Additive mfg consortium overview 2010


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Additive mfg consortium overview 2010

  1. 1. Additive Manufacturing Consortium An Overview Ian D. Harris, Ph.D. Technical Director, AMC Technology Leader, Arc Welding (614)688-5131
  2. 2. About EWI Most extensive joining expertise in the western hemisphere Located in Columbus, Ohio in a 132,000 square foot facility $20 M in capital equipment Mix of industry and government clients Not-for-profit 501(c)(3) organization with revenue ~$30 MM and 134 employees
  3. 3. EWI Mission Advance our customers’ manufacturing competitiveness through innovation in joining and allied technologies
  4. 4. About EWI EWI bridges the gap between fundamental research and production processes - EWI finds, develops, and deploys new technologies and materials Fundamental Research Technology Development Technology Application Universities, National Labs & Inventors Member Companies & Suppliers
  5. 5. Possibilities of Metal Additive Manufacturing Produce net-shape components by successive metal build-up Offer potentially disruptive competitive advantages Many U.S. companies and researchers exploring AM Many emerging AM technologies - Based on laser, electron beam, arc, high-power ultrasonics, etc. - Using powder, wire, strip, sheetNickel-alloy pressure vessel components
  6. 6. AM – Progressive Layers Build in layers, Stress relieve/PWHT, Machine
  7. 7. AM Processes for Metals EBW freeform fabrication - EB(FFF) Laser powder and wire for FFF LAM, LENS, DMLS, from companies such as Arcam, EOS, POM – powder and wire based laser and EB metals AM in confined envelope Arc processes – GTAW-HW, GMAW-P, PTA (wire and powder) based on commercially available equipment for FFF VHP UAM – very high power ultrasonic AM
  8. 8. Example Metals AM Processes Concept Laser DCM® EOS DMLS® MTT SLM® Phenix Systems Optomec LENS® MTS Aeromet LAM (No longer in business). Sciaky EBFFF Arcam EBM®
  9. 9. Deposition Rate vs Resolution Courtesy Boeing Decreased Resolution IncreasedDepositionRate
  10. 10. Example Applications EB FFF and DMLS parts for aerospace components
  11. 11. Example Applications Land vehicles - OEM - Repair Power generation and nuclear
  12. 12. Arc-Based Additive Manufacturing Demonstration of low cost arc-based processes for Titanium AM - GMAW-P - RWF-GMAW - PAW (Cold Wire) - PTA (Powder) - GTAW (Hot Wire) GMAW-P PAW (Cold Wire)GTAW (Hot Wire) RWF-GMAW PTA (Powder) Proprietary to Lockheed Martin Copyright 2009
  13. 13. Emerging Apps Range of emerging applications … rapid prototyping, low volume tooling, direct parts manufacture, tailored materials, MMC, embedded fibers, smart materials, sensors, cladding, armor, thermal management Embedded Ni Tape 0.003” Diameter NiTi Wire (400X)
  14. 14. Potential Competitive Advantages Reduce material waste and energy usage Lower cost (fewer operations, reduced inventory, simplified supply chain) Support lean/agile manufacturing (shorter lead time, less hard tooling, reduce batch size) Enable new product design features (internal features, tailored materials, reduced parts) Reduce time to launch new products Produce replacement parts for legacy systems Support environmental sustainability
  15. 15. Realities of Metal Additive Manufacturing Relatively few U.S. industrial applications beyond prototyping. Some perceptions: - Performance of AM components not sufficiently characterized - ROI not sufficiently understood to support business justification - Not sufficiently productive, cost effective, or capable of producing part sizes and alloys needed Multidisciplinary solutions are needed - No one company has the capacity to address all the needs - Shared investment is needed to quickly close gaps
  16. 16. Additive Manufacturing…. Need for Collaboration Pooling of Resources Developing from MRL 1–9 at each OEM is costly/time consuming Network of end users, OEMs, service bureaus and academia Need more coordinated effort…. generate a critical mass Business Case Cost modeling, Need mature process costs Technical Challenges Material property database Process development/distortion control Equipment OEMs Voice of the Customer… size capacity, build times, etc. Controls/Requirements Design rules/guidelines for AM, F42 Committee  Low cost input materials  Cost effective NDE  Process control (real time)
  17. 17. Collaboration Needed Wide Range of Processes Necessitates Investigating Each Process in Detail – this is very expensive and requires collaboration Initial Acceptance Values Based on LAM Process Form Lower Bound for Tensile Properties, Typical for Fatigue Crack Initiation Stage 2 Evaluation of Several Processes Necessary to Fully Validate Use of LAM Values for All Approvals of Proposed AMS 4999 Revision Stage 2 Evaluation of 6 to 7 Processes Needed for Certainty of Generating MMPDS Allowables
  18. 18. AM in Europe Most metal AM capital equipment is built in Europe by Arcam, EOS and others Large, informal, network of users for plastics and metals Loughborough University, England hosts annual AM conference, all materials and markets Fraunhofer Institutes have a coordinated focus on AM in Germany There is a concern in the US with technology lag
  19. 19. AM Evaluation Stages Evaluation Stages – AMS-4999 Revision - 1 Initial Screening - 2 Process/Source Approval - 3 Deposition Parameter Approval - 4 Approval on Non-Critical Flight Hardware - 5 Approval of Critical Flight Hardware MMPDS data generation Non-flight Hardware Qualification stops at Stage 4
  20. 20. The Answer: AMC The Additive Manufacturing Consortium (AMC) was founded to provide a U.S. AM forum National consortium of industry, government, and research organizations Mission: Advance the manufacturing readiness of metal AM technologies to benefit consortium members
  21. 21. Time to deployment ManufacturingReadiness University & Federal Labs Manufacturers & Suppliers Additive Manufacturing Consortium MRL 3-7 Significant commercial impacts in 2-5 years MRL 8-10 Incremental improvements and implementation Short time horizon MRL <3 High-risk basic research and education Long time horizon Advancing Manufacturing Readiness
  22. 22. AMC Structure Encompass a wide spectrum of manufacturers Include technology and material suppliers Engage a national technology network of research partners; “National Test-Bed Center” Creates a non-competitive environment for industry to share experience and best-practices Leverages public and private funding sources Distinct from university-led centers which often focus on education and basic-research
  23. 23. Setting AMC Priorities Discussions with stakeholders - Industry, universities, government Review of past efforts - 2009 Roadmap for Additive Manufacturing - 2009 Air Force additive manufacturing workshop - 2009 EWI Ultrasonic Additive Manufacturing symposium 2010 AMC Meeting Ideation: “What should be the highest priority AMC activities?” - 3 breakout groups; 125 ideas contributed; 64 ideas had votes; distilled into 15 themes AMC members ultimately identify the priorities
  24. 24. AMC Business Priorities Sustained consortium funding Education & supplier development Business analysis Additive manufacturing solutions network Technology/IP assessments Collaborative leadership
  25. 25. AMC Technical Priorities Property database Quality control Distortion control Equipment development Feedstock/input materials Design rules Standards Process modeling/optimization AM knowledgebase
  26. 26. Proposed 1st year goals & deliverables Obtain broad industry & government support Conduct state-of-the-art review of metal AM technology Establish a database for collecting metal AM property information Organize “National Test Bed Center” research partners network Identify technology priorities and create development plan
  27. 27. AMC Member Structure Member types - Full members: Major manufacturers / end-users - Supplier member: Equipment/material suppliers: - Associate member: SME component suppliers - Research partners: Universities/labs (by invitation only) - Government: Partnering agencies Seeking members to identify 1st year priorities - All members and research partners attend AMC meetings and receive research results - Full members and partnering agencies eligible to serve on AMC Industrial Advisory Board
  28. 28. Benefits Members identify AMC priorities Members receive results regularly; 2 year moratorium on public release Programs engage a broad range of technical resources Continuity allows long-term planning to advance AM manufacturing readiness Collaboration with industry and government facilitates acceptance and commercialization AMC provides program management to oversee projects and deliver results
  29. 29. Benefits Funding leveraged with other members, government programs, and other EWI programs Full members and associate members receive a worldwide, non-exclusive license to use IP from member-funded programs Supplier members receive first opportunity to commercialize developments Research partners have access to funding opportunities Regular update meetings allow members to interact with colleagues and review activities
  30. 30. AMC Differentiation National center - through collaboration with other centers and programs AMS 4999 and MMPDS configured data and data sharing – National standards and data for aerospace and other designers Consortium uses equipment and human resources at existng centers – no need to replicate activity – this is happening now Funding from government agencies as well as congressional requests – all data available to all AMC members
  31. 31. AMC Differentiation Navy SBIR awarded – AMC member Applied Optimization/EWI effort – results available to AMC members Coordinating needs in process, material, properties and modeling Army, Navy and AF along with NASA – significant synergy DOE Green and sustainability aspects Nationally directed programs Linked into ASTM F42 activities
  32. 32. EWI’s Role About EWI - Non-profit corporation - Largest material joining technology application center in the Western Hemisphere - Mission to advance our customers’ manufacturing competitiveness through innovation in joining and allied technology - Broad range of technical capabilities and expertise - Experience in managing centers / consortia - Staff of full time program managers AMC Role: Organize, operate, seek funding, program manage, contribute to technology development activities Ultrasonic additive manufacturing system
  33. 33. AMC - Current Member Status Air Force (partner) NASA (partner) Army (partner) GE P&W R-R Honeywell Lockheed Martin Northrop Grumman GDLS Morris Technologies Applied Optimization The Ohio State University (partner) University of Kentucky (partner) University of Texas, Austin (partner) University of North Carolina (partner) October 1, 2010 AMC membership year The First AMC Members Meeting is scheduled for Dec 7, 2010
  34. 34. Questions? Ian Harris 614.688-5131 Rene 142 Laser powder deposition