titanium additive manufacturing – a novel game changing ... · pdf filetitanium additive...
TRANSCRIPT
Titanium additive manufacturing – a novel game changing technology
TITANIUM 2014 Conference September 21-24, 2014 Francisco Vega, VP Sales & Marketing
Slide 1
September 21-24, 2014 • Hilton Chicago, Chicago, Illinois, USA
Introduction
Private & Confidential Slide 2
» Norsk Titanium has developed an innovative additive manufacturing technology based on wire feedstock as raw material and utilizing plasma arc as a heat source.
» The process has been developed for deposition of titanium and titanium alloys, hereunder the most common used alloy for aerospace applications, Ti6Al4V.
» The process lends itself to production of parts with geometries and properties of industrial interest, such as structural aerospace components.
Introduction (suite)
Private & Confidential Slide 3
» Production of aerospace parts by conventional technologies requires about 5 times the material amount in the final part, and individual parts may have “buy to fly” values of 10 or more. Additive manufacturing can reduce the “buy to fly” ratio significantly, typically to 1.5 or better.
» Reduced lead time and flexibility in design as additional benefits. The Norsk Titanium process is presently pending qualification for the commercial aerospace market.
» This presentation will give an introduction to the process and material properties achieved.
About NTi
Private & Confidential
» NTi is a titanium component producer based in Norway
» NTi has developed a novel game changing technology (3D printing) to produce complex Titanium components with unsurpassed quality
» This technology uses the principle of Direct Metal Deposition (DMD) technology, with a patented plasma arc based 3D printing production method
Slide 4
Chronology of milestones
» 2007 NTi is established by Scatec AS » 2008 First prototype cell (POA) » 2009 Second production cell (POB) » 2009 Cooperation agreement with Spirit
Aerosystems » 2011 Norsok qualification » 2012 TRL3 with Airbus » 2012 Next generation cell P01 » 2012 TRL6 with Spirit Aerosystems » 2014 Completion of production of
allowables material » 2015 TRL8 (FAA) qualification expected
in 12 months » 2015 TRL8 (EASA) qualification expected
within 2015
NTi: Introducing industrial scale 3D printing
NTi is close to commercial Aerospace qualification
Slide 5
Actual system «flight proven» through successful mission operations
Actual system completed and «flight qualified» through test and demonstration (ground or flight)
System prototype demonstration in a space environment
System/subsystem model or prototype demonstration in a relevant environment (ground or slight)
Component and/or breadboard validation in relevant environment
Component and/or breadboard validation in laboratory environment
Analytical and experimental critical function and/or characteristic proof-of-concept
Technology concept and/or application formulated
Basic principles observed and reported TRL 1
TRL 2
TRL 3
TRL 4
TRL 5
TRL 6
TRL 7
TRL 8
TRL 9
Technology Demonstration
Technology Development
Research to Prove Feasibility
Basic Technology research
Large scale consistency test/allowables plan
Component test/commercial
launch/operations
TRL: Technology Readiness Level
Titanium 3D printing still not widely adopted within aerospace
Slide 6
3D printing is referred to as the 3rd industrial revolution
Slide 7
1st 3rd 2nd
Late 18th century Early 20th century Now
United Kingdom United States of America Globally
Mechanization of textile industry Mass production (Ford)
Mass customization through digitalization of manufacturing
Multiple Titanium manufacturing processes available
Slide 8
Conventional part manufacturing processes
Additive Manufacturing/ 3D Printing processes
Milled plate • Mill annealed • Beta annealed
Powder based • Laser
• Powder melting • Powder sintering (SLS) • Powder blowing
• Electron beam • Powder melting • Powder sintering (EBS)
Wire based • Electron beam
• Electron beam free form fabric. (EBFFF) • Laser • Arc
• Plasma arc direct metal deposition (DMD)
Forgings • Forged block • Die forgings
Extrusions
Castings • Precision castings ++ • Hot Isostatic Pressing (HIP) castings
Sheet metal based • Sheet metal ultrasonic consolidation
Conventional forming
In commercial aerospace, Ti AM (powder based) mainly replacing castings
Many AM initiatives related to engines...
Slide 9
• GE Aviation JV with Snecma to manufacture >30000 fuel nozzles annually for its LEAP engine starting with 2016.
• Pratt& Whitney to make the PW1500G engine (for Bombardier Cseries) will contain 24 AM metal parts from 2015.
• Rolls-Royce is gearing up to use 3D printing technology to produce components for its jet engines, as a means of speeding up production and making more lightweight parts.
…but, no viable alternatives on aerostructures - until NOW!
Titanium 3D print in commercial aerospace » Not yet adapted, mainly
future applications » Lower quality
requirements to replace casted parts, mainly engine
» Represents a relatively small share of the Titanium fly weight
» No solution for structural parts implemented yet
Slide 10
3D printing of titanium components A technology that will transform the titanium market
Slide 11 Private & Confidential
Private & Confidential Slide 12
A
B
NTi technology » Production of Ti Wire and Production of Components
Pilot Cell 0A (Dismantled)
Slide 13
» Started production in December 2008
» Produced prototype products: - Oil & gas industry (flanges & el-pods) - Aerospace industry (test samples) - Industry (ball valves) - Desalination (valves – energy recovery)
» Market focus: - Oil and gas (exploration), and general
industry - Emerging markets - Prototype products for emerging
markets
» Capability of manufacturing a part of up to a gross mass of 450 kg, and a size of 120 cm x 80 cm, Ø = 80 cm
» Gross deposition rate of 0.4 Kg/hr
Seismic O & G exploration
Development Cell 0B
Slide 14
» Started production in September 2009
» Produced prototype products: - Oil & gas (flanges) - Defense (rocket engine part) - Aerospace hybrid component - TRL 4, and 6 aerospace samples
» Market focus - Aerospace - Oil and gas (production) / industry - Defense
» Capability of manufacturing a part with a gross mass of up to 180 kg, and a size of 90 cm x 50 cm, Ø = 100 cm
» Gross deposition rate of 3-5 Kg/hr
Production Cell P01
Slide 15
» Started production in February 2012
» Produced prototype products: - Defense (titanium armored plate
samples) - Aerospace aerostructure component - TRL 6, and 8 aerospace samples
» Market focus - Aerospace complex components
» Capability of manufacturing a part with a gross mass of up to 200 kg, 180 cm x 120 cm x 120cm, Ø = 120 cm
» Wall angle upto 45°
» Gross deposition rate of 5-10 Kg/hr
Aerostructure component
It all starts with a CAD design of the component
NTi technology and production process
Slide 16
Deposition program is generated using the
CAD data
Transferred to the DMD production unit
Plasma arc welding of titanium wire directly on
substrate
Manufacturing a near net shape component
Minimum machining to obtain finished shape
Homogenous microstructure across
layered material
Reduced waste compared to traditional
production methods
Pre-form to finished component
Slide 17
Manufacturing of Titanium Components Titanium sponge Melting companies Forging Milling companies Rough machining Finish
mach.
Product Sponge Melting Bloom 80-90% Forging Rolling Mill product
Mill product
Pre-form
Mill/ Pre-form
Titanium sponge NTi Machining
Wire production/supplier Final product DMD production
Private & Confidential Slide 18
Source: Titanium Center of Competence and NTi
Ultra high Forged parts for
commercial aero
Casted quality
Forged parts for military applications
(Ti64 challenges)
Casted quality
5 - 10 kg/hour (Net production rate
~15,000kg/year)
5 - 10 kg/hour
5 - 10 kg/hour
Production rate
~200 kg/year
Wire + plasma arc (Inert atmosphere)
Blown powder based + laser
Wire + electron beam based
(Vacuum)
Powder bed based + laser or el beam
(vacuum or inert atmosphere)
NTi vs other 3D metal printing technologies Technology Deposition rate Quality Ideally suited for…
Both small and large components
Both small and large components
Both small and large components
Small high value components with highly complex
internal structures
Slide 19
Norsk Titanium (NTi)
Microstructure
» Controlled microstructure through thermal management, atmosphere control, and automation of other production parameters
» Able to achieve forged requirements consistently.
As deposited microstructure – lamellar/basketweave α/β structure
Slide 20 Private & Confidential
Meets the highest material standards Yield strength Tensile strength Production type
>910 >835
896 827 Forging
(Standard: AMS 4928, Rev. “S”)*
893 827 Plate - Mill annealed (Standard: AMS 4911, Rev.
“M”)*
841 745 Plate - Beta annealed
(Standard: AMS 4905, Rev. “D”)*
Private & Confidential Slide 21
862 793 Casted
(Standard: AMS T-81915, Rev. “T-81915”)*
Design defect factor
N/A
N/A
N/A
N/A
Applicable due to pores and voids
* SAE International Aerospace Material Specifications (AMS)
NTi value proposition
Cost efficiency
Shorter lead times
Flexibility & ability to customize
Quality & reliability
Green technology
» Reduced production cost » Reduced price volatility due to improved near-net-shape
» Conventional technologies: 4-12 months for aerospace & 4-6 months for defense
» Flexibility in design changes, time & form, reduces risk for obsolete design
» Attractive for prototyping
» Detailed production database » Accreditations for aerospace (Spirit TRL6*, going for TRL8*) and oil &
gas (NORSOK)
» Reduced waste & energy consumption due to the improved near-net-shape
Private & Confidential
* Technology Readiness Level
Slide 22
Summary
Slide 23
Titanium market under pressure, high demand and concentrated supply chain
Titanium 3D printing still not widely adopted within aerospace
Norsk Titanium breaking aerospace misconceptions by offering a new solution
A shift in the demand for advanced titanium components
Market growth is driven by lighter and more fuel efficient aircrafts
Concentrated supply chain results in long lead times
3D printing believed to be the 3rd industrial revolution
Ti 3D print mainly used to replace castings (engine) in commercial aerospace
No solution for 3D printed To structural parts implemented yet
Large scale additive manufacturing of Ti parts (drop-in replacement) for medium to large parts
High material quality and TRL8 maturity level
Competitive cost, price and high delivery flexibility
Norsk Titanium (NTi) Eggemoen Aviation & Technology Park Flyplassveien 21 | 3514 Hønefoss | Norway Phone: +47 97 42 22 00 Web: www.norsktitanium.no E-mail: [email protected]
Slide 24 Private & Confidential
THANK YOU