT/M&S/ALM (ITT AQ1-7103) Evaluation of the potential benefits (and drawbacks) of a designed combination of ALM technology, materials and applications for future launchers and next generation of space hardware Design of more efficient parts (aprox. 19.000€/Kg) “Decrease manufacturing costs” Design leading technology (ALM) Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  13. 13. ALM in Space Identification of potential target applications in Launcher Vehicles and ALM Technology assessment ALM Project Logic Phase 1 (finished) Screening for target application Phase 2 (finished) Definition of development and verification plan Mechanical characterization and advanced NDT ARIANE 5 Launcher Structural Stages with EADS CASAESPACIO participation Phase 3 (in progress) Phase 4 (in progress) Execution of technology development and verification plan Dic 2013 Preliminary Breadboard definition and topological optimization Inspiring Day: Industria y Fábrica del Futuro Phase 5 (not started) Manufacturing & Verification Fernando Lasagni / flasagni@catec.aero
  14. 14. Composites - Manufacturing today Research and innovation priorities (H2020) (1) Innovative processing: Advanced Manufacturing (2) Adaptive and smart manufacturing systems (3) Digital, virtual and resource-efficient factories (4) Collaborative and mobile enterprises, (5) Human centric manufacturing and (6) Costumer focused mnf. Automation Raw Material: Pre-preg Vacuum Bag SHM NDT + automation Repairs + Automation Autoclave Curing NDT + automation Out Of Autoclave Repairs + Automation Finishing New possibilities? Dic 2013 SHM Joining and Assembly Inspiring Day: Industria y Fábrica del Futuro NDT + automation Fernando Lasagni / flasagni@catec.aero
  15. 15. Automated inspections Target: Increase flexibility - Automated flexible process - Object and NDT system manipultation Multi Robot inspection (ultrasonics) - Non-contact inspections Source: TECNATOM S.A. - Data acquisition and Non-contact Laser UT processing - Quantitative analysis and evaluation Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Source: TECNATOM S.A. Fernando Lasagni / flasagni@catec.aero
  16. 16. Dimensional analysis Contactless 3D reconstruction CCD cameras Location Positioning Acquisition Control Path optimization Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  17. 17. Interior Inspections Project Reduced work space Detection of indications, objects and leakages : subcontractor Source: OC Robotics (www.ocrobotics.com) Dic 2013 Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  18. 18. Composites - Monitoring Structural Health monitoring of aerostructures during: Manufacturing In service Scheduled maintenance Application example: FBG Real time signal bonded Dic 2013 Data processing strategies embedded Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  19. 19. Composites – Aging Effect of environmental factors on composite life e.g. temperature, humidity, oxygen 30 cycles, inert 500 cycles, oxidative Sample level 300 cycles, inert+ “T” CFRP profile Temperature + Vibration + load Dic 2013 Mechanical characterization Relationship between highly accelerated aging cycles and fatigue behaviour? Inspiring Day: Industria y Fábrica del Futuro Fernando Lasagni / flasagni@catec.aero
  20. 20. Prospects and Challenges of Additive Manufacturing and Process Automation in the Aerospace Industry Fernando A. Lasagni Head of Materials & Processes Juan Pedro Vela Carlos Pérez General Manager Head of Automation & Robotics Andalusian Foundation for Aerospace Development (FADA) Center for Advanced Aerospace Technologies (CATEC)

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