techrepublic | ge no.1 3d
TRANSCRIPT
Imagination at work.
GE Aviation – Additive Road to Production
Two Primary Observations:
1. When designing for additive, every element of the design process needs to be thought about differently.
2. Qualification of additive is no different than qualification of any new cast or forged alloy.
2
Imagination at work.
GE’s Additive Pedigree
3
GE Aviation Metal Additive Toolkit
4
Metal Heat Source S
pee
d Pre
cis S
ize
Comments
Pow
der B
ed DMLM
Direct Metal Laser Melting
Powder Bed Laser LEAP Fuel Nozzle
EBM Electron Beam Melting
Powder Bed
Electron Beam
Alternate Process for Castings
Dep
ositi
on
LPF Laser Powder Forming
Powder Deposition Laser Large Prototypes
EBFF Electron Beam Free Form
Wire Electron Beam Large Prototypes
Hot Wire
Wire TIG/ Laser Large Prototypes
Con
solid
atio
n MIM Metal Injection Molding
Binder Injection Consolidation Small Part, High Volume
Binder Jet Binder Jet Consolidation
L
L
TIG/L
EB
EB
H M L
1 | GE Global Research Lab • Began work in early 1990’s
2 | Create New Materials
3 | Additive Design Expertise 4 | Accelerate Industrialization with Acquisitions
5 | Strategic Industry Partnerships
GE Additive Manufacturing Pedigree
5
“GE has been developing additive technologies since the early 1990s.. the first signs that additive was about to take off appeared about five years ago. It was not so much a Eureka moment, but rather a natural reaction to helping our industrial businesses address a more competitive manufacturing landscape.”- Christine Furstoss, GE Manufacturing Technology Director
Est. 1994 Est. 2004
Imagination at work.
GE’s DMLM Fuel Nozzle
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History of DMLM Maturation
7
1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Method and apparatus for producing parts by selective sintering
WO88/02677 US4863538 EOS M250 – First Commercial DMLS
First Fully Dense Material Milestone
EOS M160 – First Prototype DMLS
New Machine OEMs • SLM Solutions • Concept Laser • Phenix • Renishaw
GE: Prototype Testing
GE/Morris: First Metal Parts
First Commercialized & Regulated DMLS Part
GE: Acquisition of Morris
GE: Powder Laser Weld Repair Filed 2/89: US5038014
GE: LEAP 1-Piece Nozzle FETT
GE: LEAP 1-Piece Nozzle 1st Flight
GE: Laser Clad Blades in Repair & New Make
Photo Courtesy: EOS
Photo Courtesy: EOS
Preferred power for narrowbody
651 M I L L I O N f l i g h t h o u r s
CFM56 … • 25,000 engines
delivered • 28+ years
in service
• 34,000+ departures per day
2,400 3,400
'13E '20F
Shop visits
LEAP … • 2016
service-entry
• Selected by Airbus, Boeing, COMAC
• 7,500 orders, through Sept. 2014
*Compared to today’s generation CFM56. Claims based on GE estimates
8
15 L O W ER fuel consumption*
%
Low-NOx Combustor Evolution
Single Annular Combustor (SAC)
• Rich burning (tech insertion) • 10% margin to CAEP/8 NOx
CFM56 DAC
GEnx
CFM56 SAC
Double Annular Combustor (DAC)
• Lean burning • 20% margin to CAEP/8 NOx
Twin Annular Premixing Swirler I (TAPS I)
• Lean burning • 40% margin to CAEP/8 NOx
Twin Annular Premixing Swirler II (TAPS-II) • Lean burning • >40% margin to CAEP/8 NOx
LEAP
NOx
Why Additive?
Better, lighter, cheaper parts and systems • Performance improvement (Precise features, less stack, eliminate leakage)
• More complex functions (Complex and internal fluid/air passages)
• Longer life, more durable (Organic designs, design for stress/life)
• Lighter (Use only value added material, eliminate the rest)
• Cheaper (Multiple pieces built as one, less resources to produce)
• Faster (Tooling elimination, net shape, reduced machining)
• Capital equipment reductions
10
GE Additive – Fuel Nozzle
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Global Research Center
20 pieces replaced with 1 piece
GE Aviation – Design Engineering
Develop Materials and Processes
Parameters & Prototypes
GE Aviation – Development Center
GE Aviation – Lean Lab
GE Aviation – Auburn, AL
Design Freedom
Photo Courtesy: EOS
GE Additive Fuel Nozzle Design Freedom…
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1 | Design For Manufacturing
2 | Aero Design
3 | Fluid Dynamics 4 | Thermal Design
5 | Mechanical Design
CAD Design
Additive Design vs. Traditional: • 20 pieces replaced with 1 • 25% lighter • 30% lower cost • 5X more durable
The Additive Transformation
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From: 20 components manufactured and assembled GE Proprietary Information
Photo Courtesy: EOS
1 2 3 4 5 6 7
8 9
10 11 12 13 14
15 16 17 18 19 20
1 piece additively manufactured
Imagination at work.
Qualification
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GE Material Technology Maturation
Materials & Process Content • Microstructural evaluation & heat treatment • Process optimization/producibility • Mechanical property and design curves • Environmental evaluation (fluids, corrodants, temperature/time, etc.) • Effects of thermal processes (fabrication, brazing, welding, etc.)
Deliverables Material understanding Processing & robustness Specifications Physical/Mechanical Props Environmental evaluation Component suitability
Concept
Feasibility
Development
Maturation
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New Material Process
• Standard specification control system of property testing and generation
• Property Data determined from alloy & application requirements
• Thermal process conditions may be are determined from entire operating and manufacturing range
• Feature validation test plan determined from component-specific requirements
• Lifing methodology is performed consistent with existing GE lifing standards.
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Fully Dense, Small Grain, Isotropic Material
Stress Relief – Required to eliminate residual thermal stresses left during build process Hot Isostatic Press – High temperature, high pressure thermal cycle to eliminate sub-surface porosity Solution – Completes conversion of material to near wrought, isotropic structure
As-built (Top View) As-built (Side View) Heat Treated (All directions)
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Explicit Controls on Critical DMLM Parameters
Preheat Temp Interpass Temp Contour Pass Parameters Laser Dwell Time Line Spacing or Boundary Overlap HIP Cycle Parameters Heat Treat/Solution Atmosphere Braze HT Parameters Solution Temperature Surface Conditioning
Powder Source Powder Size Powder Composition Powder Reuse Procedures Layer Thickness Recoater Arm Material / Design Laser Parameter Changes Spot Size Laser Power Laser Travel Speed Build Atmosphere
18
Today’s Inspection/Quality Touch Points
• Build Trials & Qualification per Machine • 100% Dimensional & CT Scan • Up to 2 Cut-ups per Build via Quality Plan • 100% Tensile Bar Test • Grain Size, Porosity, Surface Finish Samples • 100% Fuel Flow (All Circuits) • 100% Air Flow (All Circuits) • 100% Proof Pressure
Photo Courtesy: EOS
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Qualification Road Map
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Identify • Additive opportunities based on value • Durability, Fuel burn, emissions, weight, cost, etc…
Mature • Materials • Process: thin wall, surface finish, inspection, etc…
Design • To additive practices • Taking full advantage of design freedom
Qualify • Establish requirements • Demonstrate requirements are met
Validate • To performance level requirements • Using advanced analytics and testing
Certify • Component level qualification • Engine Level qualification
No New Cert Regulations Required For Additive
Imagination at work.
Greg Morris
Thank You!