Additive Manufacturing at GE Greg Morris Imagination at work.
Who We Were…Who We Are
Pre-GE Acquisition MTI & RQM
Founded 1994
Introduced DMLM to NA in 2003
135 employees
Services included:
Engineering & Design
Additive (Metals/Polymers) (25 additive machines)
Post-Processes (Machining, Thermal Processing, Finishing)
Collaborations/JV’s…i.e. MicroTek Finishing w/BinC, etc.
Customer Base: Aerospace, Medical, Consumer Goods, Energy
Page 3 7/27/2014
GE Acquisition of MTI & RQM (Nov 2012)
Additive Development Center - GEA focus - Other GE - Select Externals
Additive Lean Lab / Pilot Production - Low rate initial production
Page 4 7/27/2014
Manufacturing Technology Development
DMLM (Today) Material Development Machine Development Process Development ------------------------Test Fixture/ Tooling Mfg Prototype Manufacturing Material Development Test Article Manufacturing Pre-Production Mfg Physics Models Early Process Dev
GRC TRL / MRL 0 ID New Technologies
Additive Development Center (ADC)
TRL / MRL 3 Develop Technical Technologies Feasibility
Early Production Mfg Product VSE Production Process Dev Low Rate Manufacturing
Final Production Site (Auburn, AL) High Rate Manufacturing Entitlement Cost
Production
Additive Lean Lab (ALL) TRL / MRL 6 Mature Technologies
TRL / MRL 9 Support Production
Page 5 7/27/2014
How the Process Works...
Basic Process (DMLM) AM Process
Thermal Processing
Post Processing and Inspection
3D CAD Model
Final Part
Prep for Process
GE Proprietary Information
Additive Modalities
Types of Additive
Photo Courtesy: Arcam Photo Courtesy: Stratasys Photo Courtesy: EOS
Photo Courtesy: Stratasys
Photo Courtesy: 3D Systems
Photo Courtesy: Stratasys
Rapid Prototyping? Additive Manufacturing? 3D Printing? GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Polymers - SLA
Photos Courtesy: 3D Systems
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Polymers - SLS
Photos Courtesy: EOS
Photos Courtesy: Materialise
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Polymers - FDM
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Photos Courtesy: Stratasys
Polymers - PolyJet
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Photo Courtesy: Stratasys
Metals
Photo Courtesy: EOS
Photo Courtesy: ORNL
Photos Courtesy: Within Labs
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Nano Additive Mfg.
Photos Courtesy:
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Other 3D Printing
Photo Courtesy: GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Additive at GE Aviation...
GE Aviation Additive:
FDM: (1) Fortus 900
SLA: (2) 500’s, (2) Vipers (3) ProJet 3500
Phenix: (1)
ARCAM: (8) A2(xx)
PolyJet: (1) Connex 500
C-L: (1) M2
EOS: (11) M270’s (4) M280’s
SLM: (2) 250HL GE Proprietary Information
Photos Courtesy: 3D Systems, Stratasys, EOS, SLM
GE Aviation Additive Support:
CAD Modifications Multi axis milling Multi axis Turning
Extrude Hone
Airflow test stand CMM/Laser Scan
5-axis EDM Hole Drill GE Proprietary Information
Wire EDM
Production Prep:
Inspection
DMLM: (7) M270’s
Powder Size Analysis GE Proprietary Information
Thermal Processing: (1) Vacuum Stress, (1) HIP
Design Matters...
Design to the Process Critical
GE Proprietary Information
Instrument Probe - 2005
GE Proprietary Information
Instrument Probe - 2007 • • • • •
Successful builds (no crashes) Less cost to produce Higher test life More accurate probes Lower number of probes required • Better data collection • Shorter fabrication time
CopyrightGE2014 General Information Electric Company, U.S.A. Proprietary
Design For Additive
Topology & Shape Optimization
Crowdsourcing Design Challenge Public challenge to find new design strategies for additive manufacturing 150 entries in less than 30 days Top designs will be manufactured and tested by GE
Makers Guild
Original design
Corporate initiative to gain exposure and expertise in the world of 3D printing Learn about: • Build orientation • Shape capability • Support structure
GE Proprietary Information
Example entry
Design Challenge and the Potential of Additive Tapped into 750k+ online community Over 700 entries received Many submissions over 80% weight reduction
Traditional Design
GE Proprietary Information
GE Proprietary Information
Parts Grown and Tested
Winning Design GE Proprietary Information
7/27/2014
Materials are the Reason Why…
Material Properties Drive Applications • • • •
Super Alloys (2005) Many similar to wrought strengths Some materials characterized Large opportunity for novel alloy development
SS 316L
Inco 625
Inco 718
MS-1
Ti64
W Cu
AlSi10 Mg 6061 T6
Hast X
CoCr 17-4 PH
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Ti 6242
SS 15-5
TiAl
Material Properties Drive Applications YS (ksi)
"UTS (ksi)"
200 180
160
DMLM
Wrought
ASTM
140 120
Vertical
100
ASTM
80 60 40 DMLS - V DMLS - H Wrought Wrought Low High
Horizontal
Solution Heat Treatment Elongation (%)
"Hardness (HRC)"
42 38 34 30
Melt Pool Directionality Similar to Wrought Vertical Grain Growth Isotropic / Homogeneous
Typical Equiaxed Grain Structure
ASTM ASTM
26 22 18
DMLS - V DMLS - H Wrought Wrought Low High
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Material Properties Drive Applications 180
YS (ksi)
"UTS (ksi)
160
DMLS
EBM
Wrought ASTM
140
Vertical
ASTM 120
Horizontal
100
Elongation (%) 35 30 25 20
Typical Alpha + Beta Widmanstatten Structure
Similar to DMLS Alpha on Deposition Layer
Finer than DMLS or EBM
ASTM ASTM
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
15 10 5 0
"Hardness (HRC)
After the Build…the Role of Post Processes
Machining
Surface Finishing
Metallurgical Lab
Thermal Processing
Special Processes
GE Proprietary Information
Additive Metal Challenges…
Build Learnings
GE Proprietary Information
Witness Line due to a power outage
GE Proprietary Information
EBM ‘Cake’ – Limit of Internals
GE Proprietary Information
7/27/2014
How GE Aviation is Using Additive Metals
Leveraging AM – NPI Hardware
7th set of HPT’s in 6 years Substantial cost and lead time reduction Design refinement options
Fuel Swirlers
GE Proprietary Information
Land-based Gas Turbine Engines 90 parts in (3) months Met testing timetable Eventually will be castings
DMLM Design Advantage
LEAP Fuel Nozzle
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
DMLM Fuel Nozzle Design History Begin TAPS Development
2000
2001
CoCr DMLM Material Development
2002
2003
2004
2005
2006
2007
LEAP 1 piece DMLM Nozzle
2008
2009
2010
GEnx certifies Traditional Mfg. GE Proprietary Information22 piece construc.
DMLM for prototype testing
DMLM supply chain acquisition
2011
2012
2013
LEAP FETT
LEAP 56 Next Generation Fuel Nozzles 19 Fuel Nozzles in each engine – 40K full production 20 pieces to 1 5x durability improvement 25% weight reduction (compared to GEnx) Fuel Nozzle is a very efficient heat exchanger
GE Proprietary Information
Exploring Optimized Structures Optimized Result: 30% less weight
Original
• • • Re-designed (conceptual) • GE Proprietary Information
Combine parts to eliminate weight Performance gains Maintenance reduction Optimal structure designs
EXPERIENCE ON EBM - TiAl Advantages of the EBM process: low level of internal defects, no typical casting
defects, therefore low scatter in material properties homogeneous microstructure very fine grain size, leading to good material properties, in particular fatigue properties, and no need for grain refinement no limitations in chemical composition no residual stresses due to high process temperature little waste material: powder can be recycled as the oxygen pick-up is very low
45
GE Proprietary Information
AM Integration Within GE Corporation
GE Proprietary Information
Additional Considerations…
Accelerating Adoption
Process Automation
Predictive Analysis Tool Diversified Materials Surface Finish
Validation Tools Process Variation
Present
Process Monitoring
Application Specific Machines
Accepted Best Practice
Gradiated Materials
Higher Capacity Machines
Accepted Industry Standards
2014
2016
2018+
Growing Acceptance with Continuous Innovation GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Gaps and Challenges General • Rapid Qualification & Materials Database • IP: Rights & Tracking • NDT / Internal Flaw detection • Supply Chain: Development & Protection • Available Materials • Technician Skill Level
Process Specific • Surface Finish • Distortion • Build Volume • Throughput • Process Monitoring and Control
GE Proprietary Information
Supply Chain Shift? From To
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
More Local? Field Operation
Substantial supply chain challenge in remote locations Spare / Repair parts on-site? Mobile Additive Center concept
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Parts Inventory
Local ability to grow parts? Controls inventory Balance inventory with needs/delivery Flexibility for design changes (no order minimum)
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Broad Trends Challenging IP landscape Further consolidation (all areas) Increased adoption of technologies Accelerating innovation New business models
160 140 120 100
Applications
80
IP
60
Alloys
40 20 0 2012
GE Proprietary Information
2013
2014
2015
2016
What Phase Are We In?
Creators & Pioneers
Early Adopters
Primary Majority
Secondary Majority
Technology Maturation and Acceptance Curves
GE Proprietary Information Export Authorization, ECCN: 9E991, NLR
Holdouts
Additive’s Potential::
Global Mfg. Output: ~$10.5 Trillion
GE Proprietary Information
~$2.2 Billion Professional Industrial Additive Market ~0.02% of total global Mfg. output What if was 1%?...=$100B!
Thank You!
Imagination at work.
