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Copyright © TWI Ltd 2016

Austrian Additive Manufacturing Delegates Visit to TWI Rotherham

30/11/2016


Agenda


Introduction - TWI

TWI’s Mission

To deliver world class services in joining materials, and associated engineering technologies to meet the needs of Industry

Dedicated to Materials Joining

• £70m R&D per year

• Non profit distributing

• 800 staff

• >700 industrial members worldwide

• 70 years track record


>800 confidential projects per year

150 ongoing industry-led research projects

25,000 training and examinations students per annum

5,000 new technical abstracts per annum

Representation on over 100 standards committees

Introduction - TWI


2014 Structural Integrity Research Foundation

(SIRF) and new Integrity Research Centre (NSIRC) established in Cambridge

Major expansion of facilities in Cambridge

New purpose-built centres in Port Talbot, Wales and Kuala Lumpur, Malaysia

1979 The Robert Jenkins Laboratory for heavy and high-voltage equipment (electron beam, friction welding) opened by HRH The Prince of Wales

A Brief History of TWI

2015 1920 1970 1990 2010 1940 1930 1950 1960 1980 2000

1946 British Welding Research Association (BWRA)

established to take over the research activities of the Institute of Welding

Abington Hall purchased and research laboratories set up

The start of TWI in its recognisable form

1968 The Welding Institute formed by the merger

of BWRA and The Institute of Welding

1952 Purpose-built fatigue

laboratory erected

1966 The Ramsay Moon Conference

facility is built

1981 Purpose-built Training Centre opened in Cambridge

1984 The Welding Institute becomes a founding member of the Edison Welding Institute (EWI) in Columbus, Ohio, USA and seconds a team of specialists to set it up

1994 TWI achieves ISO 9001 accreditation

1990 ‘TWI’ adopted as trading name to reflect wider interests in joining, materials and engineering research and consultancy

1948 A founding member society of the

International Institute of Welding (IIW)

1923 Institution of Welding Engineers founded in London

1934 Institute of Welding formed by merger of Institution of

Welding Engineers and British Advisory Welding Council

1957 First metallurgical laboratory

built in Abington

1961 Engineering laboratory built – for fracture, pressure vessel and resistance welding research

Great Abington, Cambridge, 1969

Great Abington, Cambridge, 1958

1993 TWI South East Asia Centre opened in Kuala Lumpur, Malaysia

2010 TWI North America established in

Houston, Texas

The new TWI Technology Centre (Wales) building, 2014 New facilities in Abington, Cambridge, 2014

Abington Hall Stables, pressure vessel testing, 1948


TWI - Industrial Sectors


Cambridge

National Network

Port Talbot

Sheffield Middlesbrough

Aberdeen


International Centres and Offices

North America China Central Asia

Middle East

Africa India

South East

Asia

Japan


TWI Expertise

1. How to Join Materials Effectively

2. How do Joints Perform in Service

• Metals • Plastics • Ceramics • Composites • Welding • Adhesives • Fasteners • Surfacing


Additive

Manufacturing Laser and sheet

processes, incl. laser welding and cutting

Friction and forge processes, incl. linear friction and friction stir welding

Electron beam welding

Adhesives and composites

Ceramics Brazing R&D developing

new technologies

Key Technologies and Expertise

Fitness-for-service assessment (FFS)

Risk-based inspection (RBI)

Advanced & specialist NDT/inspection

Fatigue & fracture testing & assessment

Testing in critical environments, e.g. sour (H2S), sweet (CO2), HTHP, H2

Software tools

Specialist training

Materials and failure mode characterisation

Materials/joints performance and degradation testing

Materials performance improvement for demanding service

Surface engineering

Welding engineering and fabrication

JOINING

ENGINEERING

MATERIALS

www.twi-global.com


TWI Service Delivery Overview

Core Research Programme Industrial contacts

Public funded projects

Single client projects

Exploratory Programme Far from market ideas generation

Advisory & consultancy services

Joint Industry Projects


Member Products and Services

Technical helpdesk

R&D, consultancy

and manufacturing

support

Training and examinations

Information services

Technology transfer /

supply chain support

Online technical

knowledge

Software packages and development

Welding, AM, inspection and testing

Failure investigation


Metallic Additive Manufacturing at TWI: An Overview


Metallic AM Overview at TWI

Activity in AM since

1990’s

TRL 1-9 AM business

solutions offering

>£63Mn AM project

work (associated) in last 5

years

>£6Mn AM project

work (direct) during last

18 months

>£0.5Mn PA

TWI Core Investment

>25 live collaborative

projects underway

>35 AM Staff

directly in AM

NADCAP, ASTM-F42, AM-EC SP,

UK AM Strategy

Annual Industrial

AM Conference

at TWI


AM Technology at TWI

Processing

Arc-based

EB-based

Powder-bed: SLM

Powder-fed: LMD

Thermal Spray

Materials

Metallurgical Analysis

Heat Treatment

Powder Quality & Recycling

HS&E Issues

Metrology Mechanical

Testing Standards & NADCAP

Numerical Modelling

Topology Optimisation

Process Modelling

Structural Integrity

Manufacturing Services

NDT

In- & post-process

Certification Validation

Prototypes Systems & Automation

Manufacture

Testing


AM Technology Transfer Program: Working with TWI


Additive Manufacturing Workshop

AM Product

Suitability Workshop

for Members

Concise AM Feasibility Report Business case for AM adoption

Guidelines for future activities supporting your product portfolio’s transition towards the adoption of AM technologies


Additive Manufacturing Workshop

TWI

• CMG Officer

• Numerical Modelling Team

• AM/SLM Design Team

• AM/SLM Technician Rep

• Materials Group

• SSN, SMJ

• Welding Experts

• LAS, EBM , ARC

• Structural Integrity

• Reps – Static/Fatigue

• NDT Team Rep

• Manufacturing Services

Client

• Commercial Managers

• Design/FEA Engineers

• Materials Engineers

• Fabrication/Assembly Engineers

• Structural Integrity/Stress Engineers

• QA/QC Engineer

• Validation & Verification Managers

Recent Projects & Case Studies

AM Materials & Post-Processing

Current defects /Challenges

AM Knowledge & CRP Database

Ideas, New Product Introduction

Design for function & AM

Mechanical Performance Requirements

Pre-Production Trials and market needs Brainstorming

and Feasibility Exercise


AM Technology Workshop

•Product suitability evaluation for AM

•Return on investment exercise

Topology

Optimisation

•Light-weighting

•Lattice sub-structures

•ATOM and TOSCA software

Design for AM

•Dimensional accuracy

•Machine Allowance

•STL Re-design for buildability

•Materialise 3-Matic STL Software

Material Selection

• Application based alloys

• Powder Characterisation

• Particle Size Range

• Morphology

• Flowability

Part orientation

• Critical surfaces & tolerances of features

• Post-processing needs

• Ease of support removal

• Minimal distortion

•Materialise MagicsRP

Support generation

•Solid supports & tree-like structures for build success

•Support Optimisation for heat dissipation to reduce Residual Stress

Process Development and Prototype generation

•Process parameters development

•Prototype Trials

•Destructive Tests

•Best Density &

•Surface Finish

Post Processing Activities

•Hot Isostatic Pressing

•Heat Treatments

•Surface Finish Improvement

•Cleaning of Parts

Manufacturing

•QA/QC

•Validation and Certification

•Full rate production

AM Product Evolution


Product Selection for AM

Client’s Business Ranking

TWI’s Technical Ranking

Client’s Component Reference

Approximate SLM cost per

Component in £ (Including Heat Treatments and

HIPing) (Based on number of parts

nested in a build)

1 x Component 1 1000




5 x Component ‘n’ 5000


Outcome of Workshop

Concise AM product feasibility study List of recommendation/actions for AM Technology

adoption Down selection of most suitable parts for AM adoption

(business / technical aspects)

Next steps detailing new product AM introduction programme for selected products Guidance on IP and business exploitation


Agenda


Chris Dungey

Business Development Group Manager

Joining Technologies DD: +44 (0)7711 558 553 E: [email protected]

TWI Ltd Granta Park

Great Abington Cambridge CB21 6AL

UK

T: +44 (0)1223 899 000 F: +44 (0)1223 892 588 W: www.twi-global.com

mailto:[email protected]

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