an automotive supply chain overview including the material ... · gmw15634 volatile organic...
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SmartManufacturingSeries.com
An Automotive Supply chain Overview including the
Material Qualification process
BRENNON WHITE ADDITIVE MFG. APPLICATIONS ENGINEER INTERIORS & ELECTRICAL
AN AUTOMOTIVE SUPPLY CHAIN OVERVIEW INCLUDING THE MATERIAL QUALIFICATION PROCESS
AGEN
DA
AM VALUE PROPOSITION FOR AUTOMOTIVE
SUPPLY CHAIN: AUTOMOTIVE VS AM
INDUSTRY
PRODUCTION SUPPLIER EXPECTATIONS
APQP PROCESS AND THE IMPACT TO AM
QUALIFICATION: MATERIAL, PROCESS AND
PRODUCT
CLOSING THE GAPS TO PRODUCTION
Page 4
Page 8
Page 9
Page 10
Page 12
Page 15
TRADITIONAL APPLICATIONS
PROTOTYPE: FIT & FORM
PROTOTYPE: FUNCTION
ASSEMBLY: TOOLS, JIGS, & FIXTURES
MANUFACTURING TOOLING
WHAT VALUE IS ADDITIVE MANUFACTURING TO THE AUTOMOTIVE MARKET?
[email protected] 6/7/2018
EMERGING APPLICATIONS
PERFORMANCE VARIANTS
MOTORSPORTS
ACCESSORIES
SERVICE PARTS
WHAT VALUE IS ADDITIVE MANUFACTURING TO THE AUTOMOTIVE MARKET?
ADDITIVE BUSINESS MODEL
Cost Reduction Rapid prototype avoids production design changes Functional prototype parts and tools Manufacturing tools, jigs, & fixtures at low cost Service part inventory reduction Capital amortization across multiple programs Combined parts leads to lower supply chain costs
Revenue Growth Low capital low volume program enabler Accessory customization/personalization Classic car service parts
WHAT VALUE IS ADDITIVE MANUFACTURING TO THE AUTOMOTIVE MARKET?
[email protected] 6/7/2018
Automotive Suppliers Full service (large team) Engineering (All) Validation (testing) Data management Logistics (Returnable dunnage…) Qualification (PPAP & Control plans) Warranty
Multi year contracts Long Term Agreements Amortization of tooling Liability coverage
AUTOMOTIVE SUPPLIERS VS AM SUPPLIERS
Service Bureaus Limited Service (small team) Engineering (Specialized) Limited metrology, finishing or validation Limited Digital thread TS/ITAR certification? Limited process management controls Print and ship/ No warranties
Single part to limited production 3-4 x internally printed pricing High overhead (Salesforce, Capital…) Lower level liability coverage
[email protected] 6/7/2018
Guaranteed good parts on time Guaranteed parts
HOW GM GRADES SUPPLIERS:
AUTOMOTIVE SUPPLIER EXPECTATIONS
[email protected] 6/7/2018
Development support Launch support Quality performance Warranty support
APQP consists of five phases: Plan and Define Program Product Design and Development Verification Process Design and Development Verification Product and Process Validation and Production
Feedback Launch, Assessment & Corrective Action
ISO/TS 16949 Certification required for all Tier 1 suppliers <<APQP Process Wiki Link>>
ADVANCED PRODUCT QUALITY PLANNING
APQP Tools: failure mode and effects analysis (FMEA) statistical process control (SPC) measurement systems analysis (MSA) production part approval process (PPAP)
[email protected] 6/7/2018
APQP IMPACT TO AM WORKFLOW
Material Qualification (Material suppliers)
Process Qualification (Material converters)
Product Qualification (Component and System manufacturers)
Series production work flow
Material Qualification (Material suppliers)
Process Qualification (Material converters)
Product Qualification (Component and System manufacturers)
AM Production work flow
[email protected] 6/7/2018
EXAMPLE OF TESTING FOR QUALIFICATION CORRELATION
Material qualification variables Lot to Lot Chemistry/ Additives Environmental
Process qualification Variables Machine to Machine Part orientation and location within Build Operators to Operator Machine parameter sets
[email protected] 6/7/2018
POLYMER VALIDATION REQUIREMENTS EXAMPLE: COMPOUND PROPERTIES INTERIOR (BLACK OR NATURAL)
Property Standard Filler Content ISO 3451-1 Method A Density ISO 1183-1 Tensile Modulus at 23 °C ISO 527-1, ISO 527-2
Specimen 1A, 1 mm/minute test speed Tensile Stress at Yield ISO 527-1, ISO 527-2
Specimen 1A, 50 mm/minute test speed Tensile Elongation ISO 527-1, ISO 527-2
Specimen 1A, 50 mm/minute test speed
Tensile Stress at Yield after Heat Aging (1000 h ± 5 h at 105 °C ± 3 °C) Note 1 ISO 527-1, ISO 527-2 50 mm/minute test speed
Multiaxial Impact Strength at 23 °C ASTM D3763, Specimen 100 mm diameter x 3.2 mm or 100 mm x 100 mm x 3.2 mm, 6.6 m/s speed
Multiaxial Impact Strength at Cold Temperature ASTM D3763, 100 mm diameter x 3.2 mm or 100 mm x 100 mm x 3.2 mm, 6.6 m/s speed
Multiaxial Impact Strength at Cold Temperature after Heat Aging (1000 h ± 5 h at 105 °C ± 3 °C) Note 1 ASTM D3763, 100 mm diameter x 3.2 mm or 100 mm x 100 mm x 3.2 mm, 6.6 m/s speed
Notched Charpy Impact at 23 °C ISO 179/1eA Notched Charpy Impact at Cold Temp. ISO 179/1eA
Heat Deflection Temperature (HDT), Method B, 0.45 MPa ISO 75-1, ISO 75-2, ISO 75-3 flatwise
Mold Shrink, Flow Direction, 48 h after molding Note 2 ISO 294, plaque size 101.6 mm x 152 mm x 3.2 mm Mold Shrink, Crossflow Direction, 48 h after molding Note 2 ISO 294, plaque size 101.6 mm x 152 mm x 3.2 mm Mold Shrink, Flow Direction 48 h after molding, bake 1 h at 82 °C Note 2 ISO 294, plaque size 101.6 mm x 152 mm x 3.2 mm Mold Shrink, Flow Direction 48 h after molding, bake 1 h at 82 °C Note 2 ISO 294, plaque size 101.6 mm x 152 mm x 3.2 mm
Coefficient of Linear Thermal Expansion (CLTE) – Flow Direction (report one lot for information only) ASTM E831 or ISO 11359-2
CLTE – Cross Flow Direction (report one lot for information only) ASTM E831 or ISO 11359-2
Flammability (report one lot) GMW3232 Emission Testing of Interior Materials. For initial approval, test 1 lot in black. GMW16853
Odor GMW3205 Code B3 Fogging GMW3235-B-Y1-T2
Emissions GMW15634 Volatile Organic Compound (VOC) value Semi-volatile Organic Compound (SVOC) value
Chemical Resistance GMW14334 (report one lot in black) GMW14334-A-Rating 1 Laser Scoreable (report one lot in black)
Jenoptik or Similar Evaluation for Residual Wall Thickness
Paintability GMW16172 using any GMW15520A Soft Touch Approved Paint with Flame Treatment Preparation
[email protected] 6/7/2018
METALS VALIDATION REQUIREMENTS Test Information Specimen Manufacture Conditions
Test Property Note 1 Test Standard Specimen Type & Standard Min Number of Specimens per Orientation Note 2, Note 3
Build Location
Surface Finish Note 2
Post-Process Thermal Condition
Uniaxial Tensile Test Initial Strain Rate Sensitivity Check Note 4
ASTM E8, OR ASTM D638 (but can be lab dependent)
GM drawing SH20_7p5mm, OR ASTM E8 round small-size specimen 3, ASTM D638
Type V, flat/rectangular specimen
XY (flat) orientation 6
Per Purchaser
Machined (excised from printed block)
Per Purchaser (typically as-built with
stress relief) Z (vertical) orientation 6
Uniaxial Tensile Test
Ultimate Tensile Strength (UTS) [MPa] Yield Strength (YS) [MPa] Note 5 Elongation (EL) [%] Note 6 Ultimate Elongation (UEL) [%] Note 7 Elastic Modulus (E) [GPa] Note 8 Strain Hardening Parameters (σ0, k, n) Note 9
GMW16705, Appendix C (ASTM E8)
ASTM E8 round small-size specimen 3, OR ASTM E8 flat/rectangular subsize specimen
depending on application and material thickness Note 10
XY (flat) orientation 10
Per Purchaser
Machined (excised from printed block)
Per Purchaser (typically as-built with
stress relief)
Z (vertical) orientation 10
Z (vertical) with B = ±45o
orientation Note
11
10
Hardness Brinell Hardness, OR Rockwell Hardness, OR Vickers Hardness / Knoop Hardness
ASTM E10 ASTM E18 ASTM E92
See Supplementary Instructions NA 2 Per Purchaser NA
Per Purchaser (typically as-built with
stress relief)
Density As-Built Density ASTM B962 See Supplementary Instructions NA 2 Per Purchaser NA
Per Purchaser (typically as-built with
stress relief)
Micro-structure & Porosity
Metallography & Porosity Image Analysis Note 12
MPIF Standard 69, and other GM Internal Test
Practices 15 mm x 15 mm x 15 mm block NA 2 Per
Purchaser NA Per Purchaser
(typically as-built with stress relief)
Low Cycle Fatigue (LCF)
Strain-Life Fatigue Parameters (σf’, b, εf’, c) and Cyclic Stress-Strain Parameters (k’, n’)
Auto Steel Partnership Fatigue Program / (ASTM
E606, with GMW16705 Appendix F for data
analysis)
ASTM E606, 6 mm diameter round specimen, with straight (cylindrical) gage
section, a 2:1 to 2.5:1 gage length to diameter ratio, and treaded grip ends, OR rectangular (flat) specimen, dependent on
material type and thickness Note 13
XY (flat) orientation
20
Per Purchaser
Machined & polished
(excised from printed block)
Per Purchaser (typically as-built with
stress relief)
20
Z (vertical) orientation
20
20
High Cycle Fatigue (HCF)
Fatigue Strength (High Cycle Fatigue, HCF)
GMW16705, Appendix D (ASTM E466)
ASTM E466, min 6 mm diameter round specimen, with straight (cylindrical) gage
section, a 2:1 to 2.5:1 gage length to diameter ratio, and collet grip ends
XY (flat) orientation 20 Per
Purchaser
Machined & polished
(excised from printed block)
Per Purchaser (typically as-built with
stress relief)
[email protected] 6/7/2018
CLOSING THE GAPS TO PRODUCTION
Develop and educate supply chain Define finished product standards (validation, finish, repeatability…)
Coordinate qualification with materials suppliers
Validate production intent parts after material and process is proven
[email protected] 6/7/2018
THANK YOU