an overview of laser additive manufacture and repair · – minimise defects – low distortion –...
TRANSCRIPT
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
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
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
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
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
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
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
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
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
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
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
1212
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
1313
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
1414
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
1515
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
1616
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
1717
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