an overview of laser additive manufacture and repair · – minimise defects – low distortion –...

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1 1 An Overview of Laser Additive An Overview of Laser Additive Manufacture and Repair Manufacture and Repair ILAS 8 July 09 ILAS 8 July 09 Dr Robert Scudamore Dr Robert Scudamore T h l G M T h l G M Copyright © 2009, TWI Ltd World Centre for Materials Joining Technology Technology Group Manager Technology Group Manager [email protected] [email protected] tel: +44 (0)114 269 9046 tel: +44 (0)114 269 9046 Additive Manufacture Market Size Additive Manufacture Market Size 1200 1400 400 600 800 1000 1200 $M Copyright © 2009, TWI Ltd World Centre for Materials Joining Technology 0 200 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

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Page 1: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

11

An Overview of Laser Additive An Overview of Laser Additive Manufacture and RepairManufacture and Repair

ILAS 8 July 09ILAS 8 July 09

Dr Robert ScudamoreDr Robert ScudamoreT h l G MT h l G M

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Technology Group ManagerTechnology Group [email protected]@twi.co.uk

tel: +44 (0)114 269 9046tel: +44 (0)114 269 9046

Additive Manufacture Market SizeAdditive Manufacture Market Size

1200

1400

400

600

800

1000

1200

$M

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

0

200

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Page 2: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

22

Why Use Additive Techniques?Why Use Additive Techniques?

•• OEM OEM -- Improve material utilisation Improve material utilisation ––Buy : Fly ratioBuy : Fly ratioBuy : Fly ratioBuy : Fly ratio

•• Repair Repair –– Salvage partsSalvage parts•• Add ValueAdd Value•• Potential for >100% part life extensionPotential for >100% part life extension•• Add Intellectual Property protectionAdd Intellectual Property protection•• Process flexibilityProcess flexibility No toolingNo tooling

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

•• Process flexibility Process flexibility –– No toolingNo tooling•• Prototyping Prototyping –– Engine testingEngine testing•• Legacy partsLegacy parts

Buy : Fly RatiosBuy : Fly Ratios

Volume of near net shape component form, v

ComponentComponentBillet Billet

W i ht (k )W i ht (k )Component Component

t (k )t (k )Buy:Fly RatioBuy:Fly RatioComponentComponent

Weight (kg)Weight (kg) wt (kg)wt (kg)Buy:Fly RatioBuy:Fly Ratio

IntercaseIntercase 182182 3030 6.06:16.06:1

Simple Duct Flange 1Simple Duct Flange 1 6767 11.1411.14 6.01:16.01:1

Simple Duct Flange 2Simple Duct Flange 2 6767 7.667.66 8.75:18.75:1

Complex Duct Flange 1Complex Duct Flange 1 149149 7.657.65 19.48:119.48:1

Complex Duct flange 2Complex Duct flange 2 206.6206.6 10.2810.28 20.10:120.10:1

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Buy:Fly Ratio = B = V/v

Volume of original Billet, VNon – axially symmetrical feature

Large BliskLarge Blisk 810810 99 8.35:18.35:1

Page 3: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

33

Why Use Lasers?Why Use Lasers?

•• Low heat input processLow heat input process–– Minimise defectsMinimise defects–– Low distortionLow distortion–– Minimise residual stressesMinimise residual stresses–– Repair high spec alloys needed for high temperature engine Repair high spec alloys needed for high temperature engine

operation e.g. SXoperation e.g. SX

•• Near net shape Near net shape –– reduce rework in repair and OEMreduce rework in repair and OEM•• Low oxygen process Low oxygen process –– TitaniumTitanium•• AutomationAutomation

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

•• AutomationAutomation•• ProductivityProductivity•• CAD to Part AccuracyCAD to Part Accuracy•• RepeatabilityRepeatability

CAD to Part: Helicopter Gas ThrusterCAD to Part: Helicopter Gas Thruster

CAD, CAM and CAD, CAM and ,,processingprocessing

CNC entry andCNC entry and

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

CNC entry and CNC entry and processingprocessing

Page 4: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

44

CAD to PartCAD to Part

Gas thruster in Ti 6Gas thruster in Ti 6 44Gas thruster in Ti 6Gas thruster in Ti 6--44for Bell Helicopterfor Bell Helicopter

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Courtesy: Optomec Corp

11 P d b d d itiP d b d d iti

Two Types of Laser Additive Processing:Two Types of Laser Additive Processing:

1 1 –– Powder bed deposition Powder bed deposition

2 2 -- Nozzle powder delivery Nozzle powder delivery

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 5: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

55

Powder Bed Based Laser DepositionPowder Bed Based Laser Deposition

Terms: SLM, SLS, DLF, LaserCusingTerms: SLM, SLS, DLF, LaserCusing

Applications: Rapid Prototyping, OEM (Parts and Applications: Rapid Prototyping, OEM (Parts and Assemblies), Legacy Parts, Medical ImplantsAssemblies), Legacy Parts, Medical Implants

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Assemblies), Legacy Parts, Medical ImplantsAssemblies), Legacy Parts, Medical Implants

MTT Selective Laser MeltingMTT Selective Laser Melting•• Laser selectively fuses a thin layer of metal powderLaser selectively fuses a thin layer of metal powder•• Platform retracts in the Z directionPlatform retracts in the Z direction•• New layer of loose powder delivered to the build areaNew layer of loose powder delivered to the build areaNew layer of loose powder delivered to the build areaNew layer of loose powder delivered to the build area•• Process continues until finish building partProcess continues until finish building part

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 6: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

66

SLM Laser Powder Bed DepositionSLM Laser Powder Bed DepositionKey Factors:Key Factors:•• Material IntegrityMaterial Integrity•• Material PerformanceMaterial Performance•• Surface FinishSurface Finish•• ProductivityProductivity

Features:Features:•• PrePre--heat heat

–– Minimise residual stressesMinimise residual stressesMinimise solidification defectsMinimise solidification defects

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

–– Minimise solidification defectsMinimise solidification defects•• Reactive AlloysReactive Alloys

–– Low Oxygen (<50ppm or lower)Low Oxygen (<50ppm or lower)–– HSE requirementsHSE requirements

Inconel 718 SwirlerInconel 718 Swirler

STL file of swirlerSTL file of swirler

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

STL file of swirler STL file of swirler provided by Rollsprovided by Rolls--RoyceRoyce

Inconel 718 swirler Inconel 718 swirler fabricated using SLM100fabricated using SLM100

Page 7: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

77

Parts 1Parts 1

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Parts 2Parts 2

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 8: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

88

Titanium 6Titanium 6--4 Demonstrators4 Demonstrators

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Powder Bed, Anything is possible…Powder Bed, Anything is possible…

•• Vacuum processing for Vacuum processing for oxygen sensitive oxygen sensitive

i l i ii l i i

Ti-6Al-4V demonstrator

materials e.g. titaniummaterials e.g. titanium

•• PrePre--heat for crack heat for crack susceptible materialssusceptible materials

•• Small (40 micron) spot Small (40 micron) spot for intricate featuresfor intricate features

•• 20 micron layers for 20 micron layers for

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

yygood surface finishgood surface finish

Page 9: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

99

Nozzle based laser Nozzle based laser d i i / l ddid i i / l ddideposition/claddingdeposition/cladding

(DMD, LENS, LMD, DMLD)(DMD, LENS, LMD, DMLD)

Usages: Repair, tipping and Usages: Repair, tipping and

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

hybrid manufacturehybrid manufacture

High Speed Video of Laser CladdingHigh Speed Video of Laser Cladding

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 10: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

1010

Laser Deposition NozzlesLaser Deposition NozzlesCoaxial Nozzle MultiJet Nozzle Off-Axis Nozzle

•• Powder Spot Powder Spot ≥ 0,3 mm≥ 0,3 mm •• Powder Spot Powder Spot ≥ 1,5 mm≥ 1,5 mm

Working Plane

•• 2D Nozzle for 2D Nozzle for

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

•• Laser Power ≤ 2000 WLaser Power ≤ 2000 W

•• Oxygen Contamination Oxygen Contamination ≤ 20ppm≤ 20ppm

•• Laser Power ≤ 6000 WLaser Power ≤ 6000 W

•• Oxygen Contamination Oxygen Contamination ≤ 50 ppm≤ 50 ppm

geometries geometries with limited access with limited access

•• Laser Power ≤ 2000 Laser Power ≤ 2000 WW

Courtesy of Fraunhofer ILT

Huffman Toolpath MappingHuffman Toolpath Mapping

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 11: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

1111

Blade Tip and ZBlade Tip and Z--Notch OEM and RepairNotch OEM and Repair

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Nozzle Flange and EdgeNozzle Flange and Edge

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 12: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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Repaired Trent 500 IPT SegmentRepaired Trent 500 IPT Segment

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

T1000 HPT Seal SegmentT1000 HPT Seal Segment

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 13: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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ImpellorsImpellors

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

InIn--Situ Repair of Land Based TurbinesSitu Repair of Land Based Turbines

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 14: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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Bulk Metal Deposition Test CouponsBulk Metal Deposition Test CouponsTests include:Tensile

Compressive

Shear

Fract. Tough

Fatigue

Stress corr.

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Deposited material – full blocks and hybrid

Full size coupons produced from deposited material

PROPERTY No of test Deposited S53 Wrought S53coupons

Tensile: Longitudinal 3 1855 1960

Material Properties Material Properties –– Laser Deposited High Laser Deposited High Strength Stainless SteelStrength Stainless Steel

(Mpa) Long Transverse 3 1667 Hybrid 3 1838 % El L/LT/H 3 9.8/1.7/8.5 15 % RA L/LT/H 3 27.3/3.0/36 60

Compressive: Longitudinal 3 1610 1700 (Mpa) Hybrid 3 1670

Shear: Longitudinal 3 1235 1350

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

(Mpa) Hybrid 3 1077

Fracture Toughness: Mpa√(m) Longitudinal 5 55.9 70 Hybrid 5 63.3

Page 15: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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TSB Project: Hybrid Build of Landing GearTSB Project: Hybrid Build of Landing Gear

DepositedDeposited S53

Forged S53

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

S53

Inconel 718 BossInconel 718 Boss

Inconel 718 boss Inconel 718 boss deposited using deposited using Trumpf DMD505Trumpf DMD505

NC path NC path designed in designed in Trumpf’s Trumpf’s TOPs800TOPs800

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Page 16: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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Titanium 6Titanium 6--4 ‘in air’ Demonstrator4 ‘in air’ Demonstrator

500mm

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Robert ScudamoreRobert [email protected]@twi.co.uk

+44 114 269 9046+44 114 269 9046Acknowledgments:Acknowledgments:

Fraunhofer ILT/LLTFraunhofer ILT/LLT Huffman CorporationHuffman Corporation

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

Fraunhofer ILT/LLTFraunhofer ILT/LLT Huffman CorporationHuffman CorporationLPW Technology Ltd.LPW Technology Ltd. Material SolutionsMaterial SolutionsMorris TechnologiesMorris Technologies MTT Ltd.MTT Ltd.Optomec CorporationOptomec Corporation RollsRolls--Royce PlcRoyce PlcSwinburne Univ. Swinburne Univ. Trumpf GmbHTrumpf GmbH

Page 17: An Overview of Laser Additive Manufacture and Repair · – Minimise defects – Low distortion – Minimise residual stresses ... Microsoft PowerPoint - TWI ILAS July 09 TWI RJS

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ScheduleSchedule

TimeTime SpeakerSpeaker Company/Inst.Company/Inst.

13.4013.40--14.0014.00 Robert ScudamoreRobert Scudamore TWITWI

14.0014.00--14.2014.20 Ingomar KelbassaIngomar Kelbassa LLT/FraunhoferLLT/Fraunhofer

14.4014.40--15.0015.00 Chris SutcliffeChris Sutcliffe MTTMTT

15.0015.00--15.1015.10 Break and ExhibitionBreak and Exhibition

15.1015.10--15.3015.30 Roger HayesRoger Hayes Huffman CorpHuffman Corp

15 3015 30 15 5015 50 Phil C llPhil C ll LPW T h lLPW T h l

Copyright © 2009, TWI LtdWorld Centre for Materials Joining Technology

15.3015.30--15.5015.50 Phil CarrollPhil Carroll LPW TechnologyLPW Technology

15.5015.50--16.1016.10 Carl BrancherCarl Brancher Material SolutionsMaterial Solutions

16.1016.10--16.3016.30 Lin LiLin Li Manchester UniManchester Uni