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FUTURE MANUFACTURING FLAGSHIP
CSIRO Titanium Technologies and Additive Manufacturing Chad Henry | Additive Manufacturing Operations Manager
12 February 2014
Transforming South Australia’s Manufacturing Sector
Agenda
Titanium Technologies Theme - TiRO
- Lab 22 – Metallic Additive Manufacturing – Arcam E-Beam Melting (EBM)
- Strategy and Roadmap
- Capabilities and Examples
- Thermal Assisted Machining
ore to more
Titanium Technologies - from ore to moremore Titanium Technologies - from ore to moremore
Titanium Titanium TechnologiesTechnologies
MetalMetal
ProductionProduction
Metal to Metal to
ProductProduct ManufacturingManufacturing Special ProjectsSpecial Projects
TiRO
Alloys Process
Novel Alloy Design
Project 21
BMG Prod/Proc
Sheet
Plates
Bars
Billets
Shaped Billets
Wire
Extrusions
Powder (for AM)
Cold Spray
Laser Assisted Machining
Additive Manufacturing
Lab 22
Modelling and Simulation
Online / In Situ Measurement
Victorian Productivity Network
Royal Australian Mint
SIEF Aero-engine Project
FUTURE MANUFACTURING FLAGSHIP
The TiRO™ process
Christian Doblin | TiRO™ Project Leader
Same overall chemistry as Kroll
TiCl4(g) + 2Mg(l) → Ti(s) + 2MgCl2 (s)
TiRO is continuous 2 stage process cf. Kroll batch process
• Lower capital cost • Greater process intensity • Reduced energy requirement • Very high yield
TiRO is a “non equilibrium” process • No melting of Ti occurs
TiRO produces powder directly • Cost comparable to Ti sponge
Has the potential to produce Ti alloys directly
The TiRO™ Process Mg
TiCl4
Ti Powder
MgCl2
Intermediate product (MgCl2/Ti composite)
Fluidised Bed Reactor
Vacuum Distillation Separator
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CSIRO Lab 22 Metallic Additive Manufacturing
Chad Henry | Lab 22 Operations Manager
Additive Manufacturing is...Additive Manufacturing is...
Resource efficient and Sustainable energy efficient
reduces waste
layer-by-layer processing to make 3D objects directly from CAD files, as opposed to using subtractive methods like traditional CNC machining.
9National Aeronautics and Space Administration
Langley Research Center
Metal Additive Manufacturing Landscape Today
Must Understand ... One Size Does Not Fit All
Material
Build Volume
Rate
Design and Unitization
Unique Shapes/Details (free)
Surface Finish
Inspection
Laser vs.
E-Beam vs.
Solid State
Powder Bed vs.
Powder Spray vs.
Wire Fed
Product Requirements Manufacturing Processes
Production
Prototyping (form, fit, function)
Tooling
Shop Aids
All For ...
Ti
Ni
Al
Australian Metallic Additive Manufacturing RoadmapAustralian Metallic Additive Manufacturing Roadmap
Database for Production
•
Database for Production
•Ti 6Al 4V
Low Cost Feedstock
Distortion Control Management
In Situ Inspection Methods
Microstructure Manipulation
Additional Material Data
•
Additional Material Data
•Titanium, Steel or ?
Novel Titanium Materials
Electron Beam
Wire Fed Powder Bed
•
Database for Production
•Ti 6Al 4V
Ex Situ Powder Bed
Powder Manipulation
In Situ Modelling & In Situ Modelling & Management
In Chamber Inspection In Chamber Inspection Methods
Microstructure Microstructure Manipulation
Novel Titanium Novel Titanium Materials
Additional Materials
Decrease final Component Cost
Increase the Application Space
Additive Manufacturing ... The 2+1 Strategy
Modelling and Simulation
Feedstock and Powder
New Material Development
Distortion Management
Novel Sources
Physical Modification
The AX - Powder Flow
Industry Engagement
AM Network
Build, Consult, SIEF
Casting, Welding
Cold Spray, TiRO and Alloys,
Processing
Arcam - Electron Beam Melting (EBM) - Powder Bed - Vacuum - Elevated Temp - Low Distortion - Excellent Properties - Model A1 - 200mm x 200mm x 180mm - Materials - Ti and Ti Alloys - CoCr - Nickel Alloys (Inconel) - Steel Alloys - Others??? - CSRIO Level 3 Training
E-Beam AM Equipment
Lab 22 Lab 22 –– ArcamArcam ImagesImages
Lab 22 Lab 22 –– ArcamArcam ImagesImages
Lab 22 Lab 22 –– ArcamArcam ImagesImages
0
500
1000
1500
2000
0
500
1000
1500
2000
Future Today
50% of the cost in operation is labour 20% is depreciation (i.e. Cost of the unit)
If the equipment cost comes down and labour gets more productive Powder becomes the mostly costly component of AM
$ $
Operational Cost Considerations of Additive Manufacturing – Why work on materials?
Where is “Cheap” Titanium Powder???
Armstrong Process – Cristal
FFC Process – Metalysis
TiRO
Alloys
CSIR
New Zealand
Hydride DeHydride
ADMA
China
The powder is median size d50 of 67 µm with a very narrow distribution for Arcam.
SEM of Titanium Powder
Particle Diameter (µm.)
Volume (%)
0
10
20
30
0
10
20
30
40
50
60
70
80
90
100
1.0 10.0 100.0 1000.0
Volume distribution of Arcam powder size
Powder for Additive Manufacturing Fusion Systems
Powder, Particles and Aggregate
Size
Size Range
Flow
Density
Alter Either or Both: - Improve the Inexpensive Powder - Alter the AM Equipment Operating Parameters
CSIRO Powder ManipulationCSIRO Powder Manipulation
CSIRO TiRO Metal
Other Available Powders
Powder Modification Powder Modification -- SizeSize
50
25
>1000 600 – 1000
400 – 600
250 – 400
150 – 250
100 – 150
75 – 100
45 – 75
25 – 45
< 25
Arcam EOS Cold Spray
Weight pct
Particle Size in mm
Before
After
Titanium Technologies and Lab 22 Achievements
• Over 270 people through Lab 22 • MPs - Adam Bandt, Julie Bishop, Anna Burke, Greg Combet
• EVP of the Lockheed Martin F-35 Joint Strike Fighter Program, Tom Burbage
• 60 people attended and participated in the Lab 22 Open House Workshop
• 45 people from SEMIP toured
• TiRO Produced in the Saleable Pilot Plant
• Lab 22 Chosen to be a Preferred Service Provider for Arcam EBM
• Additive Manufactured (AM) Fish Anchors Implemented
• Flying Machine Bicycle
• AM Mining Drill Bit Holders Implemented
• AM Bugs and AM Orthotic Horse Shoes
• AM student projects
• Sophie’s Dragon, Toothless
• The Titanium Challenge
Topology and Design Optimisation
Same Performance ... Less Weight
Iteration 1 Iteration 6 Iteration 9 Iteration 13
Iteration 16 Iteration 20 Iteration 25 Iteration 29
Rapid Design Iteration
Manufacture all of the design candidates at once in a single build.
Inexpensive physical testing was employed to make decisions.
SIEF AeroSIEF Aero--engine AM Demonstration w/ Monash Uengine AM Demonstration w/ Monash U
I like big bugs ...
Plasma Giken PCS-1000
Cold Spray Technologies - Equipment
CGT Kinetiks 4000
Meltless Additive ManufacturingMeltless Additive Manufacturing
Cold Spray
Additive Manufacturing Repair Coatings
Near Net Shape
Ti Pipe Seamless Continuous
Ti Bike Frame
Ti Coupler
Composite Dies
Defects Repair
Corrosion Resistant
Electroplating Replacement
Design Modification
Wear Resistant
Biofowling
Composite Coatings
Bulk
Billet
Forging Pre forms
Reclamation
MaterialsMaterials
Metals & Alloys: Ti, Ni, Fe, Cu, Al, Sn Ceramics + Metals: Al + TiB2 Polymers
Cold Spray for PreCold Spray for Pre--formsforms
Continuous Billet ProductionContinuous Billet Production
CSIRO has the capability to produce 45 kg/hr of product via cold spray
Thermally Assisted Machining of TitaniumThermally Assisted Machining of Titanium
Titanium Technologies Theme 2013
Page 32 | CSIRO Titanium Technologies | August 2012
Future Ti TechFuture Ti Tech
FUTURE MANUFACTURING FLAGSHIP
Additive Manufacturing Network
Delphine Cantin | The AMN Project Leader
The Additive Manufacturing Network The hub for all things additive.
GOAL – Market globally Australian additive manufacturing capability, for both technology R&D and production for profit in industry. - Publish who has what equipment and corresponding capabilities. - Create confidence in global customers investigating Australian potential. - Collaborate efficiently for new Australian business, creating greater total revenues in which to participate. - Connect those with a need to those with a solution.
GOAL – Facilitate communication within Australia on additive manufacturing. - Use a network infrastructure, including focused working groups, to conduct regular face-to-face and web meetings. - Understand others’ roadmaps and strategies. - Coordinate and be efficient on resolving issues. - Achieve a comprehensive and non-redundant R&D project portfolio within the country. - Accelerate the deployment of technologies to industry.
MISSION – Coordinate additive manufacturing for Australia.
MISSION – Coordinate additive manufacturing for Australia.
The Additive Manufacturing Network is ... - Public with participation from academia, industry, and government welcome. - To be self governed once established. - Well poised to be a self supporting national asset.
The Additive Manufacturing Network The hub for all things additive.
Per the mission statement: co·or·di·nate (verb) - The act of harmoniously combining and interacting items to function effectively.
For further information, please contact: Delphine Cantin CSIRO Gate 7 Normanby Road, Clayton 3168 VIC Australia +61 (03) 9545 2761 (office) [email protected]
FUTURE MANUFACTURING FLAGSHIP
Thank you CSIRO Titanium Technologies Theme - ore to more
Chad Henry
Additive Manufacturing Operations Manager - Lab 22
Titanium Technologies Stream Leader
+61 3 9545 7844