additive manufacturing material implementation at ge ge...
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Additive Manufacturing Material Implementation at GEGE Additive10 August, 2017
Confidential. Not to be copied, distributed, or reproduced without prior approval.
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What is Additive Manufacturing (a.k.a. 3D Printing)
• 3D printing or additive manufacturing (AM)
• is any of various processes for making a three-dimensional object of almost any shape from a 3D model or other electronic data source primarily through additive processes in which successive layers of material are laid down under computer control.
• - Wikipedia
Subtractive(Traditional)
Additivew
aste
Successive layers of material are laid down
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DMLM (Direct Metal Laser Melting) Basic Process Map
3D CAD Model
AM ProcessThermal
Processing
Post Processing/ Inspection
Final Part
Prep for Process
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GE’s advancement in additive … so far
2010 2011 2012 2013 2014 2015 2016 2017
Tech
nolo
gyIn
fras
truc
ture
Formation of GE Aviation additive team
1st LEAP Fuel Nozzle
Acquisition of Morris
Technologies
1st Heat Exchanger
GE90 engineT25 Sensor
FAA Certified
LEAP Fuel Nozzle FAA Certified
GE Aviation Additive Technology Center
(ATC) opens
GE’s Center for Additive Technology Advancement
(CATA) opens
Acquisition ofConcept Laser GmbH (75%)
Arcam AB (76%)
A-CT7 Engine Bigger Parts
Rotating Parts
Bigger Systems
Multi Modalities
GE Additive Expansion
Customer Experience Centers
Advanced Turboprop Prelim design
Power F-Class Flex Tip Oil & Gas
Nova LT Swirler
16+ years of Additive Science
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Capabilities of full production35,000 – 40,000 per year
PARTS
DURABLEMORE
WEIGHT
It started with one part …
25%
20 1
5xREDUCTION
LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines© 2017 General Electric Company - All rights reserved
GE Proprietary Information
GE Confidential Information
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Additive value proposition – LEAP fuel nozzle actuals
0%
100%
Inventory Life Cycle Cost Mfg Cost Part Weight
Traditional TAPS Fuel Nozzle LEAP DMLM Fuel Nozzle
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Advanced turboprop engine (ATP)
PARTS
WEIGHT REDUCTION
Combustor test schedule reduced from 12 months to 6 months
LOWER MISSIONFUEL BURN
© 2017 General Electric Company - All rights reserved
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Confidential. Not to be copied, distributed, or reproduced without prior approval.
Modalities and Materials
© 2017 General Electric Company - All rights reserved
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Process Form Heat Source Speed Precis Size
Pow
der B
ed DMLMDirect Metal Laser Melting
Powder Bed Laser
EBM Electron Beam Melting
Powder Bed Electron Beam
Depo
sitio
n
LPF Laser Powder Forming
Powder Deposition Laser
Cold Spray Powder Deposition Momentum
EBFF Electron Beam Free Form
Wire Electron Beam
Hot Wire Wire TIG/ Laser
Cons
olid
atio
n MIM/SNS HIPMetal Injection Molding
Binder Injection Consolidation
Binder Jet Binder Jet Consolidation
Available metal additive optionsL
L
TIG/L
EB
EB
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Concept Laser and ARCAM Products
A2
Xline
Mline
M2
Mlab
Q20Q10
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© 2017 General Electric Company - All rights reserved
Typical DMLM to EBM comparison
Direct Metal Laser Melting Electron Beam Melting
Energy Source 100-1000 WFiber Laser
3000 W Electron Beam
Scanning Method Optical Mirrors Magnetic DeflectionBuild Layers 20 to 50 µm 50 to 70 µmAccuracy 50 µm 200 µmBuild Rate 13 cm3hr-1 55 cm3hr-1
Surface Finish 100-300 µ-in 800-1000 µ-inResidual Stress High Low
GE Proprietary Information
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Currently available materialsStandard Alloys Available:
• Cobalt Chromium• Inconel 718, 625• Titanium 6AlV4 ELI, CP Ti Grade 2• Aluminum (AlSi10Mg, AlSi12)• Stainless 316L(1.4404), 17-4PH • Maraging Steel MS-1 (1.2709)• Bronze
Many more materials currently in development
Inco 718
Inco 625
SS 316L
17-4 PH
SS 15-5 MS-1
Cu AlSi10Mg
6061 T6 CoCr HastX
Ti6242 Ti 64
W
TiAl
A205
F357
HS188
Rene 80
GE Proprietary Information
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Material properties drive applications
140
150
160
170
180
190
200
210
DMLS - V DMLS - H Wrought Low Wrought High
YS (ksi) UTS (ksi)
AMS
AMS
AMS
AMS
0.0
10.0
20.0
30.0
40.0
50.0
DMLS - V DMLS - H Wrought Low WroughtHigh
Elongation (%) Hardness (HRC)
DMLM - V DMLM - H
DMLM - V DMLM - H
GE Proprietary Information
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Confidential. Not to be copied, distributed, or reproduced without prior approval.
Qualification & Inspection
© 2017 General Electric Company - All rights reserved
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•Safetyis priority #
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Identify
• Additive opportunities based on value• Durability, fuel burn, emissions, weight, cost, new and innovative functions
Mature• Machine, material, and process development• Process including machining / finishing, process monitoring, and inspection
Design• To established additive design practices and lessons learned• Taking full advantage of geometrical freedom and material enhancements
Qualify• Establish machine, material, process, and design requirements• Demonstrate all requirements are met or exceeded; lock processes
Validate
• To performance level component, system, and engine requirements• Coupling advanced analytics and testing
Certify• Component level testing as required (14 CFR Part 33 Section 33.91)• Engine level certification (14 CFR Part 33 & 34)
Additive Component Roadmap
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Additive Materials Development Process
Concept
Feasibility
Development
Maturation
Process Content• Microstructural evaluation & heat treatment development• Process optimization / producibility• Mechanical properties & design curves / allowables• Environmental evaluation (fluids, corrodants, temperature/time, etc…)• Effects of subsequent processing / operation
Deliverables• Material understanding & use guidelines• Processing & robustness • Specifications• Physical & mechanical properties• Environmental evaluation• Component suitability
Mature
GE Proprietary Information
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Powder Spec• Powder Source• Powder Size• Powder Composition• Powder Reuse Procedures
Laser Param• Spot Size• Laser Power• Laser Travel Speed• Laser Dwell Time
Therm Proc• HIP Cycle Parameters• Heat Treat/Solution Atmos• Braze HT Parameters• Solution Temperature
Recoat Param• Layer Thickness• Recoater Arm Material • Recoater Arm Design
Build Cham• Build Atmosphere• Purge Gas• Airflow• Preheat Temp• Interpass Temp
Hatch Strategy• Contour Pass • Sky Writing• Line Spacing or Boundary Overlap
Calib & Maint• Preventative Maintenance• Pre-build Calibration• Factory Environ Controls
Post Processing• Mechanical Finishing• Thermal Exposure
Cycles to Failure
Stre
ss C
apab
ility
Contour
Hatch
Laser Parameters
Explicit Controls on Machine, Material, and Process(Examples shown, not an all inclusive list)
Qualify
GE Proprietary Information
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Qualification
Machine Material Process Part
Inspection
Non-Destructive
CT/VCT/CMM
Dimensional Defect Recognition
Functional Checks
Fuel FlowAirflowOther
Proof PressureUltimate
Test
Destructive
Part
Cut-Ups
Specimen
Grain SizePorosity Surface Finish
On-going Material Testing
Inspection and Quality Touch PointsValidate
GE Proprietary Information
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In-situ Inspection, Modeling, and AnalyticsValidate
GE Proprietary Information
MeltpoolProcess
Monitoring
Analytics
Computational Materials
Engineering
Faster• Material Development• Process Qualification• Part Certification
d
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GE Proprietary Information
Specifications Industry Groups
Supporting Industry Initiatives
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Supply chain shift in progress
© 2017 General Electric Company - All rights reserved
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PRIMARY AND SECONDARY SCHOOLS (ages 8-16)
• $8 million for metal additive manufacturing equipment
• Focus on additive learning efforts
Apply at www.geadditive.com
Investing in a limitless future
• $2 million for 3D-printing equipment and curriculum
• Focus on STEM/STEAM programs
COLLEGES AND UNIVERSITIES (2- and 4-Year)
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