additive layer manufacturing technologies for space ... · additive layer manufacturing...
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Spierings, Adriaan © 01/2017 inspire AG
Additive Layer Manufacturing Technologies for Space Applications
-
Quality Management System in Additive Manufacturing
31. January – 1st February 2017,
Harwell Campus UK
UK-CH Bilateral Workshop on Space Technology
A.B. Spierings Head R&D SLM
Inspire AG – innovation centre for additive manufacturing Switzerland
Spierings, Adriaan © 01/2017 inspire AG
Who is inspire?
Fields of activity / institutes - Iwf-processes: Grinding, Cutting, EDM, …
- Iwf-machines: Machine Tools, Simulation, Analysis, Improvements
- Iwf-micromachining: Laser- & mikrofabrication
- icams: Additive Manufacturing (SLS, SLM)
- Ipdz: Construction & Design
- Ics: Composite-Structures
- Icmi: Material integrity
- Ifa: Automation, Optimisation, Mechatronic
- Ivp: Virtual production / Forming technology
ETH Zurich
Technopark Zurich, Headquaters
St.Gallen, icams
Spierings, Adriaan © 01/2017 inspire AG
Inspire R&D focus in SLS & SLM
Standardisation
ASTM-ISO
Industry
requirements
Quality management
systems
Industrial
applications Materials
Applications
Machines
Processes
Spierings, Adriaan © 01/2017 inspire AG
Additive Manufacturing in space and
general industry applications
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Spierings, Adriaan © 01/2017 inspire AG
Introduction
AM: Many opportunities esp. in space
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Ref to ESA-Project: «System impact of additive manufacturing technologies design features” (AO/1-8005/14/NL/MV)
• Brackets
• Waveguides & Filters
• Antennas
• Manifold systems
• Heat panels / pipes
• Monts etc.
• Baffles
• Emissivity designs
• …
Spierings, Adriaan © 01/2017 inspire AG
Introduction
High quality requirements in sectors such as
– Space
– Aerospace
– Turbine industry
– Medical
– Automotive
– …
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Aluminium space frame Audi A2
Topologically optimized antenna
bracket for Sentinel satellites (RUAG)
As-built and polished turbine
blade (Morris Technologies)
Topology optimized bike front (inspire)
Flight crew rest compartment
bracket installed on A350
Aluminium cube-sat parts, source: inspire / SSC
Spierings, Adriaan © 01/2017 inspire AG
Quality Management System in Additive Manufacturing
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Spierings, Adriaan © 01/2017 inspire AG
What is quality in AM?
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Quality
parameter
Sub-property values Ideal quality goal Typical technical
values
Material
integrity
- Material density
- Number / amount of defects, e.g.
total crack lengths e.g. per mm2
cross-section
• 100% dense
• “Crack free”
> 99.5%
max. total crack length
per mm2 and/or max.
crack length
Mechanical
properties
- Ultimate strength Rm
- Yield strength RP0.2
- Elastic modulus E
- Fracture toughness
- …
• Comparable or outperforming conventionally
processed materials
• Free of anisotropy
• Material- and machine dependent
Microstructural
integrity
- Grain size distribution
- Grain orientation
• Homogeneous grain
sizes, no texture
• Ideal grain
misorientation
distribution
Columnar grains
Grain texture in build (z-)
direction
Surface
properties
- Roughness
Ra, RZ / Sa, SZ
• Roughness as low as
possible
Rough surface qualities
with Rz 30 - 40m,
dependent on powder,
processing window and
part orientation
Dimensional
tolerances
- Parallelism of planes
- x-, y- and z-dimensions
• As engineered /
according to CAD
Typical deviations in the
range of 0.1mm
AlSi10Mg (Buchbinder, 2014)
Many quality parameters!
Spierings, Adriaan © 01/2017 inspire AG
Quality management system
SLM-processing chain
– From powder raw material to the final part
– Influencing factors in all sub-processes
– Cross-influences between processing steps
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Spierings, Adriaan © 01/2017 inspire AG
Influencing factors in the AM-process chain
Example: Alloy
composition
Example: Powder
properties
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Spierings, Adriaan © 01/2017 inspire AG
Influencing factors in the AM-process chain
Example: AM-processing
conditions / window
– The processing conditions
influence the material
microstructure, and finally
mechanical properties
«Master forming process»
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Spierings, Adriaan © 01/2017 inspire AG
State of the art in AM-quality management
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Powder qualifi-cation
Particle size distribuiton
Flowability
…
Process qualifica
-tion
Melt pool monitoring
Powder layer quality
Maschine qualificati
on
Atomsphere
Laser
Cleanliness
…
Part qualifi-cation
CT scanning
Conv. Part finishing
• No quantitative
standards
• Flowability:
Conv. methods
do not fit
• No information
about final part
quality
• For (future)
feedback control
• No quantitative
standards
• Complex
machines
• Costly
• Time
consuming
Photo diode signal of the QM-meltpool
monitoring solution of ConceptLaser
CT-scan for an Al-space part (inspire)
Ref. Spierings (2015)
Spierings, Adriaan © 01/2017 inspire AG
Conclusion: An AM-quality management system
… across the whole AM-process chain
– … with defined parameters in all sub-processes
– … measured quantitatively
– … monitored over each build job / during the build job
– … with defined quality gates between sub-processes
In order to
– Get insight into dependencies / correlations
– Directly qualify an AM-part after production
– Guaranteeing
– a certain quality level / -level for a given application
– Reproducibility
– Repeatability
– Derive appropriate standards
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Quality control chart for a certain
parameter
Spierings, Adriaan © 01/2017 inspire AG
AM-quality management system = our main goal @ Inspire
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Spierings, Adriaan © 01/2017 inspire AG
Conclusions
A comprehensive AM-quality management system is
(compleatly) missing
Inspire is therefor focussing on QM-management systems
by addressing the whole AM-processing chain
– Materials
– Processes
– Machines
– Applications
We are pushing this topic on a national &
international level
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Spierings, Adriaan © 01/2017 inspire AG
Insight into inspire-icams
Thank you for your attention
Adriaan B. Spierings Head R&D SLM
Lerchenfeldstrasse 5
9014 St.Gallen
[email protected] +41 71 274 73 19 www.inspire.ethz.ch
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3 x SLM-machines 4 x SLS-machines
Fully equiped analyse and R&D lab, with 1 own developed open R&D SLM machine