additive manufacturing at ge aviation · 2018-06-22 · at an enterprise level design manufacturing...
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Additive Manufacturing at GE Mohammad Ehteshami VP & GM, GE Additive
August 29, 2017
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Capabilities of full production 35,000 – 40,000 per year
PARTS
DURABLE MORE
WEIGHT
LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines
It started with 1 part …
25%
20 1
5x
REDUCTION
2
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Then a system … Advanced Turboprop
PARTS
WEIGHT REDUCTION
Combustor test schedule reduced from 12 months to 6 months
LOWER FUEL BURN
20 %
5 %
855 12
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At an enterprise level Design Manufacturing Services
Additive
1 Digital Twin
6-8 Engineers
1 Mfg. sources
Inspection Sys. &
Component to Repair
1 1 data lake
…powering
300 parts
60 Engineers 5
Conventional
40 data systems
Mfg. sources 50+
Turbine frame
Same frame
Repair Sources
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• HQ in Lichtenfels, Germany
• 400+ employees
• Products: • Metal additive machines (Laser technology)
• Industries served: Aerospace, Medical/Dental, Auto, Jewellery
• HQ in Mölndal, Sweden
• 340+employees
• Products: • Metal additive machines (Electron Beam technology) • Materials (from AP&C) • Additive Service Bureau for Medical Industry (DTI)
• Industries served: Aerospace, Medical, Auto, Tooling
GE Additive
Focused on three
main offerings:
• Materials
• Machines
• Engineering Consultancy Services
Today…
• 1100 employees
• 22 sites
• Stakes in Concept Laser & Arcam AB
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1
Machine Qualification
Qualification … and then fixed process control
Material Qualification … must buy-into material allowable curves, must meet material specs
Part Qualification … process must be in control, dimensional, functional
Part Inspection … methods based on traditional castings (gage, white light, FPI, X-Ray, CT)
Every Machine is a “Micro” Foundry
2
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Certification: Material Qualification
Process Structure Properties
As-Built Structure
Isotropic Structure After Thermal Processing
Physical properties
Strength properties (static, fatigue)
Damage Tolerance
Variation (Lots, machines, etc)
X, Y, & Z Build direction
Surface finish factor
Part feature factor (e.g. thin wall)
Cycles to Failure
Alt
Str
ess
Machined
As-built surface
Powder specification
Machine parameters
Build chamber environment
Machine calibration
Thermal processing
Post processing
Powder re-use
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Expanding Materials Capability
Inco 718
Inco 625
SS 316L
17-4 PH
SS 15-5
MS-1
Bronze AlSi10Mg
6061 T6
CoCr Hast X
Ti 6242 Ti 64
W
TiAl
A205
F357
HS188
Rene 80
Material allowables identified (GE Redbook design data)
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Process/Part/System Validation
Fuel Nozzle Example
9
TIME AT TEMP
RIG TESTING
NOZZLES TESTED
CERT TESTING
PREDICTED LIFE
COMPONENT TESTING DESIGN ALLOWABLE
low cycle fatigue test 1-cup coking rig LEAP-1A Icing test
DIMENSIONAL
FEATURE DEBIT
9x 100% 500+
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Powder Specification DMLM Process Specification
Chemical composition
Melting and atomization method
Powder quality
Process control
Particle size distribution (PSD)
Component Specification
Additive Specification Control
Fixed Process Controls
Equipment qualification & Preventative Maintenance
Power level verification
Facility environmental controls
Powder handling and reuse
Software control
Operator training
Record keeping
Machine restarts
Chemistry & Composition
Structure/ Porosity
Properties
Surface finish
Thermal processing
Proprietary specs evolving to industry wide specs
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Building Industry Capability
Specifications Industry Groups
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Accelerating the Additive Revolution
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We’re focused in three areas…
Materials
Engineering
Machines +
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Customer Collaboration
• Application Engineering • Rapid Prototyping • Low Rate Manufacturing
Customer Support
• Field Support • Spare Parts • Materials • Logistics
Customer Training
• Additive Design • Additive Machines • Additive Materials
GE Additive Customer Experience Centers
Our Customer Experience Centers are designed to help customers
understand the additive process; from design to prototyping to production and support them along the way
Pittsburgh Munich More coming soon…
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Investing in a limitless future
PRIMARY AND SECONDARY SCHOOLS (ages 8-16)
• $2 million for 3D-printing equipment and curriculum
• Focus on STEM/STEAM programs
• Over 400 recipients in 2017
COLLEGES AND UNIVERSITIES (2 and 4-Year)
• $8 million for metal additive manufacturing equipment
• Focus on additive learning efforts
• 8 recipients in 2017
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