Additive Layer Manufacturing Technologies for Space Applications · 2017. 2. 16. · Additive Layer Manufacturing Technologies for Space Applications - Quality Management System in

Spierings, Adriaan © 01/2017 inspire AG

Additive Layer Manufacturing Technologies for Space Applications

-

Quality Management System in Additive Manufacturing

31. January – 1st February 2017,

Harwell Campus UK

UK-CH Bilateral Workshop on Space Technology

A.B. Spierings Head R&D SLM

Inspire AG – innovation centre for additive manufacturing Switzerland


Who is inspire?

Fields of activity / institutes - Iwf-processes: Grinding, Cutting, EDM, …

- Iwf-machines: Machine Tools, Simulation, Analysis, Improvements

- Iwf-micromachining: Laser- & mikrofabrication

- icams: Additive Manufacturing (SLS, SLM)

- Ipdz: Construction & Design

- Ics: Composite-Structures

- Icmi: Material integrity

- Ifa: Automation, Optimisation, Mechatronic

- Ivp: Virtual production / Forming technology

ETH Zurich

Technopark Zurich, Headquaters

St.Gallen, icams


Inspire R&D focus in SLS & SLM

Standardisation

ASTM-ISO

Industry

requirements

Quality management

systems

Industrial

applications Materials

Applications

Machines

Processes


Additive Manufacturing in space and

general industry applications

4


Introduction

AM: Many opportunities esp. in space

5

Ref to ESA-Project: «System impact of additive manufacturing technologies design features” (AO/1-8005/14/NL/MV)

• Brackets

• Waveguides & Filters

• Antennas

• Manifold systems

• Heat panels / pipes

• Monts etc.

• Baffles

• Emissivity designs

• …


Introduction

High quality requirements in sectors such as

– Space – Aerospace – Turbine industry – Medical – Automotive – …

6

Aluminium space frame Audi A2

Topologically optimized antenna

bracket for Sentinel satellites (RUAG)

As-built and polished turbine

blade (Morris Technologies)

Topology optimized bike front (inspire)

Flight crew rest compartment

bracket installed on A350

Aluminium cube-sat parts, source: inspire / SSC


Quality Management System in Additive Manufacturing

7


What is quality in AM?

8

Quality

parameter

Sub-property values Ideal quality goal Typical technical

values

Material

integrity

- Material density

- Number / amount of defects, e.g.

total crack lengths e.g. per mm2

cross-section

• 100% dense

• “Crack free”

> 99.5%

max. total crack length

per mm2 and/or max.

crack length

Mechanical

properties

- Ultimate strength Rm

- Yield strength RP0.2

- Elastic modulus E

- Fracture toughness

- …

• Comparable or outperforming conventionally

processed materials

• Free of anisotropy

• Material- and machine dependent

Microstructural

integrity

- Grain size distribution

- Grain orientation

• Homogeneous grain

sizes, no texture

• Ideal grain

misorientation

distribution

Columnar grains

Grain texture in build (z-)

direction

Surface

properties

- Roughness

Ra, RZ / Sa, SZ

• Roughness as low as

possible

Rough surface qualities

with Rz 30 - 40m,

dependent on powder,

processing window and

part orientation

Dimensional

tolerances

- Parallelism of planes

- x-, y- and z-dimensions

• As engineered /

according to CAD

Typical deviations in the

range of 0.1mm

AlSi10Mg (Buchbinder, 2014)

Many quality parameters!


Quality management system

SLM-processing chain

– From powder raw material to the final part

– Influencing factors in all sub-processes – Cross-influences between processing steps

9


Influencing factors in the AM-process chain

Example: Alloy

composition

Example: Powder

properties

10


Influencing factors in the AM-process chain

Example: AM-processing

conditions / window

– The processing conditions influence the material

microstructure, and finally

mechanical properties

«Master forming process»

11


State of the art in AM-quality management

12

Powder qualifi-cation

Particle size distribuiton

Flowability

…

Process qualifica

-tion

Melt pool monitoring

Powder layer quality

Maschine qualificati

on

Atomsphere

Laser

Cleanliness

…

Part qualifi-cation

CT scanning

Conv. Part finishing

• No quantitative

standards

• Flowability:

Conv. methods

do not fit

• No information

about final part

quality

• For (future)

feedback control

• No quantitative

standards

• Complex

machines

• Costly

• Time

consuming

Photo diode signal of the QM-meltpool

monitoring solution of ConceptLaser

CT-scan for an Al-space part (inspire)

Ref. Spierings (2015)


Conclusion: An AM-quality management system

… across the whole AM-process chain

– … with defined parameters in all sub-processes

– … measured quantitatively

– … monitored over each build job / during the build job

– … with defined quality gates between sub-processes

In order to

– Get insight into dependencies / correlations – Directly qualify an AM-part after production

– Guaranteeing – a certain quality level / -level for a given application

– Reproducibility

– Repeatability

– Derive appropriate standards

13

Quality control chart for a certain

parameter


AM-quality management system = our main goal @ Inspire

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Conclusions

A comprehensive AM-quality management system is

(compleatly) missing

Inspire is therefor focussing on QM-management systems

by addressing the whole AM-processing chain

– Materials – Processes – Machines – Applications

We are pushing this topic on a national &

international level

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Insight into inspire-icams

Thank you for your attention

Adriaan B. Spierings Head R&D SLM

Lerchenfeldstrasse 5

9014 St.Gallen

[email protected] +41 71 274 73 19 www.inspire.ethz.ch

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3 x SLM-machines 4 x SLS-machines

Fully equiped analyse and R&D lab, with 1 own developed open R&D SLM machine

Documents

Additive Layer Manufacturing Technologies for Space Applications · 2017. 2. 16. · Additive Layer Manufacturing Technologies for Space Applications - Quality Management System in