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10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

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Page 1: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

10 September 2014

Additive Manufacturing

James Sears

Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Page 2: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

2 September 18, 2014

GE-GR: Market Focused R&D

• First U.S. industrial lab

• Began 1900 in Schenectady, NY

• Today: 3000 technologists, 6+ sites

• Founding principle … improve businesses through technology

Cornerstone of GE’s commitment to technology

Page 3: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

3 September 18, 2014

GE-GR: Manufacturing Research Efforts Advanced Machining Electro-Machining Shaped-Hole Drilling Superfinishing Processes “Intelligent” Machining

Composites Ceramic Matrix Composites Polymer Matrix Composites Automated Fiber Placement Inline Inspection & Monitoring

Metal Processing Centrifugal Casting Directional Solidification Powder Metallurgy Forging Processes

Coatings Low-Cost TBC’s Suspension Plasma Spray Thin Films for Solar Ice-Phobic Nano Coatings

Operations Research Factory Simulation & Optimization RFID Tracking Data Telecommunications Mfg Data Informatics

Manufacturing Scale Up Mfg Readiness Level Assessment Equipment Design Pilot Scale Production Low Rate initial Production

Services Repair Applications On-Site Field Services In-Situ Inspection & Repair Automated Workscoping

Additive Manufacturing Design for Additive Tools Metal & Ceramic Processes Polymer Rapid Prototyping Micro-scale deposition

Laser Processes Thick-Section Welding Laser Surface Treatments Laser fundamentals Process Controls

Inspection 3D Boroscope Inspections Optical Metrology Inline CT Automated Defect Recognition

Page 4: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

4

Additive Manufacturing (AM)

https://www.youtube.com/watch?v=GjbkxVku39Y

Metals (High-Temperature Alloys) Ceramics Polymers

Page 5: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

5

Conventional Manufacturing vs AM

Start with a pre-formed billet , which gets formed and machined.

Material properties unchanged and cannot be location specific

Limited to known set of geometries

Design constrained by manufacturing

Requires extensive tooling

Conventional Additive

Start with a powder or wire and produce part layer upon layer upon layer.

Build material properties as part is built … location specific

More complex geometries possible

Allows for faster iterations between design, materials and manufacturing

Minimal tooling required

Material properties created during manufacturing Ability to tailor by location

Page 6: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

6

AM: No Constraints on Design

One piece stapler

Structural elements + Heat exchanger

Page 7: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

PROTOTYPING: BIGGEST APPLICATION FOR AM BMW APPLICATIONS: ACCELERATE THE DESIGN CYCLE

Vehicle front using SLS

Various motor parts using SLS

Crankshaft using SLA

Rear motorcycle wheel using SLA

15-20K parts/year all consumed during testing

Page 8: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

PROTOTYPING: ELECTRONICS & FLUIDICS BMW APPLICATIONS: ACCELERATE THE DESIGN CYCLE

Courtesy of Harvard University & UTEP

Page 9: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

9

Customized One-of-Parts + Specialty Materials − Aerospace: design visualization, testing

− Healthcare: Surgical aids, dental, prostheses

− Product design: touch-feel prototypes

Healthcare

Visualization & surgical aids (full 3D color printing)

Implants – 3D printed jaw & hip joints

Custom dentures – 50K parts/day

Align Technologies, CA

CT collimators – Dunlee (Philips)

Move towards the industrial use of AM Public

Page 10: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

10

AM: Market Overview & Trends •Total market size: 1.714B (services & products worldwide)

•AM market growth in 2011: 29.4%

Services growth Product growth

Year Overall growth%

Product growth %

Service growth %

2008 3.7% 0.0% 7.9%

2009 -9.8% -13.2% -6.2%

2010 24.1% 22.9% 25.3%

2011 29.4% 28.0% 30.7%

Secondary market*( enabled by AM: $1.08B Total AM revenue: $2.79B in 2011

*Tooling, molding, castings processes etc derived from AM

Primary market:

Public

Page 11: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

11 GE Title or job number

9/18/2014

Overview of Presentation

• Where is AM being used

• Potential areas of collaboration in AM technology development

Micro-additive AM

Direct-written sensors

Metals additive manufacturing

• Future perspective

Page 12: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Additive Manufacturing @ GE Two primary uses:

• Rapid prototyping to compress the design cycle

• Manufacturing of previously “difficult-to“ manufacture high-performance components at cost

“We are standing in front of a potential revolution in manufacturing”, Michael Idelchik, VP of Advanced Technologies, GE Global Research as quoted in the

Economist , April, 2012

Design

Manufacturing

Materials

Page 13: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

AM Technologies at GE

Resolution 15 µm 200 µm 500 µm

Large-scale features

• Turbomachinery applications • Test hardware • Limited production begins 2013

• Metal leading edge • GEA Repair & feature addition • In use

U/S probes Functional metal, ceramics & polymer parts

Commercial polymer & metal machines

Large one-off functional metal parts

Custom built machines

Macro-scale features Micro-scale features

• Ultrasound probes • Direct-written CBM sensors • Pilot production 2013

• Direct ceramic deposition

• Direct written sensors

• DMLM & Electron beam

• Commercial polymer AM • Spray technologies

• Laser & EB cladding

CBM Sensors

Ceramics printing

Direct write

Public

Page 14: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Micro-AM: Digital Micro-Printing • Low cost, highly adaptive meso-scale manufacturing method - 15-20 micron feature size in X-Y

• Large area patterning – currently X-Y-Z - 6”x6”x2”, scalable to larger areas

• Layered deposition of photopolymer slurry loaded with ceramic/metal particles

• Photocuring with digital masks – wide range of 3D geometries

Public

Page 15: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Micro-AM: Digital Micro-Printing (DMP)

• High aspect ratio structures, shapes on demand

• Materials demonstrated: Alumina, Piezoceramics (PZT), Platinum, Phosphors

50 mm layers, 500 mm tall – Polymer

(Photocurable Acrylate)

50 mm layers, sintered, Alumina

15 micron posts, polymer

(Photocurable Acrylate)

Pt

PZT

Pt-PZT co-deposited & co-

sintered

Periodic piezoceramic columnar array

~80 micron columns

Aperiodic piezoceramic columns

40-80 micron columns

100 microns

Page 16: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

DMP: Ultrasound Transducers

Piezoelectric transducer elements

Conventional Process: Dicing

(Slow, expensive, resolution/geometry limited)

Disruptive: DMP

(Faster, higher resolution, unique sensor architectures)

Ultrasound Transducer

Un-dicable geometries: staggered columns High Frequency (15-25 MHz) ultrasound probes:

100 microns

Custom design of

transducers

Page 17: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Est Vol%: 0.3

fp (MHz) fs (MHz) kt Qm h33 (V/m) KS

3 KT

3Tan K

S3 K

T3

101709-101709-02_P1 17.4 14.8 0.571 6.03 2148 304 550 -0.023 1013 1833

101709-101709-02_P2 17.6 14.9 0.575 6.05 2145 315 576 -0.023 1050 1919

101709-101709-02_P3 17.3 14.7 0.567 5.36 2098 311 566 -0.027 1037 1885

101709-101709-02_P4 17.3 14.6 0.574 5.37 2086 319 591 -0.026 1063 1970

101809-101709-02_P1 16.9 14.7 0.543 5.20 1805 390 680 -0.022 1299 2268

101809-101709-02_P2 16.5 14.4 0.535 5.30 1813 355 613 -0.023 1182 2045

101809-101709-02_P3 16.3 14.1 0.536 5.48 1826 343 586 -0.022 1144 1955

101809-101709-02_P4 16.5 14.4 0.529 4.96 1775 361 624 -0.024 1202 2080

101909-101909-02_P1 27.8 24.1 0.538 6.05 1687 404 700 -0.028 1346 2334

101909-101909-02_P2 28.1 24.4 0.535 6.30 1665 417 727 -0.030 1389 2423

101909-101909-02_P3 28.0 24.4 0.530 6.18 1687 396 686 -0.028 1318 2285

101909-101909-02_P4 28.2 24.4 0.538 5.98 1770 375 658 -0.030 1251 2194

Comp Ceramic

Conventional Vs. Digital Micro-Printing

Cleaner impedance plots – via optimization of the

transducer structure

Conventional Optimized (DMP)

Modes eliminated Spurious modes

Page 18: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

DMP: Printed Materal/Fetal U/S Probes

Resolution Phantom Fetal Phantom

•Jointly funded by the National Institute of Health and GE-MCS

•Lab demo of printed 4C probes (maternal/fetal); sensitivity debit noted

In-house AM system developed Results

Coupling coefficient (kt): 0.53

This project is supported in part by Award Number 1RC2EB011439 from the National Institute of Biomedical Imaging and Bioengineering (NIBIB). The

content is solely the responsibility of the authors and does not necessarily represent the official views of NIBIB or the NIH.

Page 19: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Direct-Write Sensors and Structures

Direct Write Nozzles (nScrypt Inc.) – DARPA MICE Sample YSZ & YSZ:Eu deposition

• Directly write an ink with a high loading of ceramic or metal on 3D substrate

• Feature resolution ~50 microns w/t particle inks, ~10 microns w/t sol gels

• GRC efforts: adapt nozzles to GE materials, e.g. custom inks

Applications: • Temperature/strain sensors, condition monitoring, bio-material traces

Development requirements: • Materials: Inks with high loading, finer particle sizes, sol-gels

• Structures: Higher resolution, multi-material structures

Page 20: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Micro-Scale AM: Other Applications

Other material systems:

- Magnetics

- Optical structures

- Thermo-electrics

- Bio-materials ?

- Others ..

- Graded materials ?

Page 21: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Macro-Scale AM

Page 22: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Macro-Scale: Polymer Processes

Fused deposition modeling - Filament extrusion - Thermoplastics: ABS, polycarbonates - Companies: Stratasys, Makerbot

Stereolithography - Selective photo-polymerization - Thermosets: acrylates epoxies - Companies: 3D Systems, Envisiontec

Multi-jet printing - Direct material or binder dep. via inkjet - Acrylates, plaster-of-paris, ceramics - Companies: 3D Systems, Stratasys, Voxeljet

Selective laser sintering - Direct sintering of powder in a bed - Thermoplastics - Companies: EOS, 3D Systems

Public

Page 23: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Macro Scale: Metal AM Processes

Direct Metal Laser Melting (DMLM) E-Beam Based AM (eBM)

Consolidation Method By Methodology

Laser Electron Beam (EB)

Gas or plasma tungsten arc

Wire feed

Powder Bed

Powder Feed

Kinetic (cold) spray

Metal Additive Mfg

Public

Page 24: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Metals AM @ GE

Feature addition & repair Large Feature fab

Powder-Bed Processes - Electron-beam or laser (~1’x1’x1’) - DMLS/DMLM: EOS, SLM Solns, Concept Laser etc. - Electron-beam melting: ARCAM - DMLM: GE Aviation is largest user in the world

Powder or Wire-Fed Processes - Electron-beam or laser - Laser: Huffman, Optomec, home-grown - Electron-beam: Sciaky

Public

Direct metal laser melting (DMLM)

Electron-beam melting (EBM)

Page 25: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

25 GE Healthcare Summit

9/18/2014

DMLM and EBM Comparison

Laser

Melting

Electron Beam

Melting

Energy Source 400 W

Fiber Laser 3500 W Electron Beam

Scanning

Method Optical Mirrors Magnetic Deflection

Build Layers 20 to 50 µm 50 to 70 µm

Accuracy 50 µm 200 µm

Build Rate 13 cm3hr-1 55 cm3hr-1

Surface Finish 250-300 µ-in 800-1000 µ-in

Residual Stress High Low

Page 26: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Material Properties Drive Applications

26 GE Healthcare Summit

9/18/2014

Wrought DMLM

Horizonta

l V

ert

ical

Melt Pool Directionality Vertical Grain Growth

Similar to Wrought Isotropic / Homogeneous

Typical Equiaxed Grain Structure

Solution Heat Treatment

40

60

80

100

120

140

160

180

200

DMLS - V DMLS -

H

Wrought

Low

Wrought

High

YS (ksi) "UTS (ksi)"

18

22

26

30

34

38

42

DMLS - V DMLS - H Wrought

Low

Wrought

High

Elongation (%) "Hardness (HRC)"

Page 27: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

GE Internal

Materials Available Metals at the ADC & GRC:

Detailed design curves available for Co-Cr, IN625 (09/13)

More materials being developed, e.g. tungsten, copper alloys

Ti64 Stainless 316L Aluminum AlSi10Mg

Cobalt Chrome Stainless 17-4PH Aluminum 6061-T6 (beta)

Inconel 625 Stainless 15-5 PH Maraging Steel MS1

Inconel 718 Stainless GP1

Ceramics:

Fraunhofer Institute of Production Technology: ZrSiO4 found to be most suitable. Other materials tried: aluminum oxide, aluminum silicate. 200W laser. 50% dense parts. Phenix Systems: Laser sintering of alumina structures. GRC

has experience

Public

Page 28: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Manufacturing w/ AM: Current Plans • Industrial application: 19 additive fuel nozzles to be installed on every CFM

LEAP engine, >7000 sold

• GE P&W, GEHC and GE O&G launching products soon

• GE Appliances biggest prototyping user in-house – 30-40K parts/year

• Overall: Several hundred people working on AM

Pro

toty

pin

g

LEA

P f

ue

l no

zzle

sc

he

ma

tic

Public

Page 29: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Emerging Apps: Tooling & Spares

Direct fabrication of metals & polymer tooling (1-2 wks):

• Polymer/silicone tooling for sheet metal forming & polymer parts

• Metal die-casting/injection molding tooling

Spares on demand (< 1 wk) • Legacy turbomachinery spares

• Bespoke parts, e.g. custom ducts

• Low-volume lots or parts made w/ hard-to-

machine materials

• Custom jigs and fixtures to facilitate

manufacturing

Ref. Stratasys Ref. Maatsura

Ref. EOS Ref.: GE led US-Army DDM IBIF Pgm. (T700 focus)

Page 30: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

30

Physics-Based Modeling (PBM): Objectives

Objectives:

Understand multi-scale physics of AM processes to enable:

1) Rapid optimization of AM processing conditions for defect-free microstructure & best surface finish

2) Prediction & minimization of thermal distortion

Page 31: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

31

PBM: Laser-Material Interaction • Understand laser/powder-bed interaction • Location of maximum power absorption inside the powder bed • Impact of particle size & distribution on melt kinetics • Fraction of laser power absorbed

Powder

bed height

(um)

Averaged

thickness

(um)

Beam

radius

(um)

Fraction

absorbed

Z location

abs. density

max (um)

Laser

interaction

width

(Z-size)

Interaction

radius

(um)

50 70 50 0.52 50 60 60

50 70 40 0.52 40 50 50

50 70 25 0.52 40 60 30

100 120 50 0.63 40 80 60

100 120 40 0.63 40 80 50

100 120 25 0.63 40 80 30

Page 32: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

32

PBM: Laser Scanning Model

Track 1

Track 2

Cooling rate > 106/s

Sxx

Crack directions can be correlated to the max. principal stress

in the laser scanning model

Output of the model • Melt-pool size & shape • Temperature distribution over time • Stress build-up & predict crack formation

during laser scanning Helps in: • Optimizing AM process windows (process

parameters) for defect-free deposition Challenges • ~2 CPU hours to scan 0.015 cm on a

desktop workstation • Therefore, 1 cm3 solid ~ 1 700 000 CPU

hours (~200 years…)! • NAMII proposal w/ Louisville and Penn

State aimed at addressing these deficiencies

Page 33: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

PBM: Distortion Prediction

Parameter Value

Materials Co-Cr

Laser scanning speed 850 mm/s

Laser power 310 W

Laser absorptance 0.35

Ambient temperature 20 oC

Hatch spacing (Track width) 0.13 mm

Layer thickness 0.05 mm

Recoating Time 15 s

Build plate temperature 100 oC

Heat transfer coefficient

(metal/powder)

10 W/m2/K

Heat transfer coefficient (build

plate/environment)

150

W/m2/K

Part size: 1 inch × 1 inch × 1 inch

Predicted distortion

after removal from build

plate

~0.5mm

Page 34: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

34

Process Qualification

Ni-alloy A Co=17.5, k=0.9, m=-11

with stray grains

Typical nodal temperature Melt pool front advance

A Process Map ( for LENS by J.Beuth et al)

Distortion prediction

Microstructure prediction

• Development of a process map will facilitate rapid part qualification through

minimization of distortion, control of melt pool shape and consistent microstructure even in overhang regions that will enable improved surface finish

Page 35: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Proliferation & Future Dev.

Page 36: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Creators & Pioneers

Early Adopters

Primary Majority

Secondary Majority

Holdouts

Adoption: What phase are we in?

Technology Maturation and Acceptance Curves

PAX NAVAIR Meeting, May 9th, 2013

Public

Page 37: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

37 GE Healthcare Summit

9/18/2014

AM: Recent Acquisitions

November 12, 2012

GE Aviation Acquires MTI/RQM

ADC

ALL

Page 38: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Makers Guild AN ACTIVE LEARNING PROGRAM that will inspire GE engineers to work with new

manufacturing technology through a simple and engaging curriculum comprising a series of

progressively sophisticated challenges & training seminars

Novice level Download simple CAD models /print a 3D part

Master level Access to ADC to implement a design improvement via AM

Apprentice & expert levels Design & build complex engineering parts

Courtesy: Herb Caloud, GEHC

100 Printers Deployed

1000 Guild members

Aviation, Corporate, Healthcare,

O&G, P&W, Appliances, Lighting

Page 39: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Additive Manufacturing (AM) Quests OPEN ENGINEERING QUESTS DESIGNED TO

Engage and build the external AM ecosystem for design & materials

Leverage open innovation tools to accelerate NPI’s

Demonstrate GE’s continued investment in the space.

1 2 3

AM DESIGN QUEST AM PRODUCTION QUEST

• Reduce jet engine weight by redesigning

accessories components, e.g. brackets, hangers

• 650+ entries in 3 months. ID best design groups

• Build high-precision components in specialty

materials; stimulate supply chain growth

• High density, high atomic number metals

• 150 micron walls, with tolerances ±15 microns

CT Detector components

Challenges hugely successful, global response. Winners from Indonesia & Finland

GEA accessories bracket redesign

Page 40: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

AM Quests: Designing for Performance

Additive Design Quest

Production Quest

> 80% weight reduction realized

Page 41: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Long development times for all materials processing processes

1970 1990 2000

COMPOSITE FAN BLADE

DS CHEMISTRY AND PROCESS

2010

SC SUPERALLOYS

COMPOSITE FAN CASE

2020

POWDER METALLURGY DISKS

Ti-Al

ADDITIVE MANUFACTURING

Initial lab development

Committed to engine

Entry into Service

1980

Aviation Materials & Manufacturing Dev.

Page 42: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Improving machines

Headwinds Tailwinds • Early feasibility of AM

established @ GE

•Multiple machine producers, more competition, willing to customize •Game changing, high performance

products emerging in aerospace & power-gen industries

•Materials qualification expensive; 5+ years to qualify one material •Custom machine expensive; machine

producers are small & cannot support multiple development efforts

• Inspection methods not available

Distortion a problem; costly iterations

Future: Challenges

Page 43: Additive Manufacturing - c.ymcdn.com · 10 September 2014 Additive Manufacturing James Sears Additive Manufacturing Lab GE Global Research , Niskayuna, NY

Public

Additive Manufacturing Development

Technology needs are broad and requires a joint effort between

industry, government & academia

Adaptive,

reconfigurable

manufacturing • Custom & Location

Specific Materials

• Rapid Material

Qualification

• Design freedom

Technolo

gy D

evelo

pm

ent

2-3 years 5 years + Today

One-off manufacturing • Small Supplier Base

• Few Industry Specifications

• Limited Design Methodologies

• Productivity Enhancements

• Expanded Material Databases

• Process Monitoring & Control

• Robust manufacturing systems