Additive Manufacturing Within Honeywell Challenges to Production

This document and all information and expression contained herein are the property of Honeywell

International Inc., are loaned in confidence, and may not, in whole or in part, be used, duplicated, or

disclosed for any purpose without prior written permission of Honeywell International Inc. All rights

reserved.

Non-Destructive Evaluation Techniques for Additive

Manufacturing

Donald Godfrey – Engineering Fellow – Honeywell International

Mark Cola – President and CEO – Sigma Labs, Inc.

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• $40.5B in sales*

• Approximately 132,000 employees, 1,300 sites, 70 countries

• Morristown, NJ global corporate headquarters

Honeywell’s Businesses

Performance Materials

& Technologies

Morristown, NJ

headquarters

Automation &

Control Solutions

Minneapolis, MN

headquarters

Aerospace

Phoenix, AZ and

Rolle, Switzerland

headquarters

$15.8B*

$14.5B

$10.2B

* 2014 sales : ex-4Q14 OEM Incentives

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The Aerospace business unit develops and integrates technologies

that span air traffic modernization, flight and runway safety, engines,

cockpit and cabin electronics, connectivity, logistics and more that deliver

safe, efficient, productive and comfortable

transportation-related experiences.

Aerospace

Thousands of Honeywell Aerospace

products and services are found on

virtually every commercial, defense

and space aircraft and its

turbochargers are used by nearly

every automaker and truck

manufacturer around the world.

Possibilities. Made Easy.

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AEROSPACE FACTS

• Headquartered in Phoenix, Ariz. and Rolle, Switzerland

• Approximately 42,000 employees

• Nearly 110 worldwide manufacturing and service sites

• Total Revenue of $15.8 billion in 2014*

STRENGTHS

• Global leader in the aviation industry

• Developing innovative safety products

• Driving modernization of global air traffic management

• Revolutionizing combat technology

• Committed to improving operational efficiencies

• Serving all major automotive OEMs worldwide

About Aerospace

SALES

* Ex-4Q14 OEM Incentives

($B)

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Phoenix Engines Site Overview

Key Facts:

• ~50 years of building propulsion systems

• > 80,000 auxiliary power units produced

• > 40,000 engines produced

Key Customers:

• Airbus

• Bell

• Boeing

• Bombardier

• Cessna

• Dassault

• General Atomics

• Gulfstream

• Sikorsky

• US Military Services

• Foreign Military

• Other Govt Agencies

Gear Line Facility

Assembly & Test Facility

Engines Campus

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Honeywell HTF7000 Engines

• Historical deliveries- >1000 HTF7000 Integrated Propulsion Systems

delivered and in service

- >2.2 million flight hours to date

- Four HTF7000 models in the family:

› HTF7000 for Bombardier CL300

› HTF7350 for Bombardier CL350

› HTF7250 for Gulfstream G280

› HTF7500 for Embraer Legacy 450/500

• HTF7K Integrated Propulsion System:- Turbofan engine

- Nacelle

- Thrust reverser

- ~7000 - 7500lbf Take-off thrust (nominal)

• Applications & Entry Into Service Dates- Bombardier CL300 – In service since 2004

- Gulfstream G280 – In service since 2012

- Bombardier CL350 – In service since June

2014

- Embraer Legacy 500 – In service since

September 2014

- Embraer Legacy 450

>1000 HTF7000 IPPS Delivered– 5 Applications – 2M Fleet Hours

Bombardier Challenger 300

Gulfstream G280

Challenger 300

Embraer Legacy 450/500

Challenger 350

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Additive Manufacturing Technology Center

Benefits of Additive Manufacturing

• Rapid prototyping – development lead-time reduction

• Design freedom – high complexity, low volume

• Target markets in Aerospace:- Commercial Aerospace, UAVs, electronic housings

- Engine components, hinges & brackets, housings

- Spacecraft components

Honeywell Phoenix Focus

• Material and process development

• Prototype fabrication

External Collaboration Underway

• Air Force – Materials Affordability Initiative

- High temperature Alloys

• DARPA – Integrated Computational Materials Engineering (ICME) related

• Universities

Developing World Class Additive Manufacturing Capability

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Aerospace Engine Platforms

Over 150,000 Turbine Engines Delivered to Customers

• Wide spectrum of Aero Turbine Products

© 2014 by Honeywell International Inc. All Rights Reserved.

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Additive Manufacturing at Honeywell

• Mission: To be an industry leader in deployment of AM

- Metals

- Polymers

• Honeywell Views Technology as Game-changer Type of Technology

- Allowing Honeywell to:

Reduce costs of some components

Optimized Design

Shorten supply chain

Shorten engineering development cycle time

Honeywell is Committed to Additive Manufacturing Growth© 2014 by Honeywell International Inc. All Rights Reserved.

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Past Honeywell Powder Bed Metal AM Efforts

Success with AM Drives Technology Integration

Initial development of

prototype parts with

Morris Technologies

DMLS 718 Tangential On

Board Injector on flight

test bed

DMLS 718 swirler on

Airbus flight test bed

Began building internal R&D

lab for AM and production

planning

2007 2008 2009 2010 2011 2012 2013 2014

© 2014 by Honeywell International Inc. All Rights Reserved.

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Honeywell Components Fabricated - Powder Bed AM

Various Part Complexities and Materials Produced© 2014 by Honeywell International Inc. All Rights Reserved.

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PhoenixBrno

Bangalore

Shanghai

• Aerospace/AME leads the initiative

• Leveraging global Honeywell presence

Honeywell Global Footprint with AM Labs

Utilize Global AM Presence for Speed and Cost © 2014 by Honeywell International Inc. All Rights Reserved.

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Design for Additive Manufacturing

• AM design flexibility

- Reduced weight

- Increased efficiency

- Improvements in component life

Additive Manufacturing Is Changing The Design Culture

Original Design

Redesign with AM: 56%

weight reduction while

maintaining required strength

© 2014 by Honeywell International Inc. All Rights Reserved.

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Objective Evidence

Sigma Labs

Honeywell International

Working Together to Build an in-process NDE System for:

Objective Evidence of Compliance to Design Intent

© 2014 by Honeywell International Inc. All Rights Reserved.

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Process Monitoring - DARPA

• Ensuring quality during build important for Part Quality

- Metallurgical Properties: PrintRite3D® INSPECT™

Melt pool monitoring and defect recognition

- Geometric Properties: PrintRite3D® DEFORM™

Dimensional variations and resolution accuracy of at least 100μm

- Coating issues

• Utilizing a sensor array

- Camera monitoring

- Photodiodes and Pyrometers

- Power meters

Advancing In-Process Monitoring to Meet Quality Needs

Copyright © 2014 Sigma Labs, Inc.

© 2014 by Honeywell International Inc. All Rights Reserved.

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PrintRite3D® DEFORM™

Initial Resolution Analysis

Honeywell / Sigma Labs Technology Development

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Design Intent

PrintRite3D®

DEFORM™

Goal: Objective Evidence of Compliance to Design Intent

PrintRite3D®

INSPECT™

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PrintRite3D® DEFORM™

Real-time geometric property measurement software

• Layer-by-layer geometric property

measurements.

• Provides for comparison of ‘as-

built’ to original digital CAD model

‘should be’.

• In development with Honeywell

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Application of PrintRite3D® to DMLS®

Avoids x-ray CT and CMM through use of in-situ

geometric measurements

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Geometry

215 μm shoulder

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Extract circular hole geometry

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Extracted geometry details

Chamfered layers ignored

215 μm shoulder

11.57 mm dia. (nom)

11.14 mm dia. (nom)

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Diameter of least squares fit circles11.5

7 m

m d

ia.

(no

m)

Mean diameter:

11.61 mm (0.46 in.)

11.16 mm

(0.44 in)

11.1

4 m

m

(no

m)

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Current DEFORM™ feature resolution

At least

215 μm

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Diameter distribution

Mean 11.61

SD 0.06 mm

Mean 11.16 mm

SD 0.06 mm

11.1

4 m

m

(no

m)

11.5

7 m

m d

ia.

(no

m)

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Compare DEFORM™ to specification

Small diameter:

Spec: 11.14 mm ± 0.01 mm

DEFORM™: 11.16 mm ± 0.06 mm

Big diameter:

Spec 11.57 mm ± 0.09 mm

DEFORM™: 11.61 mm ± 0.06 mm

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DEFORM™ vs. standard techniques

*CT artifacts precludes an accurate measure

Measures

(Inches)

Shoulder

Width

Top hole

ID

Top hole

shoulder ID Base width Base ID

Center nub

to top of

bracket

Top hole

centers

Engineering

Drawing1.998 0.43 0.4383 3.7

0.218—

0.226-- 1.00

OCMM 1.997 0.4386 0.4556 3.76 0.222 1.34 1.0

CT* 2.01 0.44 -- 3.78 0.22 -- 1.0

DEFORM TBD 0.44 0.46 TBD TBD TBD TBD

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Current DEFORM™ Capabilities

Initial geometry resolution:

at least 215 μm

Measurement error:

60 μm

Goal: Objective Evidence of Compliance to Design Intent

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Summary

• Honeywell incorporating AM on Global Scale

• Working to be world leader in technology development in the area of in-process NDE for AM

• Objective Evidence of Compliance to Design Intent is the ultimate goal

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Special Credits For Team Members

Sigma Labs

David Clark

Alberto Castro

Honeywell International

Brian Baughman

© 2014 by Honeywell International Inc. All Rights Reserved.

www.honeywell.com

www.sigmalabsinc.com